TAB LE OF CONTENTS

SUBARU

1600 I BOO

FOREWORD
This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU 1600 and 1800 series. This manual completely covers the proce. dures . for maintenance, disassembling, reassembling, inspection and adjustment of components and troubleshooting for gUidance of both the fully qualified and the less-experienced mechanics. . Please peruse and utilize this manual fully to ensure complete maintenance and repair work for satisfying our customers by keeping their vehicles in op-timum condition. When replacement of parts during maintenance is needed , be su :~e to use SUBARU genuine parts. All information, illustrations and specifications contained in this manual are based on the latest product infonnation available at the time of publication approval. FUJI HEAVY INDUSTRIES LTD.

-

· ·AU,

©

and are trademarks of FUJI HEAVY INDUSTRIES LTD . Copyright 1982 FUJI HEAVY INDUSTRIES LTD.

-8-

fI

Not to be reproduced in whole or in part without the prior written permission of FUJI HEAVY INDUSTRIES LTD., TOKYO JAPAN .

CHAPTER'iJ
GENERAL INFORMATION
p.
1- 1. GENERAL SPECIFICATIONS ................................................................ 1- 2
1- 2. VEHICLE IDENTIFICATION NUMBERS (V.I.N.) ................................. 1- 4 1. Applicable V.I.N. of This Manual.......................................................... 1- 4

2. The Meaning of V.I.N. .......................................................................... 1- 6
1- 3. IDENTIFICATION NUMBERS ................................................................ 1- 6

1. Vehicle Identification Number .............................................................. ··1- 6
2. Engine Serial Number ••••••••••••••••••••••••••••••••••••••••••••••••••.••••.•.••••••••••••••••• 1- 8

3. Transmission Serial Number ................................................................. 1- 6
1- 4.
1. Safety Certification Plate ..................................................................... 1-

. LARE LS .................................................................................................... 1- 8.~'·"

~'""t

i

2. Vehicle Emi.ion Control Information Labels ...................................... 1- 6

3. Emission Data Label (California Models Only) .................~~............... 1- 6
4. VehicleldentiflCltion Number Plate ............................. L ...........~t .•"'\;;

' ' '.1_

5. Color Code Label ..•..........•••.•....•.•..•.•.•.••.•....•...••..••.•••.••.••..••.•..•.•.•....•. 1- 1 1- 6. RECOMMENDED LUBRICANTS ........................................................... 1- 7 1- 6. RECOMMENDED SEALANTS, ADHESIVES AND ,.
.~'.

GREASES .••••.••••••••••••••.•••••••.•••••••••••••.•••••••••••••••••••••••••••••••••••••••••••••••••••••• 1- 8

1- 7. TIGHTENING TORQUE OF STANDARD BOLTS AND NUTS ......... 1- 9 , 1- 8. OPENING ENGINE HOOD .................................................................... 1-10

1- 9. LIFTING POINTS AND PROCEDURE ................................................. 1-10 1. Pantograph Jack .................................................................................. 1-10 2. GarageJack ......................................................................................... 1-11
3. Lift ...................................................................................................... 1-11

1-10. TOWING HOOKS ................................................................................... 1-12

B·.I1I1

-----~----.-----~--~~-~-~."........,--

........

--.---~--~-~~~-~-~----.~-~-

----._.r'r~

----...,.,

--

-


1800 Station Wagon DL 5MT GL 5MT AT 4WD DL 4MT Dfr 4WD GL AT

1600 Hatchback STD 4MT Overall length Overall width Overall height DL 5MT GL 5MT AT

1800

1600

1800

1600 Hardtop
--

Sedan
4WD STD 4MT 4WD GL Dfr DL 5MT GL 5MT AT

I

~

--

-

BRAT 4WD DL 4MT Dfr 4WD GL
I

D

1\..

DL 5MT

GL 5MT AT

\

~

AT

I

4425 4425 4285 4285 4285 4300 4425,1 4270 4280 4250 4270 4250 3985 4010 3995 3995 mm 3985 (in) (156.9) (156.9) (157.9) (157.3) (157.3) (167.3) (168.1) (167.3) (168.1) (168.5) (169.3) (168.7) (168.7) (168.7) (174.2) (174.2) (174.2) mm (in) mm (in)
r

1610 (63.4) 1365 (53.7)

1610 (63.4) 1365 (53.7)

1615 (63.6)

1620 (63.8)

1620 (63.8)

1410 1365 (53.7) (55.7)

1610 (63.4) ---- I-----1415 1365 (55.7) (53.7)

1615 (63.6) 1365 (53.7)

1610 (63.4) 1350 (53.1)

1615 (63.6) 1350 (53.1)

1610 (63.4) 1390 (54.7)

1615 (63.6) 1390 (54.7)

1620 (63.8) 1440 (56.7)

1620 (63.8) 1445 (56.9)

1620 (63.8) 1445 (56.9)

1635 (64.4) 1440 (56.7)

1635 (64.4) 1445 (56.9)

1635 I (64.4) 1445 (56.9)

".. 3 ._. -

en

I

n ,. _. •

Co)

~

mm Length (in) Compartment

1700 (66.9)

1700 (66.9)

1700 (66.9)

1700 (66.9)

1700 (66.9)

1750 (68.9)

1750 (68.9)

1750 (68.9)

I ['~~-"]
two_u ··CalJ0 space at
four . .Is

·'1500 ·'1500 ·'1500 ·'1500 .' 1500 •• 960 •• 960 (59.1) (59.1) (37.8) (37.8) 1750 (59.1) (59.1) (59.1) (68.9) .2 785 .2 785 .2 785 .2 785 .2 785 ·$1610 ·'1610 (30.9) (30.9) (30.9) (30.9) (30.9) (63.4) (63.4) ·'1290 1345 (50.8) (53.0) .11320 (52.0) 1105 (43.5) 2460 (96.9)
--

•• 960
(37.8) ·'1610 (63.4)

.
0 ::I

m Z m
::D

r."

»

Z

~ is

··CalJ°space

Width

BRAT - rear CUlO bed only

~~

1345 (53.0)

1345 (53.0)

1345 (53.0)

1345 (53.0)

1345 (53.0)

1345 (53.0)

1345 (53.0)

1345 (53.0)

·'1290 ·'1290 ·'1290 .11290 (50.8) (50.8) (50.8) (50.8)

0
1300 (51.2) 1300 (51.2)

::D

1300 .21320 .11320 .21320 .21320 (51.2) (52.0) (52.0) (52.0) (52.0)

~ 0
Z

3:

H'gh mm el t (in)

1115 (43.9) 2380 (93.7) 1330 (52.4) 1345 (53.0) 165 (6.5)
-

1115 (43.9) 2380 (93.7) 1330 (52.4) 1345 (53.0) 165 (6.5)

1115 (43.9)

1115 (43.9)

1115 (43.9) 2370 (93.3) 1335 (52.6) 1370 (53.9) 210 (8.3)

1115 (43.9) 2460 (96.9) 1330 (52.4) 1345 (53.0) 165 (6.5)

1115 (43.9) 2460 (96.9) 1330 (52.4) 1345 (53.0) 165 (6.5)

1105 (43.5) 2460 (96.9)

.3

860 .3 860 .3 860 . l 860 .3 860 (33.9) (33.9) (33.9) (33.9) (33.9) 2455 (96.7) 1325 (52.5) 2455 (96.7) 1325 (52.5) 2445 (96.3) 1310 (51.6) 2445 (96.3) 1335 (52.6) 1365 (53.7) 210 (8.3) 2445 (96.3) 1335 (52.6)

2445 (96.3) 1310 (51.6) 2445 (96.3) 1335 (52.6) 1365 (53.7) 210 (8.3)

2445 (96.3) 1335 (52.6) 1365 (53.7) 210 (8.3)

Wheelbase
Front Tread Rear Minimum road clearance

mm (in) mm (in) mm (in)

2380 '2370 (93.7) (93.3) 1330 (52.4) 1345 (53.0) 165 (6.5) 1310 (51.6) 1345 (53.0) 205 (8.1)

1330 1330 (52.4) (52.4) 1345 1345 (53.0) (53.0) 165 (6.5) 165 (6.5)

1345 (53.0) 175 (6.9)

1345 1340 (53.Q) (52.8) 175 (6.9) 205 (8.1)

1365 1340 (53.7) (52.8) 205 (8.1) 205 (8.1)

--

mm
(in)

.': Between rear end of seat and rear gate .': Between back panel and rear gate

1600 Hatchback STD 4MT DL 5MT GL 5MT AT
.. I

1800

1600

1800

1600 Hardtop

1800 Station Wagon DL 5MT GL 5MT AT
.. I

Sedan 4WD STD 4MT 4WD GL Dfr DL 5MT GL 5MT AT
.. I

BRAT 4WD GL Dfr AT 4WD DL 4MT Dfr 4WD GL AT

DL 5MT

GL 5MT AT
.. I

4WD DL 4MT

Front

f"~~GL4)
lit;

Curb weight *

.

617 626 596 603 kg 622 631 583 587 592 615 587 592 599 (lb) (1285) (1295) .., 615 (1305) (1355) (1295) .. 1 624 (1305) ..1 626 (1320) .. , 624 (1330) (1370) (1390) (1315) (1360) (1380) (1355) (1375) (1375) (1380)
' .. I

603 (1330)

610 (1345)

615 (1335)

612 (1350)

m Z m

C)

w

~

!C

GLF models ··SMTofDL model and ATofGL& GLF models

Rear

kg (Ib)

347 (765)

347 (765)

384 .., 367 (845) (810)
.. I

359 (790)

.. I

399 (880)

379 (835)

383 (845)

.. I

.. 1

365 387 (805) (855)

474 469 469 422 .. , 379 (930) .. , 442 (1035) (1035) (1045) (835) (975)
.. I

374 (825)

.. I

435 (960)

391 (860)

401 (885)

406 (895)

» r
."

::D

Z

o

Total

kg 930 (Ib) (2050)

934
(2~0)

1032 1018 1021 987 1072 1091 1105 976 1014 966 957 (2150) (2235) (2130) ..21011 (2110) .. , 1005 (2250) "'1066 (2365) (2405) (2435) (217 5) (2245) (2275) ..2 982 (2165) (2350) (2230) (2215)

962 (2120)

.. I

993 (2190)

989 (2180)

.. 11048 (2310)

::D

i:

o z

~

Front Gross Vehicle weight Rear Total

780 780 kg 780 803 780 780 796 803 803 780 780 803 803 803 803 803 803 (Ib) (1770) (1770) (1770) (1720) (1720) (1770) (1770) (1770) (1770) (1770) (1770) (1720) (1720) (1755) (1720) (1720) (I 720) kg 658 658 658 680 680 658 658 658 658 (lb) (1450) (1450) (1450) (1500) (1500) (1450) (1450) (1450) (1450) 789 789 789 789 796 744 762 789 (1640) (1680) (1740) (1740) (1755) (1740) (1740) (1740)

1569 1569 kg 1461 1461 1461 1461 1461 1461 1547 1569 1592 1569 1565 1569 1461 1461 1461 (Ib) (3220) (3220) (3220) (3220) (3220) (3220) (3220) (3220) (3220) (3410) (3450) (3460) (3460) (3510) (3460) (3460) (3460)
- -

* Vehicle with optional eqUipment is out of this specifications.

_.

__.-

__________

______

~

________________

~

_____ __________
.~1

~

__

~

____________

~

____________

)

GENERAL INFORMATION

1·2. Vehicle Identification Numbers (V.I.N.)
1. Applicable V.I.N. of This Manual
• 1600 cc Engine 2-Door Hatchback 2-DoO£ Hatchback 4-Door Sedan Hardtop • 1800 cc Engine 2-DoO£ Hatchback 2·Door Hatchback 2-Door Hatchback 2-DoO£ Hatchback 4-Door Sedan 4·Door Sedan Hardtop Hardtop Station Wagon Station Wagon Station Wagon Station Wagon Station Wagon Station Wagon BRAT BRAT BRAT GL GL 4WDSTD 4WDGL GL GL GL GL DL GL GL 4WDDL 4WDGL 4WDGL 4WDDL 4WDGL 4WDGL (SMT) (AT) (4MT) (4MT. Dual-range) (SMT) (AT) (SMT) (AT) (SMT) (SMT) (AT) (4MT) (4MT, Dual-range) (AT) (4MT) (4MT, Dual.range) (AT) J J J J F F F F 1 1 2 2 A A A A F F F F 4 4 5 5 3 3 1 3 B B B B X X X X D D D D B C D E 1 1 1 1 STD DL DL DL (4MT) (SMT) (SMT) (SMT) J F 1 A F 2 1 B X D A 1 0 J F 1 A F 2 2 B X D B 1 0

o0 o0

0 1 and after 0 1 and after
1 and after

J F 1 A B 2 2 B X DB 2 0 0

o0

J F 1 A W 2 2 B X D B 3 0 0 0 0 1 and after

0 0 0 0

0 0 0 0

o0 o0 o0 o0 o0 o0

1 1 1 1

and after and after and after and after

J F 1 A B 4 3 B X D B 2 0 0 J F 1 A B 4 3 B X D C 2 0 0

1 and after 1 and after

J F 1 AW 4 3 B X DB 3 o 0 0 0 1 and after J F 1 AW 4 3 B X DC 3 0 0 o 0 1 and after J J J J J J F F F F F F 1 1 1 2 2 2 AM AM AM AM AM AM 4 4 4 5 5 5 2 3 3 2 3 3 B B B B B B X X X X X X DB DB DC DD DE DF 4 4 4 4 4 4

o0 o0 o0 o0 o0 o0

o0
0 0

o0 o0
0 0 o0

1 1 1 1 1 1

and after and after and after and after and after and after

J F 2 AT 5 2 BX DD 5 J F 2 AT 5 3 BX DE 5 J F 2 AT 5 3 B X DF 5

o0 o0 o0 o0 o0 o0

1 and after 1 and after 1 and after

Abbreviations used 4MT: 4-speed manual transmission SMT: S·speed manual transmission AT: Automatic transmission

1-4

GENERAL INFORMATION

2. The Meaning of V.I.N •
. . - - - - - - - - - - - - - - - - - - - - - - - - : - - - - - - Maker identifier , . - - - - - - - - - - - - - - - - - - - - - - Vehicle attribute Vehicle identification ..--""'---." .-,_---lL--_-., I'- - - - ' - - - - - , JFIAF2 BXDAIOOOOI

_---=----------[ Sequential number 100001 and after 200001 and after 300001 and after 400001 and after 500001 and after

Hatchback 4-Ooor Sedan Hardtop Station Wagon BRAT

Plant of manufacture and transmission type A: Gunma manufacture - 4MT B : Gunma manufacture - 5MT C : GUnma manufacture - AT D: Gunma manufacture - 4WD 4MT E : Gunma manufacture - 4WD 4MT, Dual-range F : Gunma manufacture - 4WD AT Model year D: 1983 Check digit othru 9 and X, varies Weight class B: 3,000 to 4,000 lb GVWR Model
1 Standard model 2 : DLmodel 3 : GLmodel

Series and engine type 1 : 1300 cc engine 2 1600 cc engine 3 1600 cc engine 4WD 4 1800 cc engine 5 1800 cc engine 4WD Body type F : Hatchback B : 4-Ooor Sedan W: Hardtop M: Station Wagon T : BRAT Line restraint type A : Fuji Subaru line and seat belts B : Fuji Subaru line and air bag Type of vehicle 1 : Passenger vehicle 2 : Multipurpose passenger vehicle Manufacturer and make Fuji Heavy Industries Ltd. SUBARU

t-5

GENERAL INFORMATION

~1·3.

Identification Numbers

1. Vehicle Identification Number
The vehicle identification number is stamped on the bulkhead panel of the engine compartment.

OM·442

Fig. 1·2 Engine serial number location

Fig. 1·1 V.I.N. location Fig. 1-3
tA-075

3. Transmission Serial 2. Enaine Serial
Number
The engine serial number is stamped on the righ t side of the crankcase at the front.

Number
The transmission number label is stuck on the right upper surface of main case (MT) or converter housing (AT).

NOTE: Engine, transmission and vehicle identification numbers are used for factory communications such as Technical information, Service bulletins and other information.

1·4. Labels
1. Safety Certification
Plate
Safety certification plate is stuck near the driver's side door striker.

2. Vehicle Emission
Control Information Labels
Vehicle emission control information labels are stuck under the engine hood.
Certification label High altitude label (Altitude kit equipped vehicle only)

3. Emission Data Label
(California Models Only)

Fig.

'·6 Emission data label

Vacuum connections lIbel

OM.819

Fig.

1-4 Safety cartification plate

Fig. 1-5 Vehicle emission control labels

I

1-6

GENERAL INFORMATION

4. Vehicle Identification Number Plate

5. Color Code Label

OM·820

Fig.

'-7

Vehicle identification number plate

Fig. ,-8 Colorcade label

1-5. Recommended Lubricants
API ITEM
CIa.·

SAE viscosity No. and Applicable Temperature
("P)
("C)

aficllion

-30" -34·

0° -180

30" 0"

60" 16·

90"
32° 40
y

J-.

130, 20W40, 20W-SO • Engine oil

-

SE SF

<

SW-30

I I

lOW·30. lOW40. lOW-SO

I

(SW-30 is not recommended for sustained high speed drivillll.) .• Transmission and differential gear oil • 4WD rear differential gear oil GL-S

<

I

I
80W

90
SSW

I

3

NOTE: Each oil manufacturer ha its baa oil and additives. Thus do not mix two or more brands.

GENERAL INFORMATION

P:1-6.
f

Recommended Sealants, Adhesives and Greases
Recommended Fuji Bond C (pIN 004403004) Fuji Bond D (PIN 004403005) Application Mating surfaces of crank and transmission cases, plugs, etc. Cover gasket of water pump (Fuji Bond C can be used instead), etc. Flywheel bolts, mating surface of fly· wheel housing. Cylinder head gaskets (Super Three Bond 50 can be used for the same purpose). Sealing against water and dust entry through weatherstrips, grommets, etc. Weatherstrips and other rubber parts, plastics and textiles except soft vinyl parts. Soft vinyl parts, and other parts subject to gasoline, grease or oil. e.g. trim leather, gear shift boot, door inner remote cover, etc. Bonding metals, glass, plastic and rubber parts. Repairing slightly tom weatherstrips, etc. Weatherstrips securing windshield to body panels to meet the requirements of Motor Vehicle Safety Standard. Splines of transmission main shaft. CVJ and DOJ joints of axle shafts. Stopper plugs of the front disk brake caliper. Brake caliper body (piston, spindle adjuster O·ring), battery terminals, distributor, hood latch, etc. Control cables and carburetor linkages subject to cold weather, water·pump impeller, door latch, striker, battery terminals, etc. Contacting surfaces of drum brake shoes and shoe clearance adjuster. Disk brake caliper (lever, connecting link and spindle head).
~teering

-----=--1. Sealant

Equivalent Dow Coming's No. 7038

Three Bond 1215 (PIN 004403007) Three Bond 120 I (PIN 004403008) Starcalking B·33A (pIN 000018901) Cemedine 5430L

Dow Corning's No. 7038 Dow Coming's No. 3145 Butyl Rubber Sealant 3M's EC·I770 EC·1368 3M's EC·776 EC·847 EC·1022 (Spray Type) Armstrong's Eastman 910 Essex Chemical Corp's Urethane E

-

Cemedine 540

2. Adhesive Cemedine 3000

Starseal U-70 for USA & Canada

FX clutch grease (P IN 000040901) Molylex No.2 (PIN 623029980) PBC (pIN 003607000) Silicone KS64 (pIN 003606010)

3.

Grease

Silicolube G·30M (P IN 004404002) ABK 100 (pIN 003602000) Niglube RX·2 (pIN 003606000) Valiant grease M·2 (pIN 003608001)

gearbox (Both manual and power

teering)

NOTE: The adhesives in the above table are not avail ble from our parts department. Some of them and their equivalent products may be purchased from your local ven, ors.

GENERAL INFORMATION

1·7. Tightening Torque of Standard Bolts and Nuts
(1) ENGINE & TRANSMISSION
5T Dia. x Pitch (mm) 4 x 0.75 1.03 - LS2 (0.105 - 0.155, 0.76 - 1.12) 2.50- 2.99 (0.255 - 0.305, 1.84 - 2.21) 4.4 - 5.4 (0.45 - 0.55, 3.3 -4.0) 12 -14 (1.2 - 1.4, 9 -10) 25 - 28 (2.5 - 2.9, 18 - 21) 41 -49 (4.2 - 5.0, 30-36) 11-84 (7.2 - 8.6, 52 - 62) 1.52 - 2.01 (0.155 - 0.205, 1.12 - 1.48) 2.9 - 3.9 (0.30 - 0.40, 2.2 - 2.9) 5.9 -6.9 (0.60 - 0.70. 4.3 - 5.1) 14.2-17.2 (1.45 - 1.75, 10.5 - 12.7) 30-36 (3.1 - 3.7, 22 - 27) 53 -63 (5.4 - 6.4. 39 -46) 88 - 106 (9.0 -10.8, 65 -18} 2.50- 2.99 (0.255 - 0.305, 1.84 - 2.21) 4.9 - 5.9 (0.50 - 0.60, 3.6 -4.3) 9.37 - 10.84 (0.955 - 1.105, 6.91 - 7.99) 23 - 26 (2.3 - 2.7, 17 - 20) 46-54 (4.7 - 5.5, 34- 40) 84 -98 (8.6 - 10.0, 62 - 72) 139 - 165 (14.2 - 16.8, 103 - 122) 2.99 - 3.48 (0.305 - 0.355, 2.21 - 2.57) 5.4-6.4 (0.55 - 0.65. 4.0 - 4.7) 10-12 (1.0 - 1.2. 7 -9) 25 -28 (2.5 - 2.9, 18 - 21) 49.5 - 58.4 (5.05 - 5.95) 36.5 -43.0) 88 -106 (9.0 - 10.8, 65 -18) 147 - 175 (15.0 - 17.8, !O8 - 129) 7T 9T

Unit· N·m (kg.m, ft·lb)
lOT

5 x 0.9

6 x 1.0

8 x 1.25

lOx 1.25

12 x 1.5

14 x 1.6

(2)

BODY
Dia.(mm) 4 4T 1.1 2.6 (0.17 - 0.27, 1.2 - 2.0) 2.9 - 5.9 (0.30 - 0.60, 2.2 -4.3) 5.4 - 9.3 (0.55 - 0.95, 4.0 - 6.9) 12.7 - 22.6 (1.30 - 2.30, 9.4 - 16.6) 275 -41.1 (2.80 - 4.80, 20.3 - 34.7) 52.0 - 85.3 (5.30 - 8.70, 38.3 - 62.9) 1.2 - 2.2 (0.12 - 0.22, 0.9 - 1.6) 2.5 -4.4 (0.25 -0.45, 1.8 - 3.3) 4.4 7.4 (0.45 - 0.75, 3.3 - 5.4) 9.8 -17.7 (1.00-1.80, 7.2 - 13.0) 22.6 - 36.3 (2.30 - 3.70, 16.6 - 26.8) 39.2 - 64.7 (4.00 - 6.60, 28.9 - 47.7) 9T--9 7T

Unit· N·m (kg·m , ft.lb)
9T

~
Qt:::"b

5

6

~
TC·002

8

10

12

Fig. '·9

22.6 -42.2 (2.30 - 4.30, 16.6 - 31.1) 51.0 - 86.3 (5.20 - 8.80, 37.6 - 63.7) 88.3 - 156.9 (9.00 - 16.00, 65.1 - 115.7)

31.4 - 51.0 (3.20 - 5.20, 23.1 - 37.6) 62.8 - 101.9 (6.40 - 11.00, 46.3 -79.6) 117.7 - 196.1 (12.00 - 20.00, 86.8 - 144.7)

~
~

4

5

~
TC·OO3-

6

8

Fig. 1-10
Including bolt or nut with washer or spring washer only
10

12

17.7 - 31.4 (1.80 - 3.20, 13.0 - 23.1) 37.3 -66.7 (3.80 - 6.80, 27.5 -49.2) 68.6 - 117.7 (7.00 - 12.00, 50.6 - 86.8)

23.S (2.40 17.4 48.1 (4.90 35.4 88.3 (9.00 65.1 -

39.2 4.00, 28.9) 83.4 8.50, 61.5) 147.1 15.00, IOS.5)

Note: The mark is embossed on the bolt head as follows:
4T 5T 7T 4

5
7

IOT---1O

GENERAL INFORMATION

1-8. Opening Engine Hood
1) Engine hood can be lifted slightly by pulling engine hood lock release located at the lower area of instrument panel. 3) Lift hood and unfasten stay from holder and put the top of stay into the stopper on hood.

I
I\

I
A4·161

Fig. 1-14 Setting the stay
OM-S02

A1·064

Fig. 1-11 Engine hood lock release

Fig. 1·13 Setting the stay

2) Push up safety catch with hood pushed down slightly and unlock it.

4) If engine hood needs to be opened wider than normal position, remove stay and set it as shown in figure.

5) When clOSing engine hood, detach stay with hood lifted slightly. Mter setting stay on holder, lower hood. Then push down the front end of hood to lock it.

NOTE:
OM-S03

Fig. 1·12 Re/68sing hood lock

Make sure thlt the hood is locked completely before driving.

1-9. Lifting Points and Procedure·
1. Pantoaraph Jack
• Mark shows each pantograph jack setting positions.

NOTE:
I.

Never get under the vehicle while it
is supported only by the jlck.

Always use safety stands to support body when you have to get under the Clr. b. Block the wheels dilgonilly by wheel chocks. c. Make sure the jack is set at the correct position on the fllnge of side sill.

Fig. 1-16 Settingjack

OM·61S6

Fig. 1-15 Lifting points

1-10

-

,.

A

ph

GENERAL INFORMATION

2. Garaa. Jack

NOTE:

~

IJUIJ

a. When jacking up the vehicle, place chocks to hold wheels. b. After jacking up the vehicle with garage jack, be sure to support the vehicle with safety stands for safety. c. Mike sure the stands are set at the correct position on the flange of side sill. (The same setting positions as those of pantograph jack)

Fig. 1·17

A1-076

Correct position

Fig. 1-19

A1-077

Fig. 1·18

d. For rear lifting points of 4WO, apply garage jack under rear dif· ferential.

3. Lift

NOTE: Be sure to lift vehicle at the same four

positions as those of pantograph jack.

E:3 a

FRONT A1-078

Fig. 1-20

GENERAL INFORMATION

1·10. Towing Hooks
Towing hooks are provided in front and rear ends of vehicle. Front Rear • Rear (Hatchback, Sedan and Hardtop)

NOTE:

Right Left Right Left Hatchback Sedan Hardtop Station Wagon BRAT

• • • • • •
....

-

-

• : installed - : not installed • Front

When towing the vehicle, pay attention to the following. a. Before towing the car, make certain that the parking brake is released and transmission is in neutral. b. Never turn the ignition key to the "LOCK" position while the car is being towed. c. When the Automatic transmission vehicle is being towed with the front wheels on the ground, place the selector lever in "N" position and do not exceed 30 km/h (20
MPH).

Fig. 1-22

.... ----

(Station Wagon and BRAT)

Front towing hOOk..!

OM-439

Fig. 1-21

Fig. 1-23

A1-012

Whenever towing the car more than 10 km (6 miles) distance, tow the car with the front wheels raised off the ground. In case of an inoperative transmission, always tow it with the front wheels raised off the ground. d. Avoid towing another car with front towing hooks. e. Not only towing hooks but also other body parts might be damaged if pulling too quickly the rope winded round the hooks and if pulling strongly the rope side ways against the hook. f. Never use tie down tabs for towing.

CHAPTER~
PERIODIC MAINTENANCE SERVICES
Page 2-1. 2-2. SCHEDULE OF MAIN-rENANCE SERVICES ................. 2- 2 PROCEDURES OF MAINTENANCE SERVICES .............. 1. Inuke and Exhaust Valve Clearances . . . . . . . . . . . . . . . . . . . .. 2. Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . .. 3. Cylinder Head Nuts, Bolts and Intake Manifold Bolts .......... 4. Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5. Engine Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6. Engine Coolant ................................... 7. Cooling System, Hoses and Connections. . . . . . . . . . . . . . . . . .. 8. Engine Idie Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . .. 9. Choke Mechanism Lubrication ......................... 10. Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11. Fuel and Evaporative System Hoses and Connections .......... 12. Air Filter Elements (Air Cleaner, P.C.V. Air Filter) . . . . . . . . . . .. 13. Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14. Transmission Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15. Engine Oil, Transmission Gear Oil and Differential Gear Oil for Leaks ................................. 16. Automatic Transmission Fluid ......................... 17. Differential Gear Oil (Automatic Transmission) .. . . . . . . . . . . .. 18. Rear Differential Gear Oil (4WD Vehicle) ................ .. 19. Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20. Disc Brake Pad and Disc. . . . . . . . . . . . • . . . . . . . . . . . . . . . .. 21. Brake lining and Drum. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 22. Brake System for Leaks or Damage ...................... 23. Brake System, Parking Brake and Brake Servo System Operations. .. 24. Cups and Dust Seals of Master Cylinder and Wheel Cylinders ..... 25. Lubricate Front Disc Caliper. . . . . . . . . . . . . . . . . . . . . . . . . .. 26. Vacuum Hose and Check Valve of Brake Servo System ......... 27. Clutch and Hill Holder Systems. . . . . . . . . . . . . . . . . . . . . . . .. 28. Steering System, Front and Rear Axle Boots . . . . . . . . . . . . . . .. 29. Power Steering System .............................. 30. Suspension (Ball Joint and Dust Cover) . . . . . . . . . . . . . . . . . . .. 31. Grease on Front and Rear Wheel Bearings . . . . . . . . . . . . . . • . .. 32. Wheel Alignment ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 33. Retighten Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 34. Headlight Aiming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 35. Lubricate .Hinges and Locks of Doors, Hood and Trunk lid .. . . .. 2222222222222223 3 4 4 5 6 6 6 6 7 7 7 9 9 9

SlIBARU
2-3.

2-10 2-10 2-11 2-11 2-12 2-13 2-13 2-14 2-14 2-15 2-15 2-16 2-16 2-17 2-18 2-20 2-20 2. -21 2-21 2-22 2-23

SPECIAL TOOLS ........•........................... 2-23

PERIODIC MAINTENANCE SERVICES

2-1. Schedule of Maintenance Services
Symbols used A
R

I P E
(I) or (R)

Adjust Replace Inspect, correct or replace ifnecessary Perform Item for emission control sYstem Recommended service for safe vehicle operation MAINTENANCE INTERVAL [Number of months or km (miles) whichever occurs fust)

MAINTENANCE ITEM
1.6

7.5 12

15 24
1<1;

22.5 36

30 48

37.5 60 37.5

45
72
45
1

52.5 84
52.5

60

E E E E E E E E E E E E E

1
2

Intake and exhaust valve clearance Drive belt

tel

e

II

I
(I)

3 4 5 6 7 8 9 10
11

Retighten cylinder head nuts and manifold bolts Engine oil Engine oil filter Engine coolant Cooling system, hoses and connections Engine idle speed Choke mechanism lubrication Fuel filter Fuel and evaporative system hoses and connections Air filter elements (air cleaner, PCV air filter) Spark plugs Transmission oil
gear oil for leaks

P R R R R
(I)

+. n
R R R R (R)
(I)

96
60

I
(I)

R R

R

R R

R R (R)

R
(I)

I
P

~
P (R) (R)
(I)
I

(R)

(R)
(I)

12
13

R R
1

R R

14 15 16 17 18 19

R
1

I
1

R
I

Ensine oil, transmission gear oil and differential Automatic transmission fluid Differential gear oil (automatic transmission) I

I I
I

R
I

I I

R
I

R R R

I
1

R R R

Rear differential gear oil (4WD vebicle) Brake fluid Disc brake pad and disc Brake lining and drum Brake system for leaks or damage Brake sYstem, parking brake and brake servo system operation
1

I R
I I
1

R
I L

ffi
22 23 24 25 26 21 28

I I

I

I
I

I

I
1

I

I

I

I

I

Cups and dust sealS of master cylinder and wheel cylinders
Lubricate front disc caliper Vacuum hose and check valve of brake servo system Qutch and hill-holder systems s.teering sYstem, front and rear axle boots

R

R
P P

~
A
I

P

pI

I I

I

I

I

;=f.
I I

I I
I

I

I

I

I

2-2

~ ..~
I

PERIODIC MAINTENANCE SERVICES
Months MAINTENANCE ITEM xl000km xlOOO miles 29 30 31 32 33 34 35 Power steering system Suspension (ball joint and dust cover) Grease on front and rear wheel bearings Wheel alignment Retighten wheel nuts Headlight aiming Lubricate hinges and locks of doors, hood and trunk lid 1.6 1
I

i

7.5

15 24 15

22.5 36 22.5

30 48 30

37.5 60 n5

45

52.5 84 52.5

60 96 60
I

12
7.5

72
45 I

I

I
I

I

I
I

I

I P P I
p p

P

P

P I

p

p

NOTE: When operating your vehicles under any of following conditions, change the engine oil every 6,000 km (3,150 miles) or 3 months whichever occurs first. • Operation in extremely cold Mather • Repeated short trips • Driving on dusty roads

2·2. Procedures of Maintenance Services
To maintain the best perfonnance of vehicle and to drive safely, periodic maintenance services must be perfonned at least at the designated intervals and strictly in the correct procedures. And also use the SUBARU genuine parts whenever replacing parts. At the specified intervals, inspect, replace or adjust each item as follows. Standard ofValve clearance (when engine is cold)

l~
Intake

All models except those with hydraulic lifter 0.23 - 0.27 mm (0.009 - 0.011 in) 0.33 - 0.37 mm (0.013 - 0.015 in)

Hydraulic lifter equipped models Omm (0 in) Omm (0 in)

I

Exhaust

1. Intake .nd Exhaust Valve Clearances
NOTE: It is not necessary to adjust valve dearances on hydraulic lifter equipped models.
1) Bring piston of cylinder to the top dead center at compression stroke. 2) Insert a thickness gauge between valve stem and rocker ann to measure the valve clearance. 3) To adjust the clearance, use Valve Clearance Adjuster (498767000). Loosen locknuts and turn adjusting screws to obtain the specified valve clearance.

4) Tighten locknuts. 14-18N·m (1.4 1.8 kg-m. 10 - 13 ft-lb)

Torque

ST'031

5) Adjust each valve clearance according to the follOWing sequence.

Fig. 2-1 Adjusting valve clearances

Cylinder number

#1 ... #3 ... #2 ... #4

_________ ~ NOTE: When replacing belt with new one. A3·186 Fig. retighten the cylinder head nuts in advance..\'1 Repeat 4 to 5 times.1 nut to the specified torque. 2) 2.79 in) 3. Bolts and Intake Manifold Bolts 1) Remove both sides of valve rocker covers. apply grease on lip of idler cap and try to install it again. J) Loosen No. 221b) 14 mm (0. retighten the No. • Oil pump belt for power steering Oil pump belt tension 15 20mm(0.~ .22lb) NOTE: a.l:l #3 cylinder head by 60°. When installing idler cap. When making the adjustment within the first maintenance interval. ( I) Loosen lock bolt installing idler after taking out idler cap. 15 I 20mm (0.lb) i NOTE: a. Apply engine oil . Adjust the valve clearances when the engine is cold with its coolant temperature between 20 and 40"C (68 and 104"F).59 . Wipe off any oil or water on belt. 2) Wipe off any oil or water on belt and pulleys. NOTE: Do not loosen the nut more than 90°. I (Idler lock bolt) .39 in)! 98 N (10 kg.)~0 '0'''0 .. and then turn adjust bolt so as to obtain the specified belt tension. since water leak might occur. pulley and idler.alternator mounting bolt (2) Retighten idler lock bolt anJ in· stall idler cap.59-0.PERIODIC MAINTENANCE SERVICES 6) Rechec k the valve clearances on both sides after rotating crankshaft several times. and adjust it if necessary as follows.l1J 14 _ 22 n. adjust its tension to 10 mm (0. Make sure to install idler cap securely by turning it. If not available to do so.. b. _ _. ___ 20 . Alternator belt tension 13 Power steering pump 98 N (10 kg. turn it while pushing. 13 (0. 22Ib). The other #4 cy· manifold bolts 011 the #2 linder head side should be intact.79in)/ 98N(IOkg.29 N·m ~··--·-I--------l Torque ( ~• 3 kg.51 Crank· shaft Idler Fig. ficlent engine oil to its thread portion as shown in figure. 2·2 Alternator belt tension I) Inspect alternator belt tension. After repeating 4 to 5 times of loosening and tightening operation in the range of 60°. 2) Loosen the tlHee bolts securing the intake manifold on the. 3) Replace belt if crack or other damage is found. 2·3 Tightening. 2·5 Turning adjust bolt A3·111 Fig. L . 3) Replace belt if crack or other damage is found. Drive Belt • Alternator belt I i . I) Inspect oil pump belt tension for power steering and adjust it if necessary as follows. Cylinder Head Nuts.24 Oil pump belt tension for power steering OM 101 Fig.51 0. 2·6 Loosening nut and applving engine oil 2-4 .55 in)/ 98 N (10 kg. Fig.. b. . __. Loosen alternator mounting bolt and change alternator installing position so as to obtain the specified belt tension.. 22lb) :.0.1 nut on cylinder head by around 60° and apply suf.

Engine Oil I) Drain engine oil by loosening engine oil drain plug. (0.Ql5 in) 2) Open engine oil filler cap for quick draining the engine oil.013 9) Install the rocker covers. 7) Retighten the intake manifold bolts on the #1 .O. 18 ft·lb) NOTE: a.3 0. A3-119 OM-514 Fig. 2. fngilll: oil 'pc. 13 16 ft-lb) The proper viscosity helps car get good cold and hot starting by reducing viscous friction and thus increasing cranking speed.PERIODIC MAINTENANCE SERVICES 0.27 mm . retightening operation should be carried out when engine is in cold condition below 40°& (104°F).23 -. 2UW·SO . I 6) Also tighten all nuts on another side cylinder head with the same manner. Make sure that vehicle is placed level when checking oil level.Qll in) 0. NOTE: 8) Adjust the intake and exhaust valve clearances when engine is cold. 2·7 Tightening sequence for cylinder head nuts and bolts 25 N·m (2. lOW-40. ITlM API Classili~a- SAL VI~i.'osi!y No.#3 cylinder head side to the specified torque. d. lEXhaust valve .4 N·m (0.5 kg-m. : 0. 4 and 5 bolts.22 N·m (1.2 kg·m.2-9 Engine oil filler cap 3) Tighten engine oil drain plug after draining engine oiL Fig.) < I I IOW-3I1.2. A3-007 Fig. 5) After tightening all nuts. As a rule.2-8 Draining engine oil 4) Fill engine oil through filler pipe up to upper point on level gauge. Use Socket Wrench (899988607) to retighten No. do not mix two or more oils of different brands. (Except hydraulic lifter equipped models) Each oil manufac1Urer has its own base oil and additives. Retightening procedure for the nuts should be carried out one by one. 4) Retighten all nuts in the sequence shuwn in figure with same manner. reo tighten No.9 nuts. and Applicable Temperature (OF I lion 30" 34" 0" _III" 30" 60° 16" 90" ("0 U" I 30. 2-5 OM·745 Fig.1 and No.2. Use Socket Wrench (499987006) to retighten No. b.2 .8 .9 ft·lb) 4. c. selected in accordance with the next table. 20W-4U. 1 nut again to the speci· fied torque without loosening.009 . lOW-50 SIY-JII Torque 18 .37 mm 0. 64N·m (6.47 Intake valve r. Thus.5 kg-m. 2-10 Checking engine oil level .33 I (0. ! Torque 3 .4 kg·m.0. Use engine oil of proper quality and viscosity. SE SF (SW-30 oil is not recommended for sustained high speed driving.

8) Stop engine. If necessary. therefore. 5) Fill the SUBARU coolant up to level plate. Engine Coolant • Inspecting Inspect that the coolant level is above level plate by removing radiator cap. check thermostat. 5) If radiator hoses are damaged. 4) Tighten drain cock firmly. • Replacing 1) Put heater control knob on instru· ment panel to heat position. Do not attempt to open the radiator cap immediately after the engine has been stopped. recheck the oil level. 4) Tighten more approximately two thirds tum after the seal rubber con· tacts the oil pump case.8 Imp qt 1600 cc Engine Approx. Always use SU BARU Coolant. Fig. NOTE: The filter element and filter case are permanently joined.6lmpqt 2. interior cleaning is not necessary. The SUBARU Coolant containing anti-freeze and anti-rust agents is especially made for SUBARU engine. and wait until the engine temperature is decreased. 6) Start engine and warm it up for a time. Cooling System.2·11 Inspecting coolant level 5) Close engine oil filler cap. add coolant up to level plate.2 USqt ) 3. clean the inside of hoses or tube with cleaning oil. which has an aluminum crankcase.0 II (4. 6) Install radiator cap and close firmly. Top up coolant to level plate if the coolant level is 10 mm (0.39 in) or more below it.6 USqt ) 2.8 Fig. The radiator is of the pressurized type. 7. Hoses and Connections 1) Check the components of· the cooling system and each connection for leak. replace it with a new one. 1) Remove oil nIter with an oil fIlter wrench.7 3. run engine and make sure that no oil is leaking around seal rubber.0 II (3. 9) Inspect the coolant level. (Except hydraulic lifter equipped models) 2-6 . 7) Start engine and warm it up for a time. s.1lmpqt Lower level 3. NOTE: Inspection of engine idle speed should be carried out after inspection of intake and exhaust valve clearances.S C (188 to 193°F).7 Imp qt C.S C (188 to 193°F) while radiator is not so hot. add the engine oil up to upper point on level gauge. Engine Idle Speed 3) Open radiator cap for quick draining coolant. 7) After stop engine. 3) Install oil fIlter by turning it with hand. or oil may leak.5 to 89. 2) Loosen coolant drain cock after installing hose onto drain plug.5 to 89. 5) After installing oil fIlter. Do not tighten excessively.6US q t ) 4.2 USqt ) 2. replace with new ones. being careful not to damage seal rubber.s!! (2. check thermoswitch or fan motor. If necessary.S Irnpqt 1600 cc Engine Coolant capacity 1800 cc Engine Approx. 6. 5.5 Q US qt ) 4.2lmpqt OM-519 e. b.S!! USqt ) 3. 2) If the coolant temperature ex· o ceeds 86. and drain coolant. 5. 2) Get a new oil fIlter and apply a thin coat of engine oil to the seal rubber. since other coolant may cause corrosion. 6) If by-pass hoses or overflow tube are clogged.3 Q (S. 4) If electric fan does not operate with coolant temperature above 93 to 97°C (199 to 207° F). 3) If thermostat does not open o at 86.PERIODIC MAINTENANCE SERVICES Engine oil capacity 1800 cc Engine Upper level 4. Engine Oil Filter NOTE: a.2·12 Draining coolant 8.

11. 3) Inspect idle speed. 5 Retainer A3·256 A3·192 Fig. Check for the valve case with no crack. c. b. Check for unobstructed evaporation line on canister side with no resistance by blowing air into hose.. Fuel Filter Fuel fIlter cannot be disassembled as it is of the cartridge type. Disconnect evaporation line at evaporation pipe CP. 2·15 7oo± 100 800 ± 100 [At neutral (or N) or P position] Tank vapOr line 9. Idling speed (rpm) All models except automatic transmission vehicle Automatic transmission vehicle Fig.PERIODIC MAINTENANCE SERVICES 1) Disconnect purge hose from pipe and clog hose with plug or the like. 2-74 Fig. Remove fuel rdler cap. Check for unobstructed evaporation line on fuel tank side except for a little resistance due to 2-way valve by blowing air into hose. 2·13 ] A3·256 2) Start engine and warm it up for 5 minutes or more. b. To fuel tank 1 Valve "8" 2 Valve "A" 3 Cue 4 Spring . d. A3·254 Fig. c. A3·257 Fig. Check for air passage with slight resistance due to the valve by blowing air into the nipple on the side marked with letters "To engine". Repeat the same step on the other nipple.2-16 Evaporation line (2) Two way valve a. Fuel and Evaporative System Hoses and Connections 1) Fuel piping and connections Check fuel piping and connections for leakage. Choke Mechanism Lubrication Lubricate choke linkage and other operating parts. 10. If cracked. a. R~~"canister To ~~§ . replace it with new one. 2) Evaporative emission system (I) Evaporation line from fuel tank to canister.2-17 Two way valve 2-7 .

After the engine has cooled below 50°C (122°F). c. @- I From carburetor Purge vent Vacuum release orifice 0. Blow through the nipple of the vacuum switching valve on the carburetor side to ensure there is no leakage. replace canister with new one. replace the vacuum switching valve. If air can be blown into canister.2·18 Purge line Fig. 2·20 to ensure there is no leakage. If there is no air flow. If air passes. disconnect the hose @ from the vacuum switching valve CD.059 inl dia. c. Disconnect two hoses of carburetor vapor line and tank vapor line from pipe CP CD. Then check for no air leak of vacuum chamber for purge control valve in canister by blowing into hose. ~.4 mm (0. Check for unobstacled line by blowing air into the hose. b. If air does not pass. Similarly. Disconnect vacuum vent hose from pipe CP CD. Purge control valve Activated carbon 00 000 00 00 PipeCP 2 Canister 3 Carburetor 4 Hose clamp A3·258 Filter Fig. From fuel tank Vacuum vent ® 1 Orifice 1.PERIODIC MAINTENANCE SERVICES (3) Purge line a. Disconnect the hoses @ and @ from the vacuum switching valve CD . 2-8 . 2·19 A3-259 (4) Canister a. If there is air flow. replace the thermo valve. Then check for air passage by blowing lightly in it. disconnect the hose @ from the vacuum switching valve CD. b. replace the thermo valve. b. (5) Vacuum switching valve and thermo valve (California models and non4WD of non-California models) a. Disconnect hose of purge line from pipeCP CD. Blow through the open end of the hose to check if there is air flow at the port in the thermo valve. In either case. Check for air passage by blowing in it. if there is a leak. blow through the nipple on the thermo valve side A3-260 I 2 3 4 Vacuum switching valve Thermo valve Hose Hose 5 Carburetor Fig. After the engine has warmed above 64°C (l47°F).5 mm (0.016 inl dia. d. Disconnect purge hose from the pipe CP CD. If canister case is cracked. Blow through the open end of the hose to ensure there is no air flow at the port in the thermo valve ®. replace it with new one. replace canister with new one. replace it with new one because disphragrn is broken.

55 in) Pitch = 1. OM'755 Spark plug gap 1.039 0. the filtration layer thus formed will be lost along with the viscous liquid.1 mm (0.0 . 12.C. be careful about the air suction manifold switch maybe hot. 2-9 . which function as a filtration layer to reduce dust penetration into the filter paper.0 . Be sure to place the gasket between the cylinder head and spark plug. 13 17 ft·lb) I A3·262 Fig. 2-23 Air cleaner element NOTE: Each oil manufacturer has its base oil and additives.8 . air filter 1. and Applicable Temperature (OF) -30° _34° 0° 18° 30° 0° 60° 16° 90 SSW 90° 32° ~ (oC) • • OM·539 Transmission and differential gear oil 4WD rear differen· tial gear oil GL-5 . b.S. Air Filter Elements (Air Cleaner P.039 ·0. U.UII) Champion: RN9YCA (or RNllYC4) For i IChampion: RN9YCA I Canada (or RNlIYC-4) Recommended oil ITEM I 18 24 N·m ( 1. tighten them to the specified torque. If there is not.0492 in) To thermo vacuum valve III A3·261 Fig.UlI. Spark Plugs Recommended spark plugs NGK: BPR6ES-Il (or BPR5ES·ll.PERIODIC MAINTENANCE SERVICES d.C. 14.4 kg·m. " I SOW I ~ r ~ Fig. The filter paper of the element is wetted with a special noninflammable slow-evaporating viscous liquid. 2-21 Vacuum switching valve NOTE: Do not attempt to clean the air cleaner element. blow through the nipple on the carbure· tor side to ensure there is air flow.2. Dirt adhering to this filter paper forms porous laminations with the viscous liquid. disconnect the hose ® from the vacuum switching valve. Thus. With the engine running. It is resistant to cold weather and has a long service life.A. V. 2·25 Spark plug When installing spark plugs on cylinder head. Torque 13. If this filter paper is cleaned. W22EPR. V. Transmission Oil NOTE: Use transmission gear oil of proper quality and viscosity that is selected in accordance with the next table.1 mmlO.25 mm (0. After the temperature of engine coolant has reached 64°C (l47°F) or more.043 in) Fig. When replacing the spark plug on #4 cylinder head. BPR7ES·ll) Nippondenso: W20EPR·Ull For (or W l6EPR. do not mix two or more brands. Air Filter) I API Classification SAE Viscosity No. = 14 mm CO. 2-24 P. 1. A9·163 Fig. replace the vacuum switching valve. 2-22 Thermo vacuum valve III NOTE: a.1.043 in) Spark plug thread Oia.

2-10 CALTEX a. If the oil leaks are found. When transmission is hot. 3) Place selector lever in "P" position and run engine on at idling speed. 44N·m (4. (2. the level should be above the center of upper and lower marks. Engine Oil.tween die transmission case and drain plug.7 f. 2) Park vehicle on a level surface. 2·28 Inspecting oil leaks Recommended automatic transmission fluid (ATF Dexron) B.4 Imp qt 3. add some oil through the oil level gauge hole up to the upper point of gauge.PERIODIC MAINTENANCE SERVICES • Inspecting Inspect the transmission gear oil level. Autran DX Texamatic fluid 6673 Dexron CASTROLTQ Dexron Mobil ATF 220 Texamatic Fluid 6673 Dexron Torque NOTE: 16. Transmission Gear 011 and Differential Gear 011 for Leaks Inspect the underside of engine. • Replacing 1) Drain oil by removing drain plug.5 kg-m. transmission gear case and differential gear case (include 4WD rear differential gear case). 6) Remove it again and note reading.0 f.. 2-26 OM·515 15. 2-29 Fig.P.P. b. Automatic Transmission Fluid • Inspecting 1) Drive vehicle several miles to bring automatic transmission fluid (ATF) up to nonnal operating temperature. correct them. 2-27 2) Reinstall drain plug after draining oil and tighten it to the specified torque. add recommended ATF until the fluid level is within the specified range (within upper and lower limit marks). Replace iIle gasket widl new one. • A3·244 OM·746 Fig. B. Nonnal operating temperature is 60 to 80°C (140 to 176°F). and when it is cold. Capacity 4-speed and S-speed (except 4WD) 2. the level should be below the center of these two marks. S) Reinsert the level gauge all the way.9 US qt ) 2. NOTE: Do not fill the fluid above upper point of level gauge. 4WD C·2USqt) 2. 3) Fill transmission gear oil through the oil level gauge hole up to upper point on level gauge. CASTROL MOBIL TEXACO . ATF level gauge hole also serves as fluid filler. If the oil level is at the lower point or below. 4) Remove level gauge and wipe it clean. 33 ft-Ib) OM·748 Fig. Be sure to place a gasket .6 Imp qt Fig. If the fluid level is below the lower limit mark.

2-32 2) Reinstall drain plug after draining oil.---.02 (4.. Be sure to place a gasket between oil pan and drain plug.5 kg·m. • Replacing 1) Drain oil by remOVing drain plug_ 2) After installing drain plug onto rear differential gear case firmly.6 6.8 US qt ) 0. and tighten it to the specified torque. NOTE: When replacing ATF.02 ( 5. Replace the gasket with new one.6. removing drain NOTE: a. 3) Fill differential gear oil through the oil level gauge hole up to upper point on the level gauge.8 Q (0.ear case firmly. 2-30 OM·335 18. the normal refilling capacity is 4. 17. Differential Gear Oil (Automatic Transmission) • Inspecting Oil level should be maintained between two points on the level gauge. 2-37 OM-516 • Replacing I) Drain oil by plug.3 . 2-33 i OM-747 4WDAT I 6. 2) Reinstall drain plug after draining fluid.6. I Capacity l. 3) Fill ATF through the fluid level gauge hole. add some oil up to upper point. 18 ft·lb) 4) Check the ATF level according to the above inspection procedure 1) to 6).2 US qt.H (1. Capacity OM-517 Non4WDAT 5. . Torque 25N·m (2.3 . If the oil level is at lower point or below. Oil level should be maintained fully to the mouth of filler hole. add some oil up to the mouth.5 kg·m.5 Imp qt).8 US qt ) 5.3 US qt ) 4.. Rear Differential Gear Oil (4WD Vehicle) • Inspecting Remove plug of ftller hole and check the oil level. fill oil up fully to the mouth of ftller hole. If the oil level is below the mouth of filler hole.0 6.6 Imp qt :1J I Fig.5. b.7 Imp qt 3) Install ftller hole plug onto rear differen tial v.3 US qtqt ) 1. Be sure to place a gasket betlNeen the differential gear case and the drain plug.9 5. Torque 25N·m (2. 2-11 I Capacity 0. 3. b.~ I PERIODIC MAINTENANCE SERVICES • Replacing 1) Drain fluid by removing drain plug. Replace the gasket with new one.3 Imp qt Fig. -.42 ( 6.1 Imp Fig. NOTE: a.9 . 18 ft-Ib) Fig. then tighten it to the specified torque.

2-34 a.PERIODIC MAINTENANCE SERVICES 19. b. b. 3) Remove filler cap from brake fluid tank. Brake Fluid 1) Either jack up the front end of vehide and place a safety stand under it. 6) Open the air bleeder. ~'----'---~'---'----'---~---. Be careful not to spill brake fluid onto the painted surface. NOTE: Fig. hold brake pedal depressed and tighten screw and install bleeder cap. Then tighten air bleeder securely. cross design. slowly and repeatedly depress and release the brake completely until a solid stream of brake fluid (containing no air bubbles) runs through vinyl tube. (3) Instruct your co-worker to depress the brake pedal slowly two or three times and then hold it depressed.9 kg-m. 5. 5) Install one end of a vinyl tube onto the air bleeder of wheel cylinder located farthest from master cylinder and put the other end of tube into the container for receiving brake fluid. c. 7) Use the same procedure as the one described above to change brake fluid of front wheel cylinder.7 0. The brake piping consists of a dual system. (4) Loosen bleeder screw approximately 1/4 turn until a small amount of brake fluid drains into container. To drain fluid into container.-. Be careful not to allow dirt or dust to get into the reservoir tank. Then close the bleeder. in order to prevent the tank from run· ning short of brake fluid. Discard the drained brake fluid and do not reuse it.5 ft-Ib) Front right Rear right Primary Torque (bleeder screw) Front left Rear left A17-150 A3-124 I Fig.-.~- FMVSS No. (5) Repeat steps (3) and (4) above until there are no air bubbles in drained brake fluid. . bleed air from the brake lines as follows: Recommended brake fluid I-----. and then quickly tighten screw. 8) Always start with the primary side and then work on the secondary side. 9) After brake fluid has been changed. The amount of brake fluid required is approximately 80 cm 3 (80 ee. fresh DOn brake fluid NOTE: Start with the bleeder located farthest from the master cylinder. 2-36 (7) Bleed air from front wheel cylinder using the same procedures as described in steps I) through 6) above. 116. Use fresh DOT 3 brake fluid when replacing or refilling the fluid. open the air bleeder and repeatedly depress and release the brake pedal until a small amount of fluid remains in the reservoir tank. NOTE: a.1 6. NOTE: Add brake fluid as necessary while performing the air bleed operation. 4) Refill reservoir tank with recommended brake fluid. Avoid mixing different brands of brake fluid to prevent degrading the quality of the fluid. (l) Install one end of a vinyl tube onto air bleeder screw and put the other end into the container. Always begin changing the brake fluid on the primary side and subsequently work on the secondary side. For convenience and safety. 7 -9N·m (0. 2-35 Fig. (2) Attach a wrench to bleeder screw. To purge air out of brake system lines. it is advisable to have two men working. c. and depress and release brake pedal until old brake fluid is drained out and new fluid flows through vinyl tube. Install one end of a vinyl tube onto the air bleeder of master cylinder and insert the other end of the tube into a container to collect the brake fluid.-------.88 cu in) for each pipe on the primary and secondary sides. 4. Always check to be sure a small amount of brake fluid is in the tank while changing brake fluid.---. or drive vehicle onto the pit and then jack up the front end. The piping on the primary side connects the right front brake and the rear left brake and the piping on the secondary side connects the left front brake and rear right brake. NOTE: a. but do not loosen it at this point. (6) After completing the bleeding operation. 2) Remove both left and right front wheels. b.

.09 in) 182 mm (7.'J Thickness of ~ I 1\. J NOTE: Always replace both leading and trailing brake shoes for the left and right wheels at the same time.~ Wear limit lOmm (0.0039 in) NOTE: DO not touch the brake pedal with disc pads removed.59 in) 7.71 in) 15.-_ _ _ _ . Visually inspect bleeder screws and brake pipe joints to make sure that there is no fluid leakage. Brake drum inside diameter 20. 2·39 Measuring thickness of brake disc L Maximum permissible disc rotor runout 0. b. 11) Depress brake pedal again with a force of approximately 294 N (30 kg. 2-37 12) Install front wheels. : Wear limit IS mm (0. Thickness of pad A3-154 Fig. refer to "BRAKES". refer to "BRAKES". dents or other damage. For the removing and installing procedures of brake pads. A3'156 Fig. Brake disc pad thickness Standard .-_ _ _.10 mm (0. At this time check pedal to see if it shows any unusual movement. d.295 in) Lining Pressure plate I I 21.2-41 Measuring brake drum . I.5 mm (0.20 in) 1. the brake tubes and hoses. 2-38 Measuring thickness afdisc pad Brake lining thickness I I I I Brake disc thickness Standard Solid disc Wear limit Standard Ventilated disc ! Standard 5 mm (0.20 in) from the outer periphery of the rotor. 2-13 Measuring inside diameter A3·157 Fig. 2-40 Measuring thickness of brake lining 2) Check brake drum for wear. 66 Ib) and hold it there for approximately 20 seconds.5 mm (0.L.17 in) Fig. Brake Lining and Drum Inspect brake linings and drums of both sides of the rear brake at the same time by removing brake drums..PERIODIC MAINTENANCE SERVICES 10) Upon completion of air bleeding for the primary and secondary brake lines. Disc Brake Pad and Disc Inspect disc brake pads and discs of both sides of front brake at the same time by removing the disc brake pads. NOTE: Measure the disc rotor runout at a point less than 5 mm (0. and drive car for a short distance between 2 to 3 km (1 to 2 miles) to make sure that brakes are operating properly. depress brake pedal to determine if its operation and stroke length are correct.5 mm (0.5 mm (0. Do not disconnect.610 in) J I I Thickness of I I A3-125 Wear limit I J I Fig. For the removing and installing procedures of the rear brake. A3-155 I Standard Wear limit 180 mm (7.39 in) 18mm (0.059 in) 12. 1) Inspect brake shoes for damage or deformities and check brake linings for wear.492 in) I i i I ' .

... \ 1 Master vac \. I 2) Check the possibility of adjacent parts interfering with brake pipes/ hoses during driving... Adjust lining clearance of another side rear brake with the same manner... Brake System. 243 Fig. Turn back adjusting screw by 180 and lining clearance will be 0. 0 A3·126 Fig.004 to 0... 244 ~~ 13...... Brake System for Leaks or Damage 1) Check scratches. if air is in the hyby the feel of the If air appears to bleed it from the .. 2) Adjust lining clearances of rear brake as follows. and loosen con· nections/clamps.43 in) c.20 . Jack up vehicle to release tires and wheels slightly from the ground.'" A3.II mm (0. . 2·42 A3-127 I f the free play is not within the specified range.. 66 Ib) 2 NOTE: When the brake fluid level in the reservoir tank is lower than the specified limit. scratches. etc. A3-153 4) Check to see draulic brake line pedal operation.. swelling and/or traces of fluid leakage on brake hoses or pipe joints. Tighten adjusting screw on back side of rear brake drum fully until tire and wheel ceases to rotate.. 66 lb).PERIODIC MAINTENANCE SERVICES 22. ! \ '\.. Be sure to' rotate tire and wheel lightly by hand... 23. Brake pedal free play 5 .15 in) \ . Brake pedal reserve distance More than 80 mm (3.152 \ . Parking Brake and Brake Servo System Operations • Brake system 1) Check the free play of brake pedal by lightly depressing the pedal with your finger. Fig. adjust the length of master-vac operation rod and/or the position of stop lamp switch until correct adjustment has been made. b... 2-14 Fig. exist in the line.. on master cylinder or wheel cylinder..... d... 3) Measure the distance between brake pedal and floor when the pedal is depressed with a force of approximately 294 N (30 kg. system. 246 .1 to 0..0. .. operation rod ' \ 2 Stop lamp SWitCh"'\. 3) Check any trace of fluid leakage. ... 245 Adjusting screw for lining clearance Fig.15 mm (0. a.15 in)! 294 N (30 kg. the brake fluid warning light on the instrument panel will come on..0059 in).. e.

• Brake servo system 1) Connect a vacuum gauge to the line between the master-vac and the check valve. Lubricate Front Disc Caliper • Parking brake lever I) Remove lever cap ring. start engine. 55 Ib) to make sure lever still has a short length of stroke to go. 0. using a brake tester or by driving the vehicle for a short distance on a straight road. depress brake pedal several times applying the same amount of pressure so that a vacuum will not be created. rub it off by a wire brush. Make sure that vehicle stops on uphill road properly by operating parking lever. 3) Remove grease. Cups and Dust Seals of Master Cylinder and Wheel Cylinders Replace the cups and dust seals of master cylinder and wheel cylinders according to "BRAKES". Do not depress brake pedal. adjust it as follows: a.2-49 Replacing cups and dust seals of master cylinder and wheel cylinder 25. 0. c.3 kPa (25 mmHg. 3) Stop engine and watch the gauge to make sure that the vacuum drops below 3.98 inHg). d. Loosen the lock nut and change the setting of adjuster until the play at point A is 0 to 0. and clean the lip of lever cap and its slot of caliper body to be free from any foreign matter. After several applications of pedal pressure. NOTE: Carry out this replacing operation before replacing brake fluid. Pull parking brake lever forcibly three to five times. A3-230 Fig.3 kPa (25 mmHg. 19. Rubber cup 2 Dust seal A3-162 Fig. 2) Take off lever cap. 24. 2-15 .98 inHg). 247 2) Start engine and keep it running until a vacuum of 66. • Parking brake 1) After confirming the proper operation of brake pedal. (3) As engine starts. b. check the vacuum using the following procedures: (l) Wit h engine off. Parking brake lever stroke ! Standard Total number ' 3 . Lightly depress and release brake pedal as necessary until the parking brake lever pull is within the specifications.-----.. 4) If a vacuum gauge is not available.69 inHg) is indicated on the vacuum gauge. within 15 seconds. check the pedal height above floor to make sure that it does not vary with each depression of pedal.5 mm (0 to 0. If the vacuum drops below 3. if brake pedal moves slightly toward floor. 248 A3-231 A3·130 I Cable 2 Equalizer A17·149 Fig.7 kPa (500 mmHg. the brake servo system is functioning properly.4 notches! 245N (25kg. PERIODIC MAINTENANCE SERVICES 5) Check for even operation of all brakes. master·_-'\I'IIcls functioning properly. 551b) \ I II notches 2) If the parking brake lever pull is not within the above specifications. (2) With brake pedal depressed. pull parking brake lever with a force of approximately 245 N (25 kg.020 in). NOTE: If the slot gathers rust.

4 12 ~ 17 ft-Ib) 27. l) 16 24 N·m (1. NOTE: NOTE: Use only Silicon Compound (725191050 or 003606010) for guide pin and lock pin portions. adjust it by turning adjusting nut on engine side end of clutch cable at release fork. air flows through master-vac. Vacuum Hose and Check Valve of Brake Servo System 1) Check vacuum hose for cracks or other damage.J'UV'JV 26. air will not flow and therefore check valve should be replaced with a new one. note the direction of check valve and correctly connect valve to vacuum hoses. 2-52 Grease application to lock pin portion A3·266 A3·232 Fig. . When air is drawn in through the opening of check valve on the engine side. Clutch and Hill Holder Systems I) Inspect free play of clutch pedal by operating pedal by hand. After assembly. 2) Remove foreign materials from guide pin and sleeve. 3) Check valve conducts air in one direction only.2-50 Grease application NOTE: Never use any grease except the specified. 5) Pull parking brake lever several times. 7) Attach cap ring onto lever cap. Fig. If it is out of the specified value. When installing the check valve onto the vacuum hose or when installing the vacuum hose on the engine and master·vae. replace it with a new one. Grease Silicon Compound (725191050 or vV. 3) Then.-~~ . and apply Silicon Compound (725191050 or 003606010) to this area. do not use soapy water or lubricating oil on their connections. 2-51 Grease application to guide pin portion Fig. b. Grease NIGLUBE RX-2 grease (725191040 or 003606000) A3·265 Fig. 6) Fit lever cap properly into the slot of caliper body.PERIODIC MAINTENANCE SERVICES 4) Apply sufficient amount of specified grease to the space around lever & spindle so as to be filled inside of lever cap after fitting it. press it to purge out air. 2-53 NOTE: NOTE: Be careful not to damage the lever cap by the edge of the cap ring. 2-16 . If boot contains too much air and is expanded. install caliper body ASSY and tighten lock pin to the specified torque.---~-- .6 ~ 2. --~-. cone spring and the lever cap fitting slot without fail. Especially apply grease to the ends of lever & spindle. make sure that boots are properly fitted in grooves on guide pin and sleeve. 2) Remove check valve and manually blow through valve to check its operation. When installing. • Slide pin Remove caliper body assembly from support. 4) Check all vacuum hoses to make sure they are tight and secure . otherwise the lever cap will be deteriorated and will cause damage to the function of the disc brake. If air is drawn in through the opening on the master-vac side. If the lever cap is deformed or damaged. a.

2·57 NOTE: a.25 mm (0 0. 2-55 Pedal play 13 20mm (0. ~ I cable on clutchll (0.-\r( 13 (0. (I) Ifvehicle does not stop.3 N'm (0.. and should not vary.... refer to "STEERING SySTEM".3 mm (0.67 .98 in) o A20-051 Fig. • Case A When hill-holder is released later than engagement of clutch (engine tends to stall): Loosen adjusting nut gradually until smooth starting is enabled. (1) Steering force . 2) Lightly turn steering wheel to the left and right to determine the point where front wheels start to move.79 in) 28.PERIODIC MAINTENANCE SERVICES Adjustment standard of free play 2) Confinn stopping and starting perfonnance by activing hill-holder on an uphill road of 3° or higher inclination.08 .71 in) 1 Lock nut 2 Adjusting nut 3 Release fork ( 2) If vehicle does not start properly. (See "BRAKES". The effort required for steering should be smooth and even at all points.o.79 in) OM·526 [Free play 2 .. Whenever turning adjust nut. Then make adjustment the same as in Case A. prevent PHV cable from revolving as following illustration. Replace pressure hold valve (PHV).0. Steering System If it is necessary to correct the steering system... Measure the distance of the movement of steering wheel at the outer periphery of wheel. 2-56 b.12 in)] Full stroke 17 -18mm (0.4 ~ 9.0. return spring of PHV or PHV cable with new one. depress clutch pedal about thirty (30) times as a running-in operation prior to this adjustment.. . 2 3 ~ I • Steering wheel I) Set steering wheel in a straightahead position.5 mm (0. Steering System.2-54 Adjusting free play of clutch pedal NOTE: a. After replacing clutch cable and/or pressure hold valve (PHV) cable with new one.0. . 4.0 6. and check wheel spokes to make sure they are correctly set in their specified positions.51 .5 I 20 0.) 2-17 4) Drive vehicle and check the following items during operation. 3) Move steering wheel verticaJIy toward the shaft to ascertain if there is play in that direction. When replacing clutch cable with new one and/or making free play adjustment of clutch pedal.55.0.. b. Steering wheel free play A3·233 Fig..95 kg-m.. Maximum permissible play: 0.9 ft-lb) Fig. A3·267 Torque (Adjusting 5. Front and Rear Axle Boots 1. make adiustment of hill-holder system without fail as follows. I At clutch pedal! .~~~n) : release for~~L_ _ _ _ _ _-' A"'nt'~ o. • Case B ~ When hill-holder is released earlier than engagement of clutch (vehicle slips down slightly): Tighten adjust nut so that hillholder is released later than engagement of clutch (status in Case A). if they are defective and/or damaged. Tighten adjust nut of PHV cable. 0.98 in) Free play 25mm (0·0..020 in) Fig.08 .

refer to "SUSPENSION. OM-752 Fig.. 2-58 A3-134 2) Check boot for damage. . 29. Steering wheel should return to its original position after it has been turned and then released.. • Power steering fluid level 1) Place vehicle with engine "off' on the flat and level surface.. inspect for damage on dust seals.. 2) Check the fluid level by removing filler cap of oil pump.. Fig. 3) Make sure that tie rod lock nut is tight and secure. check the gear backlash. 22 36 ft-Ib) a. . 2) Check rubber coupling for deformities. While steering wheel is being rotated. turn back adjusting screw IS° and then tighten lock nut securely. While wheel is being rotated. .. 2-59 'A3·135 • Gear box I) With wheels placed on a level surface.0 . Check at temperature 6Q°C (l40°F) on reservoir surface of oil pump Fig.. cracks.. quickly turn steering wheel to the left and right.2-62 Indicator of filler cap . Steering wheel should not pull to either side while driving on a level surface. (2) Loosen lock nut by using Spanner (925640000) and tighten adjusting screw fully. adjust the gear backlash as follows: (I) Loosen gear box mounting clamps... damage or failure. scratches or other damage. reach under vehicle and check for looseness in gear box.PERIODIC MAINTENANCE SERVICES (2) Pull to one side . (3) Wheel runout . 2-61 Indicator of filler cap b. 2) Check connections of knuckle ball joints for play. (4) Return factor . If any unusual noise is noticed.. inspect the system as follows in addition to the previous article. Front and Rear Axle Boots Inspect front and rear axle boots for deformation. 2-18 OM-751 Fig. OM-750 Fig... turn steering wheel 90° in both the left and right directions. • Tie rod I) Check tie rod and tie-rod ends for bends. 2-60 Oil pump for power steering r--:rque I 29 49 N·m (3. • Steering shaft joint 1) Disconnect universal joint of steering shaft and check it for any play and yawing torque (at the point of the crossing direction).... cracks or deterioration. For replacing procedure. and slightly lower gear box... Power Steering System For vehicles with power steering system.... If faulty. If oil comes in contact with coupling. (3) From that position... 2.. wipe it clean.. Check at temperature 21°C (70°F) on reservoir surface of oil pump NOTE: Hold the adjusting screw with a wrench to prevent it from turning while tightening the lock nut. WHEELS AND AXLES".... replace them with new ones. and check the free play of ball studs.. 3) With vehicle on a level surface.0 kg-m. Steering wheel should not show any sign of runout.. or peeling off.5. Also inspect for any damage to sealing or worn serrations.

0. • Hoses of oil pump for damages 5) Air ven t pipe is inserted in the specified hole without fail. I 1 3 Boot 4 Clip (large) S Air vent pipe A3-200 Fig. NOTE: A3·199 Recommended fluid (ATF Dexron) Fig. add fluid to keep the level in the specified range of indicator. 2-64 Gearbox boot ~ .7 Imp qt) Inspect both sides of gearbox boots as follows. 1 Clip (small) 2 Clip (middle) A3·201 1 . drain fluid to keep the level in the specified range of indicator by using a syringe or the like. never rotate A position of gearbox boot B. If fluid level is at upper point or above. • Fitting bolts and nuts Inspect fitting bolts and nuts of oil pump and bracket for looseness. B and C grooves of gearbox and the rod. b. Also pay attention to clearances between hoses (or pipings) and other parts when inspecting fluid leaks. In this case. Replace hose with new one if neces· sary. When air vent pipe comes off hole of gearbox boot. Inspect andlor retighten them when engine is cold.P. NOTE: • Gearbox boots Fluid capacity 0. If fluid level is at lower point or below. NOTE: a. B and C positions of boot. Rotate Band C position of gearbox boot against twist of it produced by adjustment of tow-in etc. 3) Projection of boot is fitted in hole on A groove of gearbox to pre· vent boot rotating. If fluid leaks are found. 2) Clips are fitted outside of A. 6) Grease or other obstructions against air flow are not contained in air vent pipe. 2·65 Fitting bolts and nuts 2-19 . and correct the defects if necessary. I) A. NOTE: Prevent hoses from revolving andlor turning when installing hoses. b.PERIODIC MAINTENANCE SERVICES 3) Fluid level should be maintained in the each specified range on the indicator of filler cap. it is also caused by means of clogging of air vent pipe. A3·202 Fig.P. Wipe the leakage fluid off after correcting fluid leaks. Band C positions of gearbox boot are fitted correspondingly in A. swell or damage. • Power steering fluid for leaks Inspect the underside of oil pump and gearbox for power steering system. piping and their couplings for fluid leaks.8 liter (0.8 US qt. hole (except for air vent pipe) or damage. Autran DX Texamatic fluid 6673 Dexron CASTROL TQ Dexron MOBIL ATF 220 SHELL ATF Dexron Texamatic fluid 6673 Dexron Check pressure hose and return hose of oil pump for clack. and retighten them if necessary. 4) Boot have not clack. hoses. CALTEX CASTROL MOBIL SHELL TEXACO B. or a wrong diagnosis is taken later. 2-63 Hoses of oil pump a. correct them by retightening their fitting bolts (or nuts) and/or replacing their parts.

2) Remove cotter pin and castle nut from ball stud and disengage ball stud from transverse link.10 . Refer to "SUSPENSION.40) 25 . and pack it with grease. and remove wheel. NOTE: Be careful not to allow the tapered area of the ball stud to come in contact with grease. ft-Ib) 118 ..4 .0 . ft-lb) Ball stud transverse link castle nut Ball joint to housing bolt 44 . If necessary. 18 . replace ball joint with a newone. 2 .0.0 . 6) Tighten nuts and bolts which are used to secure ball joint..59 (5. 5) Check rubber boot for cracks or damage.5. 36 . If play exists.108) ) .PERIODIC MAINTENANCE SERVICES • Front wheel bearing Torque N·m (kg-m.7.13) 39 (4. 4) Installation is in the reverse order of removal.. :r~'\ -~ I .0. 7) Check the tightness of strut mounting nuts on front suspension and retighten the nuts to the specified torque. 2) Remove bolts which secure disc rotor to front wheel hub..".4.15.0. Discard the old seal and install a new one. If either the grease appears to be white or if only a small amount of grease remains.6. 1) Jack up the front end of vehicle.68 3) Remove oil seal from housing.~.5.. '" 3) Remove bolts which secure housing to ball joint.54 (4. 33 . clean it. and remove hub. A3·137 30.54 (4.18 (l.5. " I . to the specified torque setting indicated in the chart below.:.0 .147 (l2.33 . A3·158 Fig. 43 . Torque (Castle nut) 196 N·m (20 kg-m.67 NOTE: a.34 (2.-.25) 49 . 145 ft-lb) 2-20 . and remove front wheels. 29) 29 .~ j£1 A3-279 Fig. WHEELS AND AXLES" for further details. Torque N·m (kg-m. replace ball joint.5 ..69 31. 22 . b.5.0. " ~r » ~-:J~ Fig. Remove cotter pin from axle shaft and remove castle nut.39 (3. Torque N·m (kg-m..29) 1) Raise front wheel with a jack.8.5 ..0 . and check the condition of bearing grease. 2-66 )~ A3·136 8) Check the tightness of rear crossmember installing bolts on rear suspension and Tighten the bolts to the specified torque.5 . 1(1 j. . 2 . / .". remove the bearing from the housing.3. ft-Ib) Nut A (one) Bolt B (two) Bolt C (three) Nut 0 (one) Bolt E (four) Torque N·m (kg-m.43) 14 . 4) Check the axial play of ball stud.1. .5. 87 . and remove ball joint. 2 .~ LI I.5. Suspension System.54) Fig. ft-lb) 59 -74 (6. Grease on Front and Rear Wheel Bearinas Inspect the condition and the amount of front and rear wheel bearing grease as follows.40) 44 .

Refer to "SUSPENSION. 2 -72 1) Check the toe-in. parts as necessary. Toe·in Except 4WD inl±lmm (0. etc. be sure to make a prior inspection of the following points and repair/replace the damaged portions/ A3·203 A3·132 Fig. axle and steering linkage and con· nection • Vehicle height [It is recommended that the difference of vehicle height between the front and rear ends. 2-71 Fig. on body attaching portion of suspension.39 in) in the unloaded condition. 33. deformation.58N·m (4.9 kg-m.2·73 Wheel nuts 2-21 . or the left and right sides is less than 10 mm (0.9 kg-m.04 in) 4WD 3) If the toe·in is not within the specified range. rust. Retlshten Wheel Nuts ( Fig. • Tire pressure • Wear or damage of tires • Wheel balance • Looseness on suspension • Looseness and smooth operation on axle linkage and connection • Looseness and smooth operation on steering linkage and connection • Shock absorber operation and oil leakage • Damage.] • Stain. on front end parts 4) After completing the toe-in adjustment. 58 . Wheel AlIsnment Before checking/adjusting front wheel alignment. grease leakage.5 5.65 ft·lb) Torque A3·133 Fig. etc. turn left and right tie rods by equal angles. tighten lock nut to the specified torque setting. 2 -70 32.04 ± 0. and adjust the toe-in. tighten additionally in one six1l1 (1/6) 1Urn until both holes of bolt and castle nut align each other. WHEELS AND AXLES" for removal and installation of rear brake drum. I(Hub to disc Torque ! I rotor bolts) 44 .04 in) out 5 ± 1 mm (0. 78 88 N·m (8 .43 ft-lb) • Rear wheel bearing Remove rear brake drum and check its condition and the amount of bearing grease.20 ± 0.PERIODIC MAINTENANCE SERVICES NOTE: Af1er tightening 1118 castle nut to 1I1e specified torque. 33 .

adjust lower beam axis only_ NOTE: a. On vehicles with four (4) headlights. 2·14 Adjusting screw for horizontal direction NOTE: Low beam adjustment is available only for vehicles with four (4) headlights.6 m (24.9 ft) from headlights. b. Left-hand end of high intensity area makes contact with V line. Horizontal 34. 58 . Position screen at a distance of7.PERIODIC MAINTENANCE SERVICES I Torque . cover the outer headlights on both sides with black cloth or shades. 2-76 A3-246 A3-205 b. Vertical Upper end of high intensity area makes contact with H line. If necessary. Adjusting screw for vertical direction OM-868 Vertical Horizontal Center of high intensity area should be at headlight center.10 kg-m. Low beam (passing beam): OM-869 Fig. High intensity area Fig:2·11 A3-247 i II 2-22 . Tighten wheel nuts in the order shown in the following illustration. 2) Put vehicle and screen on a level surface. turn adjusting screws to adjust the beam axis vertically and hOrizontally in accordance with specifications. a spare tire & wheel and full fuel tank) 4) Check the aim of headlight. 3) Have vehicle in its unladen condition. Headlight Aiming 1) Adjust the tire pressure to the specifications. Do not use air impact tools to retighten wheel nuts. v Headlight height High intensity area Fig. and adjust the inner headlight only.72 ft-Ib) b. Fig_ 2-75 Adjusting screws a_ High beam (driving beam): NOTE: a. (with maintenance tools. On vehicles with two (2) headlights. (Wheel nuts) 78 98 N·m (8 .

2·78 2·3. Lubricate Hinges and Locks of Doors. 2-82 A3-167 2-23 . Hood and Trunk Lid A3-139 A3-140 A3-141 -----A3·142 'L Roller A3-143 Fig. 2·81 A3-066 Fig. Special Tools 498767000 Adjuster Intake & exhaust valve 499987006 Socket wrench Cylinder head nuts 899988607 Socket wrench Cylinder head nuts 925640000 Spanner Steering gearbox ST -029 Fig.PERIODIC MAINTENANCE SERVICES 35. 2-80 ST-030 Fig.

.........••..•.••••..............9. 3...3. 3..5.......8.... 3-75 SPECIAL TOOLS .. 3..•..•..-43 DiSASSEMBLy.... alBAAI ..... SPECIFICATIONS AND SERVICE DATA .2 COMPONENT PARTS ............ ... •• 3-38 3. ....... 3..............•...•.... • • .... ~....... 3.•••........ ............. 3-11....... • • • • ......••••..•••............1..•...•..••. 3-67 TROUBLESHOOTING .....•...4.•. 3..................•.....•............. 3-14 ON·CAR SERVICES ..... 3-30 DISMOUNTING AND REMOUNTING.. 3.. ..2......... REMOVAL .........................CHAPTER~ ENGINE p.•...... .• 3-84 ..... • .-46 ASSEMBL Y •.••....•. 3-61 INSTAllATION ....•.......•••.•.. 3....6.. 3.........•...... 3-46 INSPECTION AND ADJUSTMENT ........ 3.. 3... ... • • ...... .....7... It ........ .. 3-10..... ..

0.Iol Z Valve clearances (when engine is cold) mm (in) Idling speed ] [ At neutral (or N) or P position Intake Exhaust rpm Length 419 (16.177 (12.25 (0.61) 712 (28. 4WD AT) • Exhaust emission control system: and California I + Oxidation catalyst (other than California) + EGR + Air injection I Firing order Ignition timing * 1: *2: *3: *4: 49 States California Canada 49 States and Canada BTDC 8°/700 rpm 3-2-4 BTDC 8° /800 rpm 3-2 . 171) I I I Pressure ring: 2. psi) mm (in) cc (cu in) Number of piston rings Opening Intake valve timing Closing Opening Exhaust valve timing Closing r.68) 8. Specifications and Service Data 1. 4-stroke gasoline engine Overhead type 92)( 60 (3.3. liquid cooled.010) 0.206 (12. 175) 92 )( 67 (3. Entire Enalne Specifications ~ Type Valve arrangement Bore )( Stroke Piston displacement Compression ratio Compression pressure (at 350 rpm) kPa (kg/cm 1 .Iol SUBARU 1800 SUBARU 1600 WithMT Other than 4WD 4WD With AT Other than 4WD 4WD-AT I Horizontally opposed.ENGINE 3-1.18) Engine dimensions mm (in) Width Height Weight of engine without kg (Ib) transmission (Oil and coolant are included) Air cleaner element ·1: 99 (218) *2: 95 (209) *3: 94 (207) *2: 95 (209) *4: 94 (207) Emission control system PCV system • Crankcase emission control system: • Evaporative emission control system: Canister storage type with fuel return Three-way catalyst [49 States (except 4WD &.03) 607 (23.36) 1.781 (108.62 )( 2. Oil ring: 1 20· BTDC 60· ABDC 60° BBDC 20· ATDC 0.64) 1.7 1.50) 701 (27.595 (97.35 (0.014) 0(0) 0(0) 64° ABDC 64° BBDC G z r.90) *1: 105 (232) ·2: 101 (223) *1: 108 (238) *2: \04 (229) *3: 103 (227) *2: 104 (229) *4: 103 (227) Viscous type 800 ± 100 411 (16.33) 9.0 1.62)( 2.60) 700 ± 100 422 (16. 4-cylinder.

343 kPa (3.S kg/cm'.0 . splash type Trochoid type 4.IS m' (1.S Imp qt/min) or more .392 kPa (4.B (2. S7 psi) Oil pump Discharge performance II Discharge .2 US qt/min. 13. 2.6 US qt.2 US qt/min.392 kPa (4.6 Imp qt/min) or more . 3.1 Imp qt) 2.Pressure Discharge performance I SUBARU 1600 Forced feed.011 (4. 3. 2.9 US qt/min.0 kg/cm'.24S kPa (2. 21 psi) 9S kPa (1.7 US qt.64 psi) 147 kPa (1.S kg/cm'.011 (3.6 4.S kg/cm'.18S·F) 392 .0 kg/cm'.6 Imp qt) Iq ft) 3.2 Imp qt) Engine oil capacity Lower level . SO psi) 3. S7 . 14 psi) Oil relief valve Oil by-pass valve Oil filter Pressure at which valve starts to open Pressure at which valve starts to open Type Filtration area Upper level Paper.S Imp qt/min) or more .0R/min (4. 3.SS·C (167 .2 US qt. lS.H (3. Lubrication System Specifications SUBARU 1800 Lubrication method Pump type Discharge .2 US qt/min.0 kg/em'.2 Imp qt/min) or more . full flow filtration.OIl/min (15.500 rpm 7S .l8S·F) 21.8S·C (167 . 2.012/min (22.01!/min (3. cartridge type O. S7 psi) IS.441 kPa (4.S Imp qt) 3.S kg/em'.ENGINE 2.Pressure Speed Oil temperature 2.4. 36 psi) Speed Oil temperature SOO rpm 7S .2 US qt.

.... 011 Flow Diacram Crankshaft r" front 1-+ Crankcase (Right) Main gallery main bearing ~ til connecting rod bearing 111 &...ENGINE 3. Drive gear Rotor Oil filter A6-014 Cross section of trochoid pump lA-A) Cross section of trochoid pump (A-A) Fig_ 3-1 3-4 .-. Encin. /14 connecting rod bearing : Relief valve I 112 &. Valve rocker -t Oil strainer Cam bearing I Oil pan A6'012 (SUBARU 1800) (SUBARU 1600) Oil pump drive gear Left side main gallerv Camshaft Oil pump drive gear Left side main gallerv Bv-pass valve Relief valve ~iver gear ~ Relief valve ~Bv-pass v81ve Rou" A6-013 o . der valve lifters ../13 cylinIII &'/13 cylin. rear main bearing . necting rod bearings _----By-pass i Rotor r I I --I! I ........114 cylin112 &.113 con.114 cylin. der valve lifters f-1o der push rods 1- Valve rocker I- Oil filter r-r1 i I I Crankcase 1-....... Crankshaft center (Left) main bearing Main gallery 112 &.... der push rods ....valve r ' Crankshaft ..

\ i I 0.4 US qt/min.9£ (2.6·F) 91 :t 2°C (196 ± 3.26) 580 x 334 x 32 (22.05 to -0.7 Imp qt) Above 88 :t 10 kPa (0..4 ft Aq) 75 8S·C (167 .I Fully opens ON OFF Motor Fan dia.5 sq ft) AT & 4WD-AT: 0.3 sq ft) 4WD: 7.511 (5.29 m Aq (0.6·F) 25 ± 2·C (77 :t 3. 9.90 m' (63.4 sq ft) Others: 5.4 psi) Below -4.0 m Aq (16. pressure type •·d.9:t 0.ENGINE 4.--- Number of impeller vanes Pump pulley diameter Type Starts to open Thermostat Fully opens Valve lift Valve bore Type Thermo valve Thermoswitch Electric fan Fully closes ~~ -.7 to -1.6·F) 120W or less 280 mm (11..9 US gal/min.15 x 1. at • Temperature difference between coolant and ambient atmosphere: • Air velocity: 4s2/min (11.83 x 13. 2. 4.8 US qt.9 sq ft) ~ .22 in) Wax pellet type 27 ± 2·C (81 ± 3.0 Imp gal) or more 4.5.31 in) Wax pellet type 88 ± l.6 US qt.1 kg/em'.26) Others: 1.805 BTU/min) Radiation capacity Radiator { • W.83 m' (84. 4.29 m' (78.0 US qt.82 m' (51.9 Imp gal/min) 6s·C (l49·F) 8 m/sec (26 ft/sec) Core dimensions Radiator capacity mm (in) SUBARU 1800 AT & 4WD-AT: 625 x 334 x 32 (24. .690 BTU/min) 4WD: 0.7 Imp qt) Cooling system !----~ Electric fan + Forced cooling water circulation system 5.789 kW (678 kcal/min..9 to -10 kPa (-0.4 psi) Corrugated fin type Pressure range in which cap valve is open Fins . 2.02 in) Cross flow. Type Total radiation area AT & 4WI).000 rpm ..95 ft Aq) 75 . Cooling System Specifications SUBARU 1800 ~ SUBARU 1600 5.31 in) 31 mm (1.AT: 7.440 BTU/min) Others: 0. 1.0.52 in) 5 --.· .6·F) 95 :t 2°C (203 :t 3.8 Imp qt) Total coolant capacity Type Discharge Discharge performance I Pump speedtotal water head Water temperature Water pump Discharge Discharge performance II Pump speedtotal water head Water temperature Impeller diameter Centrifugal impeller type 7 II/min (7._ .1 kg/em" -0.000 rpm .8s·C (167 . 11. 84 mm (3.18s·F) 64 mm (2. 2.S·C (190 ± 3°F) 100°C (212·F) 8 mm (0.18s·F) SOli/min (13.15 x 1.f .2 US gal.to< flo.61 x 13. 1.715 kW (615 kcal/min. 13 :t 1.2 Imp qt/min) or more 1.311 (5. 6.630 kW (542 kcal/min.151 BTU/min) 4.529 kW (455 kcal/min.

Ind aD specill clre is neces- sary. Avoid using Iny coollnt or only water other thin this designated type to prevent corrosion.072 It 30°C (86°F) 1. NOTE: I. SUBARU Coolant specifications are as follows: Coolant Specifications SUBARU coolant-to·wllter ratio (Volume) % Specific gravity It 10·C (SO°F) 1.ENGINE 5. 000016218 This coolant is anti-freeze. Coolant Flow Dle. b.ram Intake manifold Intake eir preheating (Carburetor! '--------------------1 start ThermoAS·6SB 1 2 3 4 S 6 7 8 9 10 11 12 13 14 IS 16 17 18 Radiator inlet hose Water by-pass hose Thermostat cover Thermostat Water by-pass hose Water by·pass pipe Water by-pass hose 3-wey cock Water by-pass hose Intake maoifold Water by-pass pipe Water by-pass hose Radiator outlet hose Water pump Thermo switch Electric Thermo valve Water by-pass hose fan Fig. 8.078 at 20°C (68°F) 1.058 It 50·C (122°F) Freezing point Lowest atmospheric anticipated temperllture Above -30°C (-22°F) SO . 3-2 Flow of coolant in cooling S)f$tIm AS-6!59 3-6 . SUBARU'a engine is Iluminum IlIoy. SUBARU COOLANT (net 18 liter) Parts No. Coolent It is recommended to use "SUBARU genuine coolant" when replacing or refllling the engine coolant.SO LOSS -36·C (-33°F) • It il recommended that distilled water be used.067 It 40·C (104°F) 1. anticorrosive ethylene glycol coolant. and is especially made for SUBARU vehicle.

the coolant passage from carburetor to water by-pass pipe is shut off by means of thermo valve so that the fuel in carburetor is not heated. 4. By-pass passage: a.3 US gal/min. 1 1·1 1·2 1-3 1-4 Hose assembly Outlet hOle Inlet hose Clamp Clip Pipe complete Hose clamp Cooler Radiator Side frame Fig.\.-=::=~==~To radiator --+ A5-660 Fig. System Automatic transmission fluid cooling system (SUBARU 1800 AT & 4WD-AT) Radiation capacity ..4 Imp gal/min) Temperature difference between water inlet and oil inlet: 30c e (86°F) The fluid cooling system of automatic transmission consists of an cooler built in radiator. Water pump 11:~~1\.\. 3-4 Component pam of automatic trllflltn/. Intake manifold case~ Thermostat 3-way cock Water by-pass hose . pipes and hoses to circulate fluid between torque converter and cooler.357 BTU/h) Oil flow: 6~/min (l. /andPiPe He~er . 3-3 Cross section of thermo valve 2) Cooling with thermostat open When the coolant temperature exceeds the specified degrees. thus shortening engine warm-up time. Heated fluid circulating through torque converter returns to cooler and is cooled by coolant. 7._. To intake manifold t b. Automatic Transmission Fluid Coolin. 1.570 kW (1. coolant flows only through the by-pass passage. 5. Intake manifold -+ Carburetor -+ Thermo valve -+ Water by-pass base and pipe -+ Water pump When the environmental temperature around thermo valve exceeds the specified degrees.~- --""'I ENGINE The operation of the cooling system is as follows: I) Cooling with thermostat closed When the coolant temperature is under the specified degrees.350 kcal/h.p 1. thermostat begins to open and coolant flows through radiator and by-pass passage.3 Imp gal/min) Water flow: 20~/min (5.lon fluid cooling 'ystem 3-7 .---. increasing the cooling function. thereby being maintained at an adequate temperature. This limited coolant circulation reduces cooling action. -. the thermoswitch turns on to operate the electric fan. 3) Cooling with electric fan in operation When the coolant temperature exceeds the specified degrees.6 US gal/min.

ENGINE 8. Immediately after the engine sterts. As this happens. Therefore. This is not an indication of abnormality. 8 Valve Lifter". When the valve lifter is pushed by the cam lobe.. if the clicking does notc. The valve lifter also clicks continuo ally for a long time if air enters the pressure chamber of the valve lifter (although this occurs very _Idom). It occurs bec:au_ the viscosity of engine 01 increases due to low ambient temperature and therefore the valve lifter does not respond accordingly. der head and/or entire engine.) This happens also after removing/ instilling valve rocker ASSY.500 to 2. the valve lifter may sometimes meke clicking noises within 10 seconds. Then. NOTE: a. the check ball comes into contact with the plunger. 3·5 Hydraulic valve lifter Fig. check ball and valve body. (Check the valve lifter according to "3·1. Hydraulic Valve Lifter Camshaft ~M'ln"'''V CD (V @@@ @ 1 2 3 4 5 6 Check ball retainer Check ball spring Plunger spring Check ball Plunger Valve body AS·561 Push rod Pressure chamber Reservoir chamber AS·662 7 Push rod seat 8 Clip Fig. Plunger spring always pushes out plunger. b. 3-6 Operation of the hydraulic valve lifter The hydraulic valve lifter always maintains the valve clearance at zero by means of engine oil pressure. When this happens. the plunger is pushed up so that the valve clearance is zero. engine oil pressure in the pressure chamber increases rapidly and this moves the intake or exhaust valve through push rod and valve rocker arm. maintein the engine at a speed of 1. plunger. the check ball is separated from the plunger and opens the passage to the pressure chamber.. cylin. This causes engine oil to flow into the pressure chamber. In this condition. plunger moves out· ward when the clearance to produced in the valve mechanism. The hydraulic valve lifter consists basically of a push rod seat. check the engine oil level and add engine oil if the level is at the lower level or below on the gauge. . The air is then expelled from the pressure chamber and the clicking ceases.000 rpm and allow it to idle for 10 to 20 minutes. At this time..

29 in) (4.8mm (1.0mm O..689 .127.3I30 .6 .5-18.30 in) (0.476 in) 185.5mm 89.7 .015 mm 17. Service Data Head surface warpage Head surface grinding Standard height "0 CI.087 in) 3-9 .028 .0.5 mm (8.0.020 in) (3.909 in) (2.783 in) 48.5 mm.925 in) (4.8 N/30.0 kg/37.0026 in) (0.6mm 90°.122 in) (0.0016 .0. -.201 in) 84.9 .031 in) (0.98.5mm 1.051 in) (0.8 N/285 mm (18.039 in) (0.0.5 mm (51.079 in or less) 2.58.921 in) 146.1lb/1.9 .0059 in) "0 u :Ei >.000 ...3 mm 1.7 .0059 in) (0.051 in) (0.7 N/39.5 .15 mm 0.5mm 22.5 .0. 41.) .3 kg/39.065 mm 0.083 in or less) (1. Valve guide Intake Exhaust Intake Exhaust Valve overall length Valve head edge thickness Intake Exhaust Intake Exhaust > 7iI ~ STO Limit STO Limit Stem diameter Stem oil clearance Intake Exhaust Intake Exhaust STO Limit STO Limit t • With solid valve lifter Free length Tension/spring height Outer spring Inner spring Outer spring 'J: ~ ~ Inner spring > ~ Square ness • With hydraulic valve lifter Free length Outer spring Inner spring Outer spring Inner spring 45.s:: CI.950 .0. 32.5 mm 53.1 N/37.035 .48.0020 in) (0.5 mm.020 in) (0.23.3156 in) (0.071 in) (0.11b/1.040 .0 mm or less 2.21.4 .31b/1.5 mm.1.0.3 mm 0.S55 in) 500. 112.965 mm 7.886 .039 .020 in) (0.9 .960mm 0.0 .150° 0.5mm 8.0.8.0.1 mm or less 48.6mm 90.) Limit Limit 1600 1800 Refacing angle Contacting width Wear limit Inner diameter Protrusion .3150 .728 in) (0.~ .05mm O.91b/1.3 .945 -7.0 .567 in) (0.0 .2 .169.0014 .568.15 mm (0.3128 .17.3 mm 1.0028 in) (0.3134 in) (0.070 mm 0.5 mm.9 kg/28.0.38.22.0 kg/30.214. 19.10.3 mm (1.528 in) (3.5 mm l09mm 109..5 mm (14.8mm 7.8 mm O.7." .---~----~~-------.1 . Valve seat 0.-- ~ ENGINE 9.1.0.0mm (0.3136 in) (0.

4 mm 230.64 in) (9.-------~ ---------.982 18.- Tension/spring height Outer spring Inner spring Squareness Outer spring [nner spring 228.1 kg/32. 45.7100 in) 17.599.0012 .261.0035 in) 0.8283 in) 20.0 mm..050mm O.oooS .4mm (8.232.------.030 0.93.0039 in) 20.0.5 mm (11.3.0028 in) 0.6214 .260 in) 115.8248 .0020 in) 0.7093 0.0.034 mm (0.060mm (0.0.016 .S 1.0020 in) 0.9.100 mm (0.5 ..92.OlOmm (0. 51.8 13.6Ib/1.3.7 .8.S mm (23.083 in or less) 2.08 9.0.231. Inner diameter of rocker arm Outer diameter of rocker shaft Rocker arm to rocker shaft clearance • Solid valve lifter Lifter hole inner diameter of crankcase Outer diameter of lifter Lifter to lifter hole clearance • Hydraulic valve lifter Lifter hole inner diameter of crankcase Outer diameter of lifter Lifter to lifter hole clearance \8.0039 in) 219 .9 61.0.040 mm (0.2 N/32..0197 in) 0.6 134.3 mm or less (0.090 mm (0.21.-- .0 mm (20.8248 0.7 .3 26.988 21.7Ib/l..020 .003 mm (0.016 in) or less STD Limit Overall length ] iii £ Deflection at center Cylinder bore (Both 1800 and 1600) 1600 (Knurling: 2) 1800 with solid valve lifter (Knurling: I) 1800 with hydraulic valve lifter (Knurling: nothing) (Steel tube) ~ u u "5 .0: .5 .100 mm (0.82S6 in) 0.30.SS5 in) 518.681 in) 91.050mm 0.0..18. 26.----_.052 mm (O.S mm (3.0.1 mm or less (0.040 mm (0.8 .0008 .3.0016 in) (0.0020 in) 0.0004 in) (0..5 N/30. _ - --..0020 in) STD Limit 21.0.20.949 .0.20.0004 .S 23.476 in) 201.2 mm 0.0. "iilg uu >.62 .7 kg/39.010 .2 ..~ ---.5 .000 .6226 in) O.9 Ib/l.18I in) 2.0020 in) 0.8263 .98S .602 .091 in or less) > .133.563 .S mm.QlS mm (0.0mm (52.:.021 mm (0.968 mm (0..7 .- .7080 .0.5 mm.12 .0 mm.230.5 kg/30.8255 in) 0.S8..14 in) (0.0 .92.015 mm (3.7088 in) 0.950 .5 mm 3-10 .4 .013 .0024 in) 0..219.05 mm (0.1 mm 231.0006 in) (0. 116..0 .50mm (0.642 in) 90.10 in) (9.8 N/39.8268 ..8 Ib/l.072 mm (0. STD Limit Out of roundness STD Limit Cylinder to piston clearance STD Limit Enlarging limit of cylinder inner diameter Inner diameter difference limit between cylinders Limit Case surface warpage (mating with head) Protrusion of stud bolt from mating surface 1800 1600 Diameter Taper 91.4 N/37.05 mm (3.970 mm (0.6 kg/37.ENGINE .8276 in) 20..

35 mm l.5 .0.952 mm (1.0031 (0.0037 in) 0.1.1..9656 .720 mm (2.0012 in or less) 0. 0.117.485 mm 1.25 mm (0.0118 in) 54.0157 in) 0.1.49.0012 ..~ Piston outer diameter § ~ .009 mm (0.905 54.50 mm (0.2..0197 in) as ] .------------~----.0079 0.07mm (0.95 .--_r_----~------------- .-.15 mm 3.0028 in) 0.1642 in) 54.05 mm (0.1.30 mm (0.330 mm (0.940 mm (2.03 mm (0.1.610 mm (0..0012 in) US 0.0028 (0.992 .0.1636 .0016 ..970 .6402 20.1616 .08 mm 0.6216 in) 3.990 mm (3.0632 .0138 (0.8267 20.92.957 49.49.3287 4.907 .20 .5.0020 in) US 0. C~ 00 STD 0.477 1.25 mm (0.01 ..927 .035 mm (0.0.1.21.9654 .9661 .505 .0581 .6205 92.0098 in) as 0.49.9575 .25 mm (0.0.25 mm (0.49.0593 .04 .9673 .54.0.9668 .0130 in) 0.720 mm (1.0.49.0.0059 in) (0.6043 .95 ..lOmm (0.1.920 mm (2.8268 .070 0.0.9673 in) 49..f! § .1630 in) 54.240 mm (3..920 mm (1.1622 in) 54.05 mm (0.20 .0mm 0.9658 in) 49.3327 in) O.20 .039 in) (0.0012 in) US 0.6413 in) 0.35 mm 1.059 in) (0.25 mm (0.5 .0.940 .0354 (0.94 in) in length Thrust clearance Piston pin to bushing clearance Bushing bore Thickness at center u 116.2.5mm 0.0.-.6083 En) 109.2.960 .03 .0098 in) US .0.9661 in) 49.( Bend limit Crankpin and crank journal Out·of·roundness Taper limit Grinding limit STD Limit 1800 STD 0.004 .0585 in) (0.932 mm (1.0004 ..:.9579 in) '" 3-11 .0079 .~--.0020 in) US 0.05 mm (0.705 54.0028 0.0098 in) US STD Center 0..8271 in) 0. Piston pin hole inner diameter of piston Piston pin outer diameter Piston pin to hole in piston clearance Piston ring gap Top ring Second ring Oil ring rail Piston ring to piston ring groove clearance Top ring Second ring Oil ring Distance between big end and small end hole 1800 1600 Limit STD Limit STD Limit STD Limit STD Limit STD Limit STD Limit 91.1.0009 in) 21.4.0138 (0.0002 0.1624 .0079 .0.ENGINE r-----.605 .095 mm (0.Omm 0.010 mm (0.9666 in) 49.05 mm (0.0.49.9648 .0059 in) o j .0004 in) in) in) in) in) in) (0.05 mm (4.0020 in) US 0.03 mm or less (0.925 .9654 in) 49.920 .016 mm (0.25 mm (0.15 mm 0.54. u<u Q) Q) - ="0 u .0098 in) US Thrust clearance Crank journal outer diameter <!:: '" -5i .970 mm (2.732 mm (1.022 mm (0 0.460 92.490 mm (3.0.0.970 mm (1.0." STD 0.6315 in) 3.90 mm 1.1.210 .1.999 21.03 mm (0.000 21.0012 in) US 0.0.0039 in) 0.940 mm (1.982 mm (1.2.110.40 mm (0.9570 .: u ~ .039 in) (0.0634 in) .0594 in) (0.07 mm 0.8274 in) 1.955 .0098 in) 0..510 mm 1.720 .8265 0.1543 in) 49.05 mm (4. u g o c Bend or twist per 100 mm (3.6303 92.0014 in) 0.49.9678 in) 49.9575 in) 49.1537 .707 .91.0098 in) US 1600 Front & rear STD 0.0020 in) US 0..8268 in) 0.03 mm (0.000 mm (0.

020 .0.1.0010 .2693 .0795 in) 0.0098 in) US Center sro 0..0020 in) US 0.0098 in) US Crankpin oil clearance sro Limit Front & rear sro 0.975 mm (1.0059 in) 0.050 mm O.020 .010 .034 mm 2.040 2.053 mm 2.0835 (0.45.03 nun (0.25 mm (0.070 nun (0.36.0.0008 .0012 in) 0.0018 in) 0.32.25 mm (0.15 mm (0.0.122 2.0801 in) 0.959 .05 mm (0.0794 (0.0 ¢.0039 in) 0.015 2.0035 in) (0.0.022 2.0098 in) US Center sro 0.144 mm 2.0794 (0.010 .059mm (0.0.1.0022 in) 0.25 mm (0.025 0.03 mm (0. '" iii Bend limit Thrust clearance Camshaft journal outer diameter Front & center Rear Camshaft journal to cam bore clearance sro Limit 1600 1800 5 u sro Limit Limit ·1: 32.1.0804 in) 0.0841 in) Thickness at center C>O '2 .7720 in) 44.90 .030 2.0012 in) US 0.122 2.1. cu '" 1 .0788 (0.010 mm (1..140 2.008 mm 2.0004 .1.0799 (0.030 mm 2.025 nun (0.0098 in) US Front & rear sro 1600 0.0.0220 .-.760 nun (1.0835 0.0848 in) 0.960 nun (1.015 2.25 mm (0.035 mm 2.0801 in) 0.7715 .055 mm (0.7616 .0. sro Limit sro 0.959 .25 mm (0.0028 in) (0.ENGINE Crank journal oil clearance 1800 Front & rear Center .028 mm 2.05 mm (0.040 2.135 nun (0.0008 .0799 in) 0.0012 in) 0.010 .975 mm (1.0079 in) 0:20mm 25.0.05 mm (0.7622 in) 0.0226 in) 31.1 mm 2.0012 in) US 0.0.0004 .0020 in) US 0. Run out Crankshaft gear to cam gear backlash sro Limit 3-12 .001 2.030 mm 2..0843 (0.030 2.05 mm (0.010 .0020 in) US 0.34 mm (1.945 .0844 in) 0.745 .135 mm 2.1.31.0843 (0.0023 in) (0.0793 (0.043 mm 2. "'0 cu '::l 0 sro Limit sro Limit ~ = Center Crankpin outer diameter S 1600 Front & rear sro Limit 1 .0799 (0.017 2.44.0014 in) 0.035 mm 2. u .2732 in) ·2: 35.35.0098 in) US 1800 0.25.0808 in) 0.0803 (0.4163 in) 0.4173 in) (0.0004 .044mm 2.0793 (0.0020 in) 0.959 .4157 .010 .0039 in) i iii u& ·1: With solid valve lifter ·2: With hydraulic valve lifter 5 :.0803 (0.0799 in) 0.24 .0796 (0.44.lOmm (0.0020 in) US 0..7695 .0.035 nun (0.003 2.090 mm (0..045 nun (0.1.0841 in) 0.05 mm (0.25mm 0.0791 in) 0.0.s ¢.0801 in) 0.IOOmm 0.0039 in) O.4134 .0.0004 .0022 in) 0.0793 in) 0.022 2.030 mm (0.0004 .03 mm (0.00 mm (1.995 .0012 in) US 0.0010 in) 0.0.0.7701 in) 44.017 2.0098 in) (0.0789 (0.0018 in) 44.153 mm 2.1.0020 in) (0.055 nun (0.045mm (0.2589 in) 35.140 2.019 mm 2.975 mm (1.0796 (0. u '" iii Cam lobe height sro Wear limit ¢.030 nun (0.0020 in) US 0.05mm 0.015 mm 2.0.0805 in) 0.03 mm (0.0798 in) 0.2582 .0012 in) US 0.

0008 .602 in) (1. = 0 STD Limit Rotor to case and gear to case axial clearance STD Limit Rotor to case radial clearance STD Limit Relief valve spring Free length Installed length Load when installed By-pass valve spring Free length Installed length Load when installed 1600 1800 1600 1800 1600 1800 Oil fllter flltration area .5957 .1 mm (1.854 in) 33.41.4.178 .28 kg.1693 .008 in) 0.7mm (1.0.319 in) 38.0.03 .988 in) 3.008 in) 0.88 .21 mm (0. 1.70 .15 .12 mm (0.74 mm (1.53 .0083 in) 0.44lb) 4O.5968 in) 0.6 sq ft) § c.56 .02 .ENGINE Drive gear outer diameter Rotor outer diameter Drive gear to rotor tip clearance 29.0098 in) 47.805 .0.1 mm (0.893 lb) 5.159 N (0.0047 in) (0.3851b) 0. 8.0.1709 in) 40.0.528 .05 .461 in) 37.972 N (0.0.1.56 mm (1.224 in) 31.0.405 kg.1 mm 25.2mm 0. c.365 .97 N (3.0012 .628 kg.0. y.9.5 mm (1.0051 in) (0.40.2mm 0.29.1. " 3-13 .580 .1 mm (1.164 .0059 .1.3.15 m2 (1.25mm (0.0.13 mm (0.0.6.

.20 ft-Ibl 4.5 x 1 mm) Crankcase plug Crankcase O-ring Back up ring Bolt &.35 ft-Ibl 23·26 N'm (2.5. washer (6 x 13 x 13 mm) Clip Crankcase plug Gasket (36. 3.-----. ft-Ib) T1: 25 .25) T2: 62 .S kg-m.5.331 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Crankcase assembly Stud bolt Bolt (10 x 108 x 28 mm) Bolt Washer Bolt (10 x 145 x 28 mm) Washer (10..----r-.3.56) T3: 34 .76 16.7 kg-m.2 x 31.5 x 18 x 2 mm) Main gallery plug Bolt Crankcase front hanger (Hitachi carburetor) Nut Bolt (10 x 70 x 28 mm) Bolt Washer 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Fig.47 N·m (4..44 (3.2 x 44 x 1 mm) Crankcase assembly Nut (10 x 8 mm) Bolt (10 x 135 x 28 mm) Stud bolt (10 x 120 x 26 mm) Bolt Crankcase front hanger Crankcase front hanger (C·W carburetor) AS-S88 3-14 .3 .7. 25 .3 .4.4_0 ft-Ibl I I I @(j) ~\ ~@"'" /~ r. 17 .4 N·m 10.5 .5. CD Apply liquid gasket (Fuji Bond C or equivalent) on the mating surfaces .55 kg-m.4.0 . Crankcase i Thread size 10mm Smm 6mm Torque 39 . 1S . Component Parts 1.2.5 . @ • Apply liquid gasket (Fuji Bond C or equivalentl on the thread Tightening torque N·m (kg-m.4 .7..46 .34 (2. 29 .0.ENGINE 3·2.3 . 3-8 Crankcase Gasket (26.45 .

ENGINE 2. A5-589 Fig.20) 1 2 3 4 S 6 7 8 9 10 11 12 13 14 Valve guide Oil seal Cylinder head (1.2. 43 it·lb) 64 N·m 16. 3-9 Cylinder heads . Cylinder Heads .600 ee) Cylinder head 2 (1. 47 ft-lb) Applv sealant "Three Bond 1201" or equivalent evenly to both sides of cylinder head gasket with a brush.0 kg-m.2 .r Tightening torque N·m (kg-m. 22 ft-Ib) 59 N·m (6.600 ee) Cylinder head 0.0 kg-m. ft-lbl T: 22 27 (2. 16 .800 ee) Washer Nut Bolt (11 x 162 x 34 mm) Stud bolt Plug Gasket Stud bolt 1st step 2nd step 3rd step 29 N·m (3.5 kg-m.8.800 ee) Cylinder head gasket Cylinder head 2 (1.

2. ft-lb) @ I' Bolt 21 Stiffener 22 Stiffener 2 23 Oip 24 Washer 25 Spring washer 26 Bolt 27 Accelerator cable bracket (C'W carburetor) Oip T1: 46·64 (4.7· 6. 3·10 Flywheel housing and fittings A5·666 3-16 . Flywheel Housing and Fittings 1 Flywheel housing CP 2 Stud 3 seal (70 x 87 x 8. 14 .5 mm) 4 Timing hole plug on 5 Crankcase rear hanger 6 Pitching stopper bracket 7 Nut Bolt Washer 12 Washer 13 Spring washer 14 Spring washer 15 16 17 18 19 20 Flywheel housing CP 8 9 10 11 Bolt Bolt Stud on seal (76 x 93 x 10 mm) Timing hole plug Bolt Coat with liquid gasket (Three Bond 1215 or equivalent) on mating surface and dry the coated surface for 5 to 10 minutes before installation.ENGINE 3.8.40) T2: 20· 27 12. Tightening torque: N·m (kg-m.6.0 . 34 . 20) Fig.

0· 5.47·541 A 8-687 • • Apply engine oil on the thread.3. Crankshaft and Related Parts 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 I I I I I I Bolt O-ring Crankshaft pulley Drive belt on seal Distributor drive gear Woodruff key II Crankshaft Woodruff key Crankshaft gear Crankshaft bearing set Center bearing set Connecting rod CP Nut Connecting rod bearing set Piston ring set Piston pin Circlip Piston set Bo1t(Mn Bolt (An Converter back plate (An Converter drive plate (AT) Connecting rod bolt Connecting rod bushing 1 . 29 • 311 T3: 49· 53 (5./ I I V .5. Apply liquid gesket (Three Bond 1215 or equivalent! on the flange seat.4.2·4. I I \ I I I I I I I I I I I I I . @ Tightening torque: N·m (kg·m.0· 4.ENGINE 4./ . ft-lb) T1: 41·45 (4. 3·11 Crankshaft and related parts . 36 • 39) T4: 64·74 (6.6.5·7.30·33) T2: 39· 42 (4. Fig.

Valve System Tightening torque: N·m (kg-m. 2. 3-12 Valve system AS·668 3-18 . ft-lb) T: 3· 4 (0.4.) 6 Exhaust valve 7 Valve spring retainer key 8 Valve spring retainer Valve spring Valve spring 2 Intake valve Valve push rod 13 Valve lifter 14 Bolt 15 Lock washer 9 10 11 12 16 Camshaft gear 17 Camshaft plate 18 19 20 21 22 Valve rocker ASSY Camshaft Woodruff key Hydraulic valve lifter Push rod (for hydraulic valve lifter) Fig. 0.ENGINE s.2 .H.9) @ @ 1 Bolt 2 Valve rocker cover seal washer 3 Valve rocker cover 4 Valve rocker cover gasket 5 Valve rocker ASSY (R. 2.3 .

H.3·13 a ~I verocker 3-19 . Valve Rocker 1.) 18 e rocker arm 19 Valve rocker arm 2 Lock washer (on! hydraullc valve lifter) y for va:: Fig. .:~ker ASSY (R.800 cc engine AS·669 .) 15 Val spacer 16 Valve rocker shaft 17 rocker ASSY (LoH.ENGINE 6.) Nut Washer Valve rocker w Rocker shaft scn: Rocker shaf sprmg washer Valve rock t supporter R erarm CP ocker shaft 10 Valve rocker shaft spacer 11 Valve 12 Val rock er arm CP 2 1 ve rocker ASSY I!V Ralve rocker ASSY ii·HH·) ocker shaft . 3 4 5 6 7 8 9 ~:!~e .

6. Emission Control Equipment 1) Hitachi Carburetor Type *: Except 49 States 4WD &. washer 16 Thermosensor 17 Bolt &.15·670 3-20 . 4WD-AT and Canada * 1 Bracket * 2 Vacuum switch I * 3 Vacuum switch II 4 Bolt &. 3·14 EmiSlion control6quipmsnt (Hitachi carburetor type) . washer 5 EGR pipe cover 6 EGRpipe * 7 Solenoid valve III * 8 Oxygen sensor 9 Nut 10 Washer 11 Clamp 12 EGRvalve 13 Gasket *14 Duty solenoid valve 15 Bolt &.ENGINE 7. washer *18 Solenoid valve I 19 Thermo vacuum valve II *20 Carburetor protector 3 21 Vacuum pipe CP (Except 4WD and AT) 22 Thermo vacuum valve I 23 Vacuum pipe CP (4WDand AT) *24 Electronic control module *25 Ignition relay *26 Revolution sensor *27 Carburetor protector *28 Carburetor protector 2 *29 Solenoid valve II (49 States only) ® Fig.

75 Emilflion control equipment (C-W carbuffltor type) 11. washer 5 EGR pipe cover 6 EGRpipe 7 Solenoid valve II 8 Oxygen sensor 9 Nut 10 Washer 11 EGRvalve 12 Gasket 13 Thermo vacuum valve I 14 Vacuum pipe CP 15 Bolt &.5·671 3-21 .ENGINE 2) COW Carburetor Type 1 Bracket 2 Vacuum switch I 3 Vacuum switch II 4 Bolt &. 3. washer 16 Electronic control mudule 17 Thermosensor 18 Revolution sensor 19 Solenoid valve I 20 Ignition relay @ Fig.

3-16 Air injection system 3-22 . J AS-672 Screw & waSher-.l Fig. Except 49 States 4WD&4WD-AT and Canada y.ENGINE 8.~ ~~Ill @ ~ 49 Stages (Except & 4WO-A T) only (Spacer) (Air suction valve II (Air suction valve III (Air suction valve Ill) ASV cover Reed valve ASSY --~ ASV case f. Air Injection System *1 Electronic control module *2 Solenoid valve I *3 Check valve II 4 Air induction hose 5 Thermosensor 6 Air cleaner 7 Silencer 8 Air induction hose 9 Air suction valve 10 Air suction pipe 11 Air suction valve II 12 Silencer 13 Air suction pipe 14 Silencer 15 Air induction hose 16 Air suction valve III (49 States 4WD & 4WD-AT and Canada) *.

25 Air cleaner bracket 'ng (for power steen vehIcle) 26 Screw & washer 27 Stay 28 Insulator 29 Vacuum hose clamp 30 Stay 31 Washer A5-595 Fig. 3-17 Intake mam'f!0 Id (Hitachi carburetor type) . Intake Manifold 1) Hitachi Carburetor Type 1 Nut 2 Air cleaner 3 Air cleaner bracket 4 Washer 5 Bolt & washer 6 Carburetor bolt 7 Air cleaner gasket 8 Carburet or 9 Nut 10 Spring washer 11 Bolt 12 Spring washer 13 Accelerator cable bracket 14 Carburetor gasket 15 Intake manifold 16 Stud bolt 17 Stud bolt 18 Bolt 19 Fuel hose stay 20 Bolt 21 Spring pin 22 Intake manifold gasket 23 Air cleaner bracket 24 Stay 2 .ENGINE 9.

) A&-696 Fig. ft.2..Jb) T: 18·22(1. .8-2. damp Stud bolt Stud bolt FJ.13·16) ~ """I ""A"" " \ ~®~ @ @ 1 2 3 4 S 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Nut Air cleaner Air cleaner bracltet Washer Bolt & wuher Sprin& pin Bolt Sprin& washer Fuel boa stay Bolt Intake manifold pstet Intake manifold Vacuum bo.anae ().ENGINE 2) CoW Carburetor Type Tightening torque: N'm (kg-m. Intake manifold (C-W carburetor type) 3-24 .retor pstet 2 Connector Clamp Ho.rlna Insulator Bolt & washer Stay Stay 2 Washer Air cleaner bracket Carbu.. .. Bolt & washer Air cleaner p*et Carburetor bolt Carburetor spacer 34 Air clelDClr bracket (for power steerin..retor Washer Nut Carbu.

. Fig.0' 1 on level gauge 2 Oil flter duct 3 Oil filler cap CP 4 Gasket 5 Air breather duct gasket 6 on filler duct stay (SUBARU 1800) 7 Oil f"dIer duct stay (SUBARU 1600) 8 Bolt and washer 9 Bolt and washer . . 4.7. 011 Filler Duct and Flttln•• @ @ @'----. 3.17·20) T2: 22·27 (2.~.4 10.--_- (i)~ Tightening torque: N'm (kg-m. 16·201 T3: 4.3 .55. 12 Oil sttainer stay 13 O-ring 14 Oil strainer 15 Bolt 16 Spring washer 17 Nut 18 on strainer stay 2 19 Bolt & washer 20 Oil pan gasket 21 Bolt & washer 22 Oil pan CP 23 Plug 24 Gasket 'fl. 10 Bolt 11 Spring washer '.3·2. 011 Pan.45·0.ENGINE 10. ...-.2·2. ft·lb) T1: 23·2612.4· 5. oil filler duct and fittings AB·a7B 3-25 .'.8. 3· 19 Oil PIIIl.

2. 21 22 O-rinl 23 PlUS (Models with pressure gaup) 24 Oil presswe gause (Models with pressure gauge) 25 Stay Fig.2 . 23 .2712.-.3.2 ..271 T2: 22 ...3-20 A6·024 3-26 . 19 20 21 22 23 24 25 O-rinl o-rinl Tightening torque N·m (kg"".3.~-- ENGINE 11. 16 20) ~ A6·023 Oil mter Bolt Bolt Washer Oil presswe gause (Models with pressure gause) 26 Stay (1600 cc engine) torque N·m (kg"". . 12 13 14 15 16 17 18 Plug (Models without pressure gauge) Ball By-pass valve spring O-rinl Oil presswe switch (Models without pressure gause) Oil pump body gasket Oil rdter Bolt Bolt Washer 19 20 * Apply a thin coat of oil to the seal rubber. ft·lbl T1: 31 .37 13.~ / @ ' O-ring 8 Oil pump rotor 9 Oil pump drive gear 10 Oil pump body holder 11 Pan head screw 1 2 3 4 5 6 7 Oil pump assembly Oil relief valve Relief valve spring Washer Washer Plug ~ 12 Plug (Models without pressure gauge) 13 Ball 14 By-pus valve spring 15 O-ring 16 Oil pressure switch (Models without pressure gause) 17 Plug (1/8") (Models with pressure gause) 18 Oil pump body gasket thread..8.z.@4 ~? 'Z.B.·-. ft·lbl 1 . 23 .. ~.37 (3. Oil Pump (1800 cc engine) ~ '--.B.271 O-rinl 8 Oil pump rotor 9 Oil pump drive gear 10 Oil pump body holder 11 Pan head screw 1 2 3 4 5 6 7 Oil pump assembly Oil relief valve Relief valve spring Washer Washer Plug • Apply liquid gasket (Fuji Bond C or equivalent) to the thread.2 .-.

so there is no interchangeability between two manufacturers. Each is exclusively composed. Radiator Assembly and Electric Fan NOTE: There are two manufacturers in fan ASSY. ~~~~-) ® i8 --. One is Hitachi and another is Mitsuba.---. 1 Ground cord 2 Tapping screw 3 Hose clamp 4 Flange nut 5 Flange bolt 6 Shroud 7 Radiator inlet hose 8 Thenno switch 9 Packing 10 Radiator outlet hose 11 Radiator assembly 12 Radiator cap 13 Overflow tube 14 Drain plug 15 Water drain 16 Packing 17 Cushion 18 Spacer 19 Grommet 20 Washer 21 -Bolt &. washer 22 Motor 23 Washer 24 Fan 25 Fan washer 26 Washer 27 Nut 28 Plug (AT only) 29 Gasket A7. r------~~--------. ft·lb) 7-131 ~ Fig. T: 10-18(1..ENGINE 12.3·22 Engine cooling system [Oil cooler fA T) ) .. 3·21 Engine cooling system (Radiator ASSY and electric fan) 1 Hose clamp 2 Tapping screw 3 Oil cooler pipe clamp 4 Oil cooler hose 5 'Oil cooler pipe complete 6 Oil cooler pipe clamp 7 Spring washer 8 Bolt 9 Clip Fig.Q98 \ .0-1 Tightening torque N·m (kg·m.

I I "" 9 10 11 12 I I I I I I I I I I I I I I J I I I I 8 Protector stay Water pump gasket Water pump Bolt &... # 4 Hose clamp 5 Hose (For C·W carburetor) 6 Thermostat cover . washer Bolt &..: '. washer 13 Hose calrnp 14 Hose 15 Hose 16 Thermostat 17 Thermostat cover gasket 18 Solenoid valve bracket 19 Hose 20 Heater hose clamp 21 Hose 22 Thermo valve 23 Hose (For Hitachi carburetor) 24 Hose 25 Water pump pulley 26 Water pump shaft 27 Water pump mechanical seal 28 Water pump plate CP 29 Water pump impeller Fig. ".::Y -~'1 ! 1 I I I @ I I @ <. "- '··. . I @iI I '~~ : '. washer 2 Thermostat cover 3 Bolt &. (For power steering) 'I 7 Water by-pass pipe I "- " "l I I '.·:·. washer I / ! I I I I I I I I I ®~ I e.·~'1·: I I I I l " ..' ®----O " " I / I I I I I I ~\ I I I " I I I I I I I I I I I I I I I I I I ". 3·23 Engine cooling system (Water pump and relative fittings) A5-676 3-28 . Water Pump and Relative Flttln •• 1 Bolt &.t I I I .ENGINE 13. .

-...... ". ~ 49 States (except 4WO & 4WO·ATI only Gasket Oetail"F" Spring Detail "A" Selflocking nut Detail "C" 0 Detail Detail "0" "e" AT Detail"B" MT Fig.3.-~ ENGINE 14._.\ C_ ..52 (4. 31 • 38) T5: 14·22 (1.--_[ '!:-_!C -..lL.5. 18·25) A5·677 .4. {~ ~.8. _) : Ll= Hatchback only j @ 49 States !except 4WO & 4WO·ATI only ___ J / C" . 10·161 T6: 26·34 (2..J ~-. 19 • 22) T3: 22·33 (2.6· 3.2..:=:::.5·3.. 3·24 1 Front exhaust pipe 2 Rear exhaust pipe 3 Muffler 4 Bracket S Cushion 6 Tail pipe cutter Tightening torque: N·m Ikg-m. ~ ""'-.0.-. cG . -. -::::::-. .- _ _ _ _'''':_:.:_~~:_~..-r . j ..::=.'---~..16·26) T4: 42 . ··---A <~~..0 -1.. 7 ·131 T2: 25 • 29 (2...4·2.-~c-'-_ __ :::::::::!#E::': 0 ..--~.. .l . ft·lb) T1: 10-1811. .--. 9.5.3 . ..~. --... Exhaust System ( "'---'("~-:::-) .2·3.

EnKlne Compression 1) After warming up the engine. Ignition timing Without vacuum advance function. 1 Vacuum hose 2 Rod A5-S07 A5·379 Fig. The timing is advanced when the distrib· utor housing is turned clockwise and is retarded when turned counterclockwise. Fig. 2) Make sure that the battery is fully charged. 6) Crank the engine by means of the starter motor.800 4WDAT . 3-25 Plugging vacuum hose 1. proceed to the next paragraph for adjustment. while checking ignition timing. adjust the engine idle speed to the specification and illuminate the timing marks on the flywheel with the timing light. Add up the oil and coolant if necessary. 3-27 Timing mark and pointer ments per cylinder. and read the maximum value on the gauge when the pointer is steady. 3-30 . hoses. refer to Chapter 2. and make sure that the values are correct. plug the end of the vacuum hose with small rod as shown in the figure.600 1. 4) Fully open the throttle valve. b. d. check the oil and coolant level. 3) Remove all the spark plugs. I Fig. connect a timing light to #1 cylinder spark plug cord. A: After B: Before 7) Perform at least two measureAS-378 rpm Fig. c. Check to see if there is any leakage of the engine oil or coolant. For other checks and adjustments. never fail to perform the retighten· ing of the cylinder head nuts & bolts and intake manifold bolts and the adjustment of the valve clear· ances as instructed in 2·2 in CHAP· TER 2 after the engine has been run for about 10 minutes and cooled down to ambient tempera· ture. To check the ignition timing.ENGINE 3-3. 1) Checking Ignition Timing Before adjusting ignition timing. 3) Tighten the bolt and make sure tha t the timing is correct. disconnect the vacuum hose of advancer from the distributor to stop the vacuum advance function of the distributor. for undesirable interference. 2) Turn the distributor housing. and. 2) Adjusting Ignition Timing I) Loosen the 6 mOl bolt on the mounting plate of the distributor. 5) Check the starter motor for satisfactory performance and operation. Check the wiring cords. and lights off. and with gear in neutral position (MT) or N or P position (AT). NOTE: a. etc.800 MT AT& ·1 8 ± 2° BTOC at 700 rpm 1. 3-28 Adjusting ignition timing 2. turn off the ignition-starter switch. If one or both of the cylinder heads are removed in engine disassembly. If the timing is not correct. IKnltlon TlmlnK Perform inspection and/or adjustment of ignition timing according to the folloWing procedures. perform the following checks and adjustments. Upon completion of the engine adjustments.2 8 ± 2° BTDC at 800 rpm *1: 49 States 4WD vehicle with High Altitude Kit: 12 ± 2° BTOC at 700 rpm *2: 49 States 4WD·AT vehicle with High Altitude Kit: 12 ± 2° BTOC at 800 NOTE: Hold the compression gauge tight against the spark plug hole. On-car Services Also after reassembling and remounting the engine. pipes. 3-26 1.

1141 j 8:.019 t-' 1.. Leakage around cylinder. 28 psi) tween cylinders or less ~ 1) Warm up the engine. 3·30 Measuring compression Fig.. needle stops temporarily when it is lowering or becomes steady above normal position. 1561 981110 1421 I I ~ .. . When engine speed is gradually increased.peed .• pm A3·Q62 A5381 Fig. I 88319. and then vibration increases as engine speed increases.a_.' . Leaking valves or irregular valve clearances. Needle is steady but slightly higher than normal position. Defective ignition system or incorrect carburetor idle adjustment. 6. 7.ENGINE 1.I 1. 2..171112 1111 I 1. u . . .5. Needle is steady but slightly lower than normal position. Advanced ignition timing. I 1 __::s. 3·29 Compression pressure Fig. Diagnosis of engine condition by measurement of manifold vacuum Vacuum gauge indication .ne. '2 E 0. 4.1281 18518.:. 9. Needle drops suddenly and intermittently from normal position.d. By observing the gauge needle movement.079 111. Needle vibrates above and below normal position in narrow range. Needle drops slightly and intermittently from normal position. When engine speed is reduced slowly from higher speed. 3-31 Measuring vacuum 3.--~- 1. timing or insufficient valve S.. Q.16611 350 883 19. . Back pressure too high.-~ Possible engine condition Leakage around intake manifold gasket or carburetor gasket.and. Sticky valves.12111250 350 350 6861" 100! 200 250 300 S"II. Retarded ignition clearances.030 '10. the internal condition of the engine can be diagnosed as described in Table below.. 2) Disconnect the vacuum hose (air cleaner to intake manifold) and install the vacuum gauge to the hose fitting on the manifold as shown in figure. 3. Weak or broken valve springs.1281: / I' .. or exhaust muffler clogged. This tendency becomes more evident as engine temperature rises. 14911250 <11.::.d_ _ _ . Needle is steady but lower than normal position. Needle intermittently drops to position lower than normal position.0 kgJcm . 3) Keep the engine at the idle speed and read the vacuum gauge indication. S. - ~ 834 185. Intake Manifold Vacuum Difference be· 196kPa 2 (2. needle begins to vibrate rapidly at certain speed.

ir control systBm Correct position of the air control valve is the reverse of that described in I) above. malfunction of the air control valve due to disconnection or deterioration of the vacuum hose between the intake manifold and vacuum motor and insufficient durability of the air control valve will cause insufficient automatic control operation for intake air. check the hot air control system for the following items before carrying out inspection of the carburetor.ENGINE 4. If these phenomena should occur. Check the condition of the air control valve linkage. The air control valve is in correct position if the under hood air inlet is closed. it is difficult to find out malfunction of the hot air control system. and check to see if the air control valve is in correct position. however.3-34 InlP6Cting vsl". In cold weather. place a mirror at the end of the air cleaner inlet pipe as shown in the figure. These phenomena reveal malfunction of hot air control system. In warm weather. position FIg. Vacuum can be applied by sucking at the hose end as shown in the figure. and the hot air inlet is open. 1 Vacuum motor 2 Temperature sensor 2 Vacuum motor A 5·386 FIg. 3-32 . Hot Air Control System Inspect the hot air control system periodically as follows. 3-32 Hot . 2) Disconnect the vacuum motor inlet vacuum hose. and result in engine disorders: I) Stall or hesitation of engine operation. and connect another hose to the inlet to apply vacuum to the vacuum motor. and check to see if the air control valve is Mirror Vacuum motor Air intake hose A5·385 Fig.3-33 InlP6Cting vsl". 1) Vacuum Hoses Check each hose for cracks and proper connections. position 1 Vacuum motor 2 Temperature sensor 3 Throttle valve 4 Intake manifold S Vacuum hose 6 Air stove 7 Air intake bose 8 Air control valve 9 Air hom (Snorkel tube) A5·383 The air control valve is in correct position if its under hood air inlet is open and hot air inlet is closed. Place a mirror at the end of the air cleaner inlet pipe. 2) Increase in fuel consumption. 2) Vacuum Motor 1) With the engine stopped. and 3) Lack of power.

Operation of air control valve and sensor valve Under hood air temperature Vacuum on vacuum motor diaphragm Below S.72 inHg) 38 . and that the hot air inlet is open. En. Use a mirror for inspection as 3) Check that the air control valve gradually moves to open the under hood air inlet as the engine warms up. 1) With the engine stopped.lne Idle Speed and Idle Mixture 1) Engine Idle Speed Refer to 2·2. If the diaphragm spring actuates the air control valve by its spring force to open the under hood air inlet within 30 seconds. underhood air inlet should be open. the correct position of the air control valve is the reverse of 2)-1).I). In this case. In this condition. replace the vacuum motor as an assembly since this may have resulted from air leak at the vacuum motor diaphragm. 3) Temperature Sensor Check temperature sensor for proper function by proceeding as follows. Immediately after engine starting. 2) . check the position of the air control valve. the under hood air inlet is closed. ba lUre to pr_ spring pin into the hole in throttle chambar. . When the environmental temperature around the temperature sensor is low. Be sure to keep the engine cold before starting this test. 8.S. check the air control valve for correct position as described above. In this case.ENGINE 3) With the hot air inlet in open position. And after completion of adjustment.127°F) Above S3°C (l27°F) Hot air admission Cool and hot air mixture admission Cool air admission Open Open Air control valve operation Cool air admission Close Sensor valve operation . retor. as described in 2).3 kPa (40 mmHg.0 kPa(120 mmHg. 2) Start the engine and keep it idling. and the hot air inlet is open.S3°C (100 . 2) Engine Idle Mixture NOTE: Perform the idle mixture adiultment only when dismounting carburetor from angina or ditalsambling carb. 4) Rubber Plate Check the rubber plate for stickiness. 1. Engine Idle Speed in Chapter 2. check that the air control valve maintains the condition described in 2) for more than 30 seconds.57 inHg) Below 38°C (100°F) Above 16. 4. spend more time for engine warming up operation to facilitate smooth operation of the air control valve. pinch the vacuum hose with fingers so that the air does not enter the vacuum motor. 5} Air Intake Hose Check the air intake hose for damage and its connections for leaks.

b. 3-34 .ENGINE 1) For 49 States (except 4WO & 4WO-A T) and California Perform the engine idle mixture adjustment according to the following diagram. *N Z= ..600 m ( Z is constant ) regardless of the altitude. deg)~ f--l--. r::J 3S% l31 . (S. ()e~ the ~~~ter 0 f duty meier swing ~~ See Troubleshooting in Chapter 5. Yes Warm up engine by driving around for 10 minutes. adjusting Allowan~ ±5% (±4.000 .3. * Does the poin ler () f duty meter swing normally? (ie. N Duty ratio" Z Yes End ~ normally? (ie.3 minu res.000 rpm for 2 . I f-- End No t G.four cylinde(. lntrolled'!) No [ l Idling speed Duty ratio =N =Z Yes Keep engine speed \II ithin 2.5 deg) Perform the above adjustment on both main and slow duty solenoid valve by using check terminal. (1) Set the range switch to 'four cycle . Adjustment method by using dwell meter is as follows.tl(' /'] I {164 hI ( the altitude. Is duty ratio t:( Yes Idling speed Duty ratio =N Z ** No J 1 ~ Adjust duty ratio.x Duty (%) 100 B. 90 Dwell (deg) =. NOTE: Vehicle with HITACHI carburetor Standard value Duty ratio'" Z Vehicle with CoW carburetor Z'" 35% (31. (2) Adjust the idle adjusting screw so that the needle points out according to the following calculation.S deg)1 / SO m 1. Is duty ratio c ontrolJed?) Nn 700 ± 100 rpm (MT) ( 800 ± 100 rpm (AT) See Troubleshooting in Chapter 5.2S0 ft) Z is determined according to ) . Yes Confirm JdUng speed .5 deg) ~-----+-----------------------------~--------~ At checking :1:20% (t18 deg) *" Adjust idle adjusting screw so that duty meter indicates 35 ± 10%.

Detach the oil pan. Testing of radiator leakage Inspect radiator for leakage using a cap tester and applying a pressure of 157 kPa(1. 13 psi) AT& 4WD·AT 700±100 800±IOO 2. loosen the valve rocker ASSY and remove the push rod.9 kg/cml. A5·678 Fig.S±1. b. hoses and their con· nections for damage. replace cap. 4) Clog air suction pipe with rubber cap or the like. and Canada Adjust engine idle mixture as follows: I) Start engine and warm up suffi· ciently. and adjust the valve lifters for intake and exhaust valves on #1 cylinder. With secondary air.3-36 Testing the radiator 6. . for exhaust valve on #3 cylinder and for intake valve on #4 cylinder. clogging or leakage. Other than AT Idle speed (rpm) Without secondary air With secondary air Check rubber seal on cap for tears. Hydraulic Valve Lifter A. adjust idle speed and CO percentage in exhaust gas while clogging air suction pipe. Adjust both throttle adjusting screw and idle mixture adjusting screw to obtain the specified idle speed and CO percentage without secondary air. Fig.0±1. A7·026 Fig. Adjustment I) Perform adjustment in cold con· dition [coolant temperature: 20 to 40°C (68 to 104°F)). 3) Using the special tool (Socket Wrench: 899988607). 2) Inspect idle speed and CO per· centage in exhaust gas with secondary air. Use of a magnet facilitates removal. 6) Remove the drain plug to drain the engine oil completely. spring and packing in the cap for damage.O. 3) Adjust hydraulic valve lifter with the following procedures: a. Perform adjustment in two (2) sequences.ENGINE 2) For 49 States 4WD & 4WD·AT. repair or replace the radiator. Radiator Check radiator. 8. If a leakage is detected. Standard pres· sure at which valve starts to open 88 kPa (0. 4) Raise the vehicle body with a jack and support it on a safety stand. 6) If necessary. 2) Retighten cylinder head nuts and bolts previously if necessary. 23 psi).6 kg/cml. 3-35 Testing the cap 8. 2) Remove the valve rocker cover. Install the cap on a tester and if cap does not hold or does not release the specified pressure. c. recheck that idle speed and CO percentage satisfy the specifications. Remove the plug clogging air suction pipe. 5) Inspect idle speed and CO per· centage in exhaust gas without second· ary air. and connect the pipe to secondary air cleaner hose. Replacement The hydraulic valve lifter can be replaced even when the engine is mounted on the vehicle as follows: A. S) Remove the nuts which secure the front engine mounting and slightly raise the engine using a floor crane. 7. cracks or deterioration after cleaning it. a. Testing of radiator cap Check the valve. 3·37 8) The valve lifter can be installed in the reverse order.0 Disconnect both the blow·by and PCV hoses. 7) Remove the hydraulic valve lifter. I) CO percent· age (%) 0.S -- 3) Disconnect air suction hose be· tween air suction valve and secondary air cleaner.0 1. Sequence (I) Position #1 cylinder at TDC (compression).

.471 "/ -~'=_ i Xhaust cover Re:zrSkirt f I ~ --r More than More than 20 (0. and adjust 1IIe clearance correctly.. 2) If a clearance is small at any particular point. unscrew the valve rocker screw counterclockwise by 1. and adjust all the others. Finally. . r . b. p.Position #l cylinder at TDC (compression)..39) More than 12 (0. Exhaust System e. then readjust clearances by utilizing free play existing at each bolt location until correct clearances are obtained.. broken exhaust cover. _ . Leave it with the valves opened for approx. ~~ L- a . Then. check all clearances to ensure that they exceed the specified values. f. AS·702 8. the rocker arm stops moving due to the closing of valve. 1) After installing the exhaust sys· tern.ENGINE Sequence (II) . '\ Hydraulic velve \fter is adjusted ..~ ~ . A5·700 ~byl5t"~ A6·703 Front crossmember NOTE: If muffler or exhaust pipe clearance is excessively small due to a deformed or c. More than 10 (0. Leave for approx. Raise up the bend of lock washer.e. 15 minutes then pressure chamber volume becomes Crossmember for manual transmission Crossmember for automatic transmission Rear crossmember minimum~alve mov~~~ close a little. . Fig. repair or replace 1IIe cover. for intake valve on #3 cylinder and for exhaust valve on #4 cylinder.. for intake and exhaust valves on #l cylinder.5 turns. Th~ condition is called "Zero Point". 3-38 A22·065 3-36 . loosen the lock nut. i. Moreover.. AS·701 ~~~~~~::~~===d~/~. four (4) turns using Valve Clearance Adjuster 498767000. and then turn the valve rocker screw clock· wise by approx...791 Unit: mm (in) d...791 2010. Unscrew gradually. _ . 15 minutes.. ~ .791 More than 20 10. tighten all connections to the specified value. Valve opens. Tighten the lock nut.591 . More than 1510. loosen all connections. Unscrew the valve rocker screw gradually. and bend the lock washer.

) sensor to make the next removal easier.) sensor. AS'S80 Fig. Oxycen (02 ) Sensor Oxygen (0. NOTE: When removing. 2) Installation 1) Apply anti-seize compound ("SS30" made by JET-LUBE Inc.A. othelWise it will damage the front exhaust pipe. 16 . 4) Apply SUBARU GUARD (000902821) to threaded portion of oxygen (Ol) sensor again.2 . in U. 2) By using special tool (Socket: 499990100) and torque wrench.S. S) Remove oxygen (0.ENGINE 9.) sensor onto front exhaust pipe by tightening it to the specified torque. NOTE: Never apply anti-seize compound to protector of oxygen (0 2 ) sensor.3. and leave it for one minute or more. do not force oxygen (0 2 ) sensor especially when front exhaust pipe is cold. Therefore. and is one of the important emission control parts.) sensor is installed on front exhaust pipe. install oxygen (0. 3) Loosen oxygen (0. . or if it seems to be out of order according to troubleshooting etc. replace it as follows only when it is damaged by external force. 3-40 A5-679 Fig.) sensor by using special tool (Socket: 499990100) and wrench.22 ft-Ib) 3) Securely connect oxygen (0. 3·39 1) Removal 1) Disconnect 0.29 N'm (2.0 kg-m. sensor cord. Torque [oxygen (Ol) sensor} 22 .) sensor by turning it 10 to 40 degrees with special tool (Socket: 499990100) and wrench. and leave it for one minute or more. 2) Apply SUBARU GUARD (000902821) or its equivalent to threaded portion of oxygen (0. or its equivalent) only to threaded portion of oxygen (0.) sensor cord.

Disconnect electric connectors for thermoswitch and fan motor. and take out air cleaner. (Pressure Hold Valve) cable from bracket d.3-43 Draining coolant c. 9) Loosen bolts and nuts connecting transmission to engine. b. It is desirable to cover the fenders with covers during the work. a. 4) Disconnect hoses and electric wiring from air cleaner. 342 Removing upper bolts and loosening lower nuts 10) Take out radiator as follows: a. and ground wiring for noise condenser from engine. Detach right-hand side under cover. (MT only) Clutch return spring c. 2) Detach spare wheel & tire and its supporter. Remove bolts and nuts.341 Opening engine hood 3-38 . Therefore receive this gasoline with an appropriate container. intake manifold.ENGINE 3·4. 5) Disconnect hoses from carburetor. pay attention to prevent damage of air cleaner. In this process. Vacuum switch hose(s) 7) Disconnect cables. Disconnect both inlet and ou tlet radiator hoses. Dismounting and Remounting 1. NOTE: Gasoline remammg in delivery hose may flow out. e. 2) Be careful not to soil the vehicle interior (particularly windows and seats). 3) Remove ground cable between battery and engine. etc.V. Connect a vinyl hose to radiator drain plug. Alternator wiring d. Fuel delivery hose and fuel return hose from carburetor 2. Starter wirings e. High tension cords c. it is desirable to perform the job over a pit together with a chain hoist or a floor crane. etc. Engine wiring harness b. and take out radiator. pitching stopper. and drain out coolant. (AT only) Vacuum hose for kickdown solenoid from vacuum pipe 6) Disconnect electric wiring. A4-161 Fig. Dismounting I) Open/put engine hood widely by setting its stay in the correct position. (Vehicle with Hill-holder) P. Fig. Accelerator cable from carburetor b. a. Pitching stopper 8) (AT only) Remove four bolts connecting torque converter to drive plate through timing hole. If possible. Remove two bolts. A1-G63 Fig. NOTE: Use a container to catch coolant running out of inlet and outlet hoses. Precautions I) Perform the job at a place where a chain hoist or a floor crane is available. NOTE: Plug the carburetor opening to prevent dirt or dust from entering carburetor. and then remove upper two bolts only. if possible. and ground wiring of radiator. carburetor vent hose and purge hose from evapolation pipe complete c. f. b. d. 3) Be careful not to allow brake fluid and coolant to come in contact with the painted surfaces of the vehicle body. Vacuum hose. Vacuum hose for brake booster (Master-vac) from intake manifold d. etc. (AT only) Disconnect cooler hoses at radiator. a. hoses.H.

Disconnect both inlet and outlet heater hoses. c. and hang it with a crane or similar equipment. Fig. Remounting l) Set (repaired or new) engine near by transmission as follows. and then take engine out of engine room. A4-199 Fig. or car body during dismounting. 19) Carefully lift engine until bolts retaining engine mount rubber cushion clear crossmember. Loosen lock bolts and adjust bolt of idler pulley. Be careful that the oil does not flow out.3-48 Supporting transmission 21) Slowly move engine forward to prevent transmission mainshaft from interfering with flywheel housing. Detach idler cap with pliers with waste cloth around it in order not to damage it. 3·44 Removing cap A4-097 b. While engine is lowered. be careful to prevent engine from striking any adjacent parts or car body. 2) Turn crank pulley until mainshaft is aligned with clutch disc at their splines. 3-47 . and support with safety stands at the correct positions. Lower engine until the centerline of crankshaft aligns with mainshaft of transmission. Loosen bolt connecting front exhaust pipe to bracket of body. 11) (Vehicle with power steering) Remove oil pump ASSY and bracket as follows: a. 16) Remove lower two nuts loosened previously. c. b. lower the jack. NOTE: Be careful not to strike engine against any adiacent parts.ENGINE g. 15) Attach a lifting wire to front and rear hangers of engine. a. 14) Remove nuts securing cushion rubbers used to support the front portion of engine. Correct position A4·194 ? A4·152 Fig. b. 345 Removing oil pump ASS Y NOTE: a. c. A4·196 NOTE: a. Remove bolts and nut. NOTE: a. Lift engine using a crane or similar equipment. 13) Separate front exhaust pipe from engine as follows: a. Detach bracket. Be careful that the two oil hoses does not damage. 17) To facilitate dismounting engine. Move/put it near the center of engine room. Fig. IS) Visually check again that nothing has been over-locked. b. Apply grease to splines of mainshaft in advance. b. 12) Raise the front end of vehicle using a jack. But do not lift it at this time. 3-46 Fig. and then detach oil pump belt. Take care so that a lifting wire does not damage the engine parts. d. 3. Disconnect oxygen (0 2 ) sensor cord. Remove nuts securing front exhaust pipe to the exhaust ports of engine. 20) Support transmission using another jack. and put oil pump ASSY on bulkhead. and secure engine to transmission as follows. Make sure that the lifting wire hook is securely attached to the hanger. b.

0 kg-m. An-031 Fig. Fig.0 . A4-200 Torque A4·112 Fig.25 ft-Ib) (4. sensor cord.5 kg-m. c. c. Make sure that engine is properly aligned with transmission.20 ft-lb) I • I ~ I 1$''. 4) (AT only) Install drive plate on torque converter as follows: a. 11.34 N·m (2. and tighten them by bolts . Connect 0. Temporarily tighten upper two bolts.. b. Turn front wheels until the mount· ing holes for torque converter are aligned with the mounting holes for drive plate.5 3. NOTE: Place the flat surface of the gasket to the enlline exhaust port. 14 . Crank engine with a wrench and securely tighten all four mounting bolts . Securely tighten both upper bolts and lower nuts. and take it out.349 Turning crankshaft a. 3-40 . Lower the jack supporting transmis· sion.5 kg·m. 3-54 d. 19 22 ft·lb) Torque A4·095 Fig.25 ft-Ib) Fig. a.to retain torque converter and drive plate. a.1 .one bolt at a time for each turn . 25 . 3·52 Installing gasket b.3-51 Tightening cushion rubber nuts It:=:: 1) Connect front exhaust pipe to engine as follows. Turning crank pulley with a wrench. d.2. A4-093 Fig.3. 20. Attach new gaskets to the engine exhaust ports. 3·53 Installing front exhaust pipe c.40 ft·lb) Torque A4·161 3) Put engine in position as follows. Lower engine moreover.54 N·m 25 . Jack up the car until front wheels are slightly off the floor. Tighten bolt at bracket of body.33 N'm (2. Then tighten four nuts to the speci· fied torque. and carry away crane. and then lower nuts. c. Detach lifting wire from engine.3 . 6) Securely tighten engine mount cushion rubbers on the crossmember.5. 18 . and temporarily tighten nuts. b. Position engine mount rubbers onto crossmember.1 r Gasket NOTE: Be careful not to drop bolts into torque converter housinll.29N·m (2.ENGINE NOTE: Be careful to prevent mainshaft splines from interferinll with clutch diaphragm spring. Torque (Bolts and nuts) 46 .6 3. bring the mounting hole for drive plate to the center of the timing hole.1 kg·m.26 N·m (2.4 kg-m. 34 . b. 8) Lower the vehicle to the floor. This can cause damage to sprinll· Torque 23 . 3·50 Connecting torque converter and drive plate 5) Raise the vehicle with a jack just enough to work underneath it and support with safety stands. d.

5 . • Hitachi carburetor NOTE: Always make a precise adjustment of pitching stopper to prevent engine from vibrating during operation.18 mm 10. cable. 3-58 Installing accelerator cable.29 N·m ( 2 .12 inl Full stroke 17 .13 ft·lb) Torque 3-41 . 7 .61. and adjust Hill·holder system. 3-56 Adjusting clutch release fork 12) (Vehicle with power steering) Install bracket. 13) Install radiator on the car body.5 kg.m.071 .2 mm (0. and tighten it at the car body side. and adjust its tension by adjusting nuts. depress the accelerator pedal to ensure that the throttle valve fully opens. 33 .C. 3 Release fork Fig.0. 10-18N'm ( 1. and connect hoses and electric wiring.0.V.3.08 . 3-55 Installing pitching stopper 10) Attach supporter of spare wheel & tire. Connect accelerator cable.11 in) AS'581 Fig. Attach a wrench to the rear nut on pitching stopper of the engine side to prevent it from turning.ENGINE 9) Install pitching stopper as follows: a. Free play 2 3 mm (0. (Refer to Chapter "Brakes" .1. 33 .0 . Insert pitching stopper rod into the bracket on the engine side.5 .047 in) 1. Tighten the rear nut on pitching stopper of the engine side so that the specified clearance exists between rubber cushion and washer.--Specified clearance MT 0. (Vehicle with Hill-holder) Connect P.5 .40 ft·lb) 25 .22 ft-Ib) .8 kg·m. tighten lock bolt and attach idler cap. 7 . 18 .3 kg-m.25 ft-Ib) 20. 3·57 LT c. { @ 1 Lock nut 2 Adjusting nut . 11) Connect cables as before. (. 14 . a.8.5.0.13 ft-Ib) c.1.5 kg.087 in) Bolt B (two) Bolt C (three) Fig.40 ft-Ib) 44-54N·m (4.34N'm (2. b.5 kg-m.5.8 . Connect clutch cable to release fork with free play.2.2 mm (0. 10-18N·m (1.) Torque Nut A (one) 44-54N·m (4. and tighten the front nut securely.0.3·59 Fitting bolts and nuts A4·248 Fig. After adjusting the belt tension (refer to Chapter "Steering System"). BoltD (one) NOTE: Torque After making the accelerator cable adjustment.m.8 kg-m.031 .1. A3-20l Accelerator cable A4·247 • COW carburetor A4-113 Fig.0 . oil pump ASSY and oil pump belt. b.

Then.C. Ground wiring of radiator b. Inlet and outlet hoses to heater unit Fig. 3-63 A4-188 b. 17) Put hoses onto stay.C. a. Vacuum hose.V.ENGINE 15) Connect hoses as before. d. Vacuum hose to intake manifold for brake booster (Master-vac) \ \6) Attach air cleaner onto carburetor and connect the following hoses. CD Vacuum hose ® Carburetor vent hose @ Fuel delivery hose @ Fuel return hose @ Purge hose 1 Harness connector 2 Harness connector for auto-choke. tighten bolts and wing nuts securely. 3-66 Connecting fuel hoses 1 Vacuum hose2 Vacuum pipe Fig. Connectors for alternator 1 Vacuum hose 2 Carburetor vent hose 3 Pwgehose Fig. Inlet and outlet hoses to radiator d. and hold them with hose clamp. CD Air intake hose ® P. and carburetor selection (C-W) A4-245 Fig. Fig.V. Two multiple connectors for engine wiring harness A4-187 Fig. 14) Connect electric wiring as before. fill radiator with SUBARU genuine coolant to the specified level.C. Fuel delivery hose and fuel return hose to carburetor Fig. 3-64 Connecting master-vac vacuum hose Connecting hoses c. vacuum hose @ Vacuum hose to thermo vacuum valve II (Hitachi carburetor) or thermo vacuum valve III (C-W carburetor) ® Vacuum hose to thermo vacuum valve I rJ) Hose to A. 3-61 f. hose @ P. a. (AT only) Cooler hoses to radiator e. Connectors for thennoswitch and fan motor c. High tension cords c.V. vacuum hose @ A. carburetor vent hose and purge hose to pipe complete Then. (AT) Vacuum hose to vacuum pipe for kick-down solenoid A4-100 Fig.T. 3-65 Connecting hoses A4-186 NOTE: (Vehicle with power steering) Securely fit cord supporter onto blow-by hose paint marking and high tension cord. 3-68 A4-181 3-42 . 3-62 b. 3-60 I Fuel delivery hose 2 Fuel return hose A4-185 a.S.

8) Loosen the connectors of E. pipe complete and by-pass hose as an ASSY and another by·pass hose. 5) E. c. 19) Attach spare wheel & tire in position. 19) Clutch cover and clutch disc. 21) Invert engine. Start the engine and check for the condition of various parts. take corrective action. install plugs in place. (MT) NOTE: a. 20) Flywheel with a-ring (MT) or converter drive plate with back plate and a-ring (AT). Allow the engine to cool off before checking the coolant level. II) Unclamp heater hose. * Remove stiffener 2 at this time (4WD).R. NOTE: Insert a screwdriver or the like into a hole in the converter drive plate through the timing hole to prevent it from turning. Check the engine oil and coolant levels again.ENGINE 18) Install ground cable onto battery and engine. Remove distributor and distributor plate. Disconnect spark plug cords from spark plugs and cord supporters. Insert a screwdriver or the like into a hole in the flywheel through the timing hole to prevent the flywheel from turning. oil pan gasket and transmission cover II (MT). pipe cover. spark plug cord stay and drive belt. coolant levels to ensure that they are even with the specified marks. pipe. 3-69 Installing engine stand NOTE: a. b. 9) Disconnect the wiring harness lead of oil pressure switch or oil pressure gauge. and bracket 2. Take care not to allow oil or water to come in contact with the clutch disc. 4) Alternator with air cleaner bracket.G. 20) Close engine hood.G. If the levels are below the specified marks. Use Puller Set (899524100) in such a case of pulley fitted tightly. replenish as necessary. and ground wiring for noise condenser onto engine. 2) Carburetor protector. 15) Oil filler duct and oil filler duct stay as an ASSY. pipe at intake manifold and cylinder head. NOTE: Take care not to allow oil or water to come in contact with the clutch cover or disc. 3-70 Position of drain plugs 3-43 .G. b. Insert a screwdriver or the like into a hole in the drive plate (AT) or the flywheel (MT) through the timing hole to prevent the crankshaft from turning. Never open the radiator cap while the engine is hot. 7) Battery cable bracket and ASV bracket [vehicle without power steering for 49 States (except 4WD & 4WDAT)] or oil pump bracket (vehicle with power steering). After draining. If necessary. 22) Crankcase oil pan. Removal 1) Install Engine Stands (399814300 x 2) and drain the engine oil and coolant by removing engine oil drain plug and coolant drain plug. a. 6) ASV pipe and ASV. Ooing so may burn your hand. 13) Intake manifold ASSY and E. 16) Pulley by tapping it lightly. 2) Stop the engine and allow it to rest for some length of time. 14) Generator bracket complete and generator bracket 3 as an ASSY. 12) Disconnect two water by-pass hoses and heater hose from intake manifold. d.R. (For 49 States (except 4WD & 4WD·AT) and California 1 3) Distributor. 3-5. Unclamp distributor lead wire. 1 Oil drain plug 2 Coolant drain plug A5·255 Fig. 17) Oil pump together with oil filter. b. Engine Stand 1399814300 x 21 A5-472 Fig. 18) Water pump. Disconnect vacuum hose from distributor. 4.R. hose. Check the exhaust pipe connection to make sure that there is no sign of gas leakage. and lock it thoroughly. Inspection and Test 1) Check both the engine oil and NOTE: The radiator is a high pressure type. and distributor cord from cord supporter. 10) Disconnect connecting hoses from rocker covers.

b.55 in) wide across flats. 3·72 Removing piston pin 33) Crankcase plugs from crankcase with an Allen wrench 14 mm (0. O-ring and back-up ring. b. install the crankshaft pulley bolt on the crankshaft front end. 3-71 Loosening sequence of cylinder head nuts 29) Cylinder heads and cylinder head gaskets. 30) Remove bolt and nut retaining oil strainer stay. 35) Straighten lockwashers for cam· shaft attaching bolts. 3·73 Removing crankcase plug 38) Oil seal at the front of crankcase.. keep them in order. 24) Flywheel housing. 27) After loosening valve rocker lock nuts and adjusting screws for other than hydraulic valve lifters. If the push rods are to be reused. NOTE: a. so that they can be reinstalled into their original holes. If necessary. drive out oil strainer together with stay as a unit. NOTE: a.ENGINE 23) Invert engine. do not mix them up. b. Before separating the crankcase. O-ring and back·up ring. 45) Oil pressure switch (Vehicle with· out pressure gauge) or plug (Vehicle with pressure gauge). Also remove the crankcase hanger (F) and stiffener (4WD). 42) Solid valve lifters and keep them in order. Use Valve Lifter Clips (899804100) to prevent the lifters (other than hydraulic valve lifter) in the upper crankcase from dropping off. 39) Oil seal at the front of crankcase. and remove bolts. 26) Valve rocker covers and gaskets. NO'rE: If the bearings are to be used again. 37) Separate crankcase by removing bolts and nuts with # 1 and #3 cylin. 28) Cylinder head attaching nuts. Use a chisel when removing the oil strainer. Never loosen valve rocker lock nuts and adjusting screws for hydraulic valve lifters. 1 1 Piston Pin Remover (399094310) 2 Piston pin A5·276 NOTE: Loosen nuts according to the sequence below. 25) Spark plugs. 40) Crankshaft together with connecting rods. Make marks on the pistons so as not to change their installed posi· tions. 3-44 . 46) Engine Stands (399814300 x 2) from the crankcase halves. c. 43) Pistons from crankcase. remove the valve rocker assemblies and valve push rods. Set piston to its bottom dead center by turning crankshaft and insert long nose pliers through the rear service hole to reach circlip.. and take out hydraulic valve lifters. pull the camshaft toward the rear so that is does not interfere with the crankcase. . Keep the pistons and piston pins together for each cylinder so that they are not mixed up. 34) Piston pin circlips and piston pins for # I and #2 pistons in the same way as before. NOTE: a. so that they are installed in the original positions. distributor gear and crankshaft gear as a unit. Use this shape of wranch Fig. 31) Piston pin circlip on the rear side of each #3 and #4 piston. b. 36) Tilt crankcase. NOTE: a. using Piston Pin Remover (3990943 10) inserted through the rear service hole. 32) Piston pins for #3 and #4 pistons. Fig. ders facing upward. but use the front service holes (crankcase plug holes) this time. NOTE: Keep them in order so that they are not mixed up. Never attempt to remove the strain· er unless it is really necessary. 41) Camshaft together with camshaft gear and camshaft plate. A5·279 Fig. 3·74 Pulling camshaft Fig. working through the camshaft gear holes. NOTE: To turn the crankshaft with a wrench. 44) Crankshaft bearings.

Accelerator cable bracket a. NOTE: 6.3·76 Disassembled connecting rod and Canada 1) Disconnect wiring harness. c. Thennostat cover. Thennosensor. refer to 14. Solenoid valve II (except for California). gasket and duty sole· noid valve connector clamp. b. Intake Manifold Assembly 1) Hitachi Carburetor Type for 49 States (except 4WD & 4WD·AT) and California 1) Disconnect wiring harness. P. In addition. d. . b. . Piston Remove piston rings with a piston ring expander. d.C. Actuator ASSY (A/C only). two gaskets and an insulator. 4. m.ENGINE 3·6. AE: . e. b. 2) Remove vacuum hoses. clip and stay & clip.C. valve. and related parts. Thennosensor. P. Thenno vacuum valve III. Accelerator cable bracket. P.V. gasket and AAV pipe & hose d. spring retainers. n. and be careful not to mix them up. hose.V.G. gasket and ther· mostat. Heater hose. Actuator ASSY (A/C only). Then remove woodruff key and camshaft plate. f.R. E. be sure not to mix rocker arms since their screws are adjusted with every cylinder. Disassembly 1. gasket and thennostat b. Carburetor. Cylinder Head 1) Remove valves. 3·75 Removing valve and spring 2) Remove spacer with gasket. Vacuum pipe CPo n. 2) Remove vacuum hoses. Keep the disassembled parts in order. Crankshaft Remove connecting rods from crankshaft by unscrewing connecting rod nuts. solenoid valve I and bracket. Never loosen rocker arm screws for hydraulic valve lifter. Thennostat cover. Solenoid valve I. o. Stay & clip. k. NOTE: a.C. Heater hose g. e.C. Thenno vacuum valve II i. two gasket and insulator e. protector stay.C. h. a.G. Thennosensor 3) C·W Carburetor Type 1) Disconnect wiring harness. valve. a.V.V. Heater hose. 1. hose. E.. Solenoid valve III. h. 2) Hitachi Carburetor Type for 49 States 4WD & 4WD·AT NOTE: Fig. P. springs. E. c. Duty solenoid valves (slow and main) and carburetor protector 2. 3.5-039 Disassemble valve rocker ASSY to each component part. valve.C. stay. P. Camshaft Remove cam gear from camshaft using Remover Set (899714110) and press.0. Solenoid valve II.V.0. hose f. valve j. clip and stay & clip c. by using Spring Press (899724100). Thennostat cover. 2. a. Carburetor. P. m. Connecting Rod in 3·7. Clip. s. Carburetor. 2) Remove (vacuum) hoses and related parts. two gaskets and an in· sulator. Vacuum pipe CP and carburetor protector 3. g. k. gasket and thennostat. Thenno vacuum valve I k. b. Vacuum pipe h. Actuator ASSY (A/C only). For the replacement of connecting rod small end bushing. Remove bearings from connecting rod. g. l. hoses and related parts. valve. 1. i. 1. Thenno vacuum valve I.R.R. and retainer keys from cylinder head. Thenno vacuum valve I. j. Valve Rocker Assembly .G. Arrange the disassembled parts in order and be careful not to mix them up.V.5-286 Fig. Put a mark on the individual valves. hoses. Also remove circlip. valve and gasket. j. f.

If the warping exceeds 0.3 mm (0. Warping limit Grinding limit Standard height of cylinder head 1600 cc Engine 1800 cc Engine O. Fig. Oil filter b.0. When r. assembling. by-pass valve spring and ball e.528 in) 90. Water pump pulley b.Adjustment 1.ENGINE NOTE: 7. Water Pump Disassemble water pump to each component part. two washers. Mechanical seal Piston ring expander AS·03B Fig.05 mm (0. c. 7.039 . Two screws c. Oil pressure gauge or plug f. 3) Blow compressed air into the oil passages to make sure that they are not clogged.020 in) 89.051 in) I NOTE: Uneven torque for the cylinder head nuts can cause warping. so that they are not mixed up. Oil Pump Disassemble oil pump to each component part. 3-77 Removing piston rings 3 .. Cylinder Head 1) Make sure that no crack or other damage exists.8 mm (0. Press the bearing outer race.6 mm (3. pay special attention to the torque so as to tighten evenly. a. Precautions I) Before cleaning parts. 5) Arrange all relative parts in order. make sure that no leakage exists in parts which carry coolant or oil. 2) Clean all parts carefully and make sure that adhering gaskets and other substances are removed. O-ring. spring and relief valve 8.0020 in) O. drive gear. a. 4) When removing deposits such as carbon.7 . regrind the surface with a surface grinder. In addition to visual inspection. Relief valve plug.OSmm (0. or the bearings will be damaged. rotor and O-ring d. Water pump shaft Arrange the removed piston rings in order and be careful not to mix them up. and correct the contact surfaces if they are defective or when valve guides are replaced. Oil pump body holder.0 .1.6mm (3.Smm (0. Impeller d. inspect important areas by means of red check. 3-79 Dimensions of intake and exhaust valve seats 2. 3-78 Measuring cylinder head for warping Intake W Exhaust 1.0.0020 in). be careful not to damage the part surface. 2) Measure the warping of the cylinder head surface that mates with crankcase by using a straight edge and thickness gauge. Fig.5 mm (0.567 in) 3) Inspect intake and exhaust valve seats. 3-46 Wear limit of valve seat (measured in direction of valve axis) 0. Inspection and .071 in) 0.1. NOTE: Do not press the shaft.028 .020 in) for both intake and exhaust valves .

in cylinder.0059 in) ~---- 0.0 IS mm (0. f. coated with sufficient oil. b.8.IUd b9 ltS (399765101) Fig. Valve gutde adjuster (899768603) Valve guide adjuster (899768602) ---Specifications for valve stem and valve gUide ~~-- Standard cI earance between val ve gUide and valve stem Limit of de arance between val ve guide and valve st em Intake '--- 0. If the clearance between valve guide and stem exceeds the specification. the contact is satisfactory.945 .0016 . d. Place cylinder head on Cylinder Head Table (399765101) with the combustion chamber upward so that valve guides enter the holes in Cy linder Head Table.965 mm (0. Apply a thin coat of Prussian blue or red lead to the contacting surface of valve to see the contact· ing condition of valve and valve seat.15 mm (0. p. Valve Guide Check the clearance between valve guide and stem..ENGINE The correction procedure is as follows: a. (2) When reconditioning valve and valve seat surfaces.. NOTE: The above is important because the valve and seat must have a gastight fit. e.3-81 Removing valve guide 54 mm (2. Reface valve seat with valve seat cutters or grinders to the dimen· sions shown in the above figure. apply a small amount of grinding com· pound (about #400) on the valve surface and lap the valve and seat surface so that they obtain proper fit. remove intake valve oil seals..:. replace guide as follows: c. Insert Valve Guide Remover (899764104) into valve guide and press it down to remove valve guide. The clearance can be checked by measuring the outside diameter of valve st~m and the inside diameter of valve guide wi th outside and inside micrometers respectively.0026 in) ~- Fig.7.ng~ of . Rotate valve with light pressure. Put new valve guide. 4) Inspect exhaust pipe stud bolts installed on the cylinder head. Precautions (I) When valve seat correction is required. c.0059 in) 8. If the blue or red lead is transferred to the center of the valve seat surface.040 -~ 0.0.0.13 in) -~----~-~-~----~ Fig. check intake and exhaust valve stems and valve guides for wear.3156 in) 7. If defective.31 SO . make sure that neither scratches nor damages exist on the inside surface of the valve guide holes in cylinder head. 3-80 Refacing valve seat with valve seat cutter 3.3128 .960 mm (0. and the springs for squareness. etc. 899768603 for intake valve guide) as shown in the figure.3130 .950 . b. Clean valves and valve seats to remove chips.0.070 mm (0. e. Press in until the valve guide upper end is flush with the upper surface of Valve Guide Adjuster.3136 in) 7. replace them before proceeding the valve seat correction work.000 . Turn cylinder head upside 4Jown and place Valve Guide Adjuster (899768602 for exhaust valve guide.0014 . so that the finished seat and valve face will be concentric and specified interference angle will be maintained.065 mm (0. a.0.0028 in) d.7. Intake Exhaust 0. 3-82 Valve guide adjusters Exhaust --~-- -- 0.035 ~ 0. Before installing new valve guide. and replace if defective.0.: A5·288 I.---------- . and insert Valve Guide Remover (899764104) into valve guide. Install new oil seals with oil after completing the work.-----.3134 in) ~ --------'---------- Standard in side diameter of valve guide -- Standard di ameter of valve stem Intake Exhaust ----. VaJve Guide Remover (899764104) 2 Cylinder head table A5·289 t.1 5 mm (0. In case of improper contact. NOTE: Refacing of the valve seat should be closely coordinated with the refacing of the valve face. tension.

goo +1 23.5 mm (0. If the inner surface of the valve guide becomes lustrous and the reamer does not cut chips. if lip is damaged or spring is out of place.3 mm (4. f. Intake and Exhaust Valves I) Inspect the flange and stem of valve. using Oil Seal Installer (898858600). 3·86 Installed position of oil seal Fig. After reaming clean valve guide to remove chips. Ream the inside of valve guide with Valve Guide Reamer (899764105).ENGINE h.29 in) I 109. grinding as little as possible. Check the valve guide projection.051 in) A5-291 cv Ii nder head A5-057 Fig. Recheck the contact condition between valve and valve seat after replacing valve guide.3mm (0. 3-48 . or if the stem end is recessed.2 mm (0. Apply engine oil to the reamer when reaming. @ Valve Guide Remover (899764104) 2 Valve Guide Adjuster A5-290 Ii (899768603) 3 Valve Guide Adjuster (899768602) 4 Cylinder Head Table (399765101) Fig. Gently rotate the reamer clockwise while pressing it lightly into valve guide. or deformed. 4. correct with a valve refacer.0.925 in) Oil Seal Installer (898858600) 2 Cylinder Head Table (399765101) Fig.30 in) 2) If the contact surface of valve is damaged. <D---00@ NOTE: Apply oil to the oil seal prior to pressing.728 in) 22.010 mm (0. d.004 to 8.23. Press in oil seal to the specified dimension indicated in the figure.3 mm (0. worn. Intake Valve Oil Seal Replace oil seal with new one.0. the edge of the reamer should be slightly ground with an oil stone. Intake Valve (b) guide projection Exhaust (a) 17. use a new reamer or remedy the reamer. 3-84 Valve guide projection g. or if "H" is less than the specified limit.886 .012 in) Fig. c. 3·83 Installing valve guide 5.913 inl A5·292 -0 A5-293 R " 0.5 mm (0. and replace if damaged.18.3151 to 0. The outside diameter of the reamer should be adjusted to 8.689 . b. The contact surface should be at right angle with the valve axis.5 . 3-87 Valve head dimensions NOTE: a. If the inner surface of the valve guide is torn. ---------Valve overall length Intake valve I 90° +1° -0 Exhaust valve Angle of valve surface that contacts valve seat 109 mm (4.3154 in).3·85 Installing oil seal 1.5 . or when the surfaces of intake valve and valve seat are reconditioned or intake valve guide is replaced. and return it also rotating clockwise.

26.0 .5 mm (1.599.9 .0 mm (1.2 N (52.0mm(1.133.230.7 N (14.1 .7 .003 mm (0.260 in) 2.23.8 N (23.8 .1 mm (0.0005 .7093 .169. If worn slightly in a stepped shape.034 mm of rocker arm (0.5 mm (1. Install a new intake valve oil seal after lapping.7100 in) Outer diameter 17. 32. 19.0 .61.21.5 .9 .5 .555 in) Inner spring 48.0. replace the rocker arm.6 kg.58.1 N (8.10.0 mm (0. 3-89 Checking spring squareness Oearance 0.555 in) 518.127.0 .9Ib)/ 39.909 in) 228.17. 3-88 Grinding valve 3) Put a small amount of grinding compound on the seat surface and lap the valve and seat surface. 51.8 . --------Freelengtb Tension/spring height Squareness Specifications of valve spring with hydraulic valve lifter Outer spring 48.5 .0 kg.58.ENGINE Specifications of valve spring with solid valve lifter ~ Free length Outer spring 45. and tension. 26.052 mm between rocker (0.5 mm (1. .568.476 in) 201.0. A5·062 Fig.6 .5 N (20.261.134. stand the spring on I surface plate and measure its deflection at the top using I try square.0.5 mm (1.l81 in) 2.9 kg.9 .7080 .079 in) or less 6. 41. Valve Rocker 1) Inspect the inner surface of valve rocker arm and the outer surface of rocker shaft for wear.5 mm (1.0 .91b)1 30.8Ib)/ 30.1lb)1 37.7088 in) of shaft Replace valve rocker arm or shaft if defective.98.087 in) 115. Replace valve spring if it is not to the specifi· cations presented below.51.476 in) 185.9 .783 in) 146.11b)1 39. 2) If the rocker arm surface that contacts the stem head is noticeably worn. free length.214.38. 7. use a valve refacer and correct the wrface.0020 in) arm and shaft Inner diameter 18.4 N (ll.13.5 kg.3 mm (0.2 .7Ib)1 32. Also refer to 2. Squareness 2.1 mm (0. Tension/spring height 500.1 kg. 116.4 .8 N (18.0 Ib)/ 37. Valve Springs Check valve springs for damage.4 .7 .0 kg.083 in) or tess Inner spring 53.3 Ib)1 28.091 in) or less NOTE: To measure the squlreness of the valve spring.8 mm (1.18.5 mm (1.3 .6 .083 in) or less AS·061 Fig.3 mm (1. 112.2 .3 kg. Cylinder Head 3) at this time.0.22.8 N (51.013 .7 kg.921 in) 84.982 .016 . grind· ing as little as possible.48.3 .18. 45.0 mm (2.30.5 mm (1.201 in) .l22 in) 2.

21.950 .8255 in) 0.. 3·92) to facilitate removal of the plunger.8256 in) 0. a. • Foreign matter and/or damage exists around check ball and plunger.20. 3) Forcibly insert the push rod seat with push rod to see if the seat moves into the valve body. spring NOTE: Be extremely careful to prevent any foreign matter from getting into the valve lifter as it is machined to a high degree of precision.0. If the clearance between the bore diameter and outer diameter of the lifter exceeds the specified limit.0028 in) I) Check valve lifters for wear and damage.072 mm (0. 2) Hydraulic Valve Lifter Hydraulic valve lifter and lifter hole Standard inner diameter of lifter hole Standard outer diameter of lifter Lifter to lifter hole clearance Standard Limit I 20.0039 in) I Fig. etc. push rod seat and valve body amoung valve lifters. check ball spring and check ball retainer • Plunger spring A5-064 Fig. Never mix up plunger.8283 in) 20.0008 . replace it. 2) Measure the bore diameter in the crankcase at the valve lifter location. Valve Lifter 1) Solid Valve Lifter for lifter and Standard inner diameter of lifter hole Standard outer diameter of lifter Clearance between lifter and lifter hole Standard Limit .0012 0. check the following reasons and repair it as follows: • Air is sucked into the pressure chamber. and correct or replace as necessary.0.20. If it is outside the specified value.8263 0. 3-90 Correcting valve rocker arm 8.970 mm (0.030 . • • • • Clip Push rod seat Plunger Check ball. Fig.100 mm (0.0035 in) 0. 3-92 A5-682 3-50 .ENGINE 3) Replace rocker shaft washers if worn excessively.21.000 . • Plunger-ta-body clearance is too large.040 mm (0.0. b.0039 in) 0.090 mm (0. I) Measure the outer diameter of the valve lifter. Use a wire (as shown in Fig.8248 0. Remove the following parts in the order indicated. replace the lifter. and replace or correct if defective.021 mm (0. 3-91 Checking lifter hole NOTE: a.988 . 2) Check the lifter holes in the crankcase for damage.020 .100 mm (0.968 mm (0. If it does.8268 0.8276 in) .8248 0. Also check it for wear or damage and replace it as necessary.

Especially.642 in) Torque 34 .5 (1/10) dia. Use Stud Bolt Wrench (898878600) to screw the stud bolt into crankcase. 2) Check the oil passages for clogging. check ball spring and check ball retainer on the plunger. being careful not to tilt them.5 mm (3. Fig.602 . Clean all disassembled parts.10 in) A5-683 231. 0.9. Farping limit 0.7 . replace the valve lifter with a new one. 3-95 Checking push rod for bending 10.14 in) Fig. h. and correct by grinding if necessary.4 mm (8.2 mm (9. install the clip in place and remove the pin.08 . Stud Bolt 1. insert the push rod seat.600 cc 90.2 mm (l/8 in) dia. inspect important parts by means of red check. e. c. Again make sure that the push rod seat does not move into the valve body when forcibly pushing the seat with the push rod.016 in) or less 219 219. correct so that the cylinder head can be installed smoothly.93.3. NOTE: Coat the stud bolt threads with a torque-holding 58alant (Loctite 210 or 211.232. Fig.5 .800 cc Length 91.9. 25 . 9.681 in) 1.05 mm (0. 1) Check for cracks and damage visually. 3-93 d. If any stud bolt is loose. 3) Check stud bolts on the crankcase for looseness.1 rom (9.62 . f. and replace if defective.5 kg-m. A5·294 Pin-.231.ENGINE b.44 N'm (3. Install the check ball. 3-94 I I g. Crankcase Check crankcase for the following items.12 .92.] until the plunger comes into contact with the body while making an opening between the check baIl and plunger.0020 in) Fig. correct or replace.5 .7 .--I Unit: mm (in) A5·684 4) Inspect the crankcase surface that mates with cylinder head for warping by using a straight edge. 3-96 Installing cylinder head stud bolt 2.4. 2) Check the oil hole in push rod for clogging and clean if necessary.3.64 in) Deflection of center For 1600 (Knurling: 2) For 1800 with solid valve lifter (Knurling: 1) For 1800 with hydraulic valve lifter (Knurling: nothing) Overall length 230. Push Rod 1) Check for any sign of bending or damage. Insert plunger into valve body and push check ball with drift pin [outer 3. If it does.5 .5 mm (3. or equivalent) before installation.33 ft-Ib) .4 mm (0. If it is bent.563 . After refilling with clean engine oil.8. Install the plunger spring in the valve body and ftll the body with clean engine oil. Insert a suitable pin into the oil hole in the body and remove the drift pin. and correct or replace if defective.

out-of·roundness. Get four of the oversize pistons and measure the outer diameter of each piston at the height shown in the figure. replace the crankcase.0197 in) oversize 91. 3-97 Positions for cylinder bore measurement NOTE: Measurement should be performed at a temperature of 20 0 e (B8°F).010 mm (0. Cylinder head mating surface A 2) Boring and honing a.50 mm (0.010 .040 mm (0.0004 in) Immediately after reboring. all other cylinders must be bored at the same time.6402 . (Thrust direction) A5-071 Fig.6303 .240 mm (3.01 5 mm (0. d.990 mm (3.6216 in) 92.92. 0 A5-070 c. out-of-round· ness.to-piston clearance measured exceeds the specified limit or if there is any damage on the cylinder wall. Diameter difference between cylinders 0.91.3mm \1.3.6226 in) I 0. A: Thrust direction B: Piston pin direction Q A5·068 NOTE: When any of the cylinders needs rebor· ing. If the value of taper. If the cylinder inner diameter exceeds the following enlarging limit after boring and honing.6315 in) 1.18 in) 33.6214 92.0020 in) or less 0.92.490 mm (3.measuring piston diameter 0.25 mm (0. 92.ENGINE 11. b. Enlarging limit of cylinder inner diameter Fig. or cylinder.050 mm (0.050 mm (0. Do not perform boring on one cylinder only.319 in) Fig. 3-98 Measuring cylinier bore Fig.64)3 in) NOTE: 26.3. Inspect the cylinder bore for taper.015 mm 3.985 (3.0006 in) 0.0020 in) I NOTE: 91.800 cc 30mm (1. using a cylinder bore gauge.50mm (0. and diameter dif· ferences. 3·100 Measuring piston diameter Piston outer diameter Standard 0. Stmm·"~m.0020 in) 0. 3-99 Position for.0197 in) Cylinder bore Standard diameter (Both 1800 and 1600) Standard Taper Limit Standard Out-of roundness Limit Standard Cylinder to piston clearance at 20°C (68°F) Limit 0. rebore it to use an oversize piston.0016 in) 0.0098 in) oversize 0.960 .600 cc 1.060 mm (0. Thus. the cyl· inder diameter may differ from its real diameter due to temperature rise.035 in) Measurement should be performed at a temperature of 20 e (G8°F). Cylinder and Piston 1) Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights shown in the figure. 3-52 .210. pay attention to this when measuring the cylinder diameter. and use oversize pistons.0004 0.0024 in) l NOTE: Measure the inner diameter of the cylinder when the temperature is 200 e {B8°F}.5 mm (1. nor use an oversize piston for one cylinder only.3.6205 .0.460 .050 mm (0.

or when the piston is replaced.0.Specifi~~tions for pistoIl and piston pin Standard outer diameter of piston pin 1"-----" -------. -.5 mm (0.999 to 21.90 mm (0. Cylinder and Piston.20 .Spacer lower rail A5-074 2) Squarely place piston ring in cylinder and measure the piston ring gap with a thickness gauge.010 mm (0.0138 in) 0.992 to 21.000 mm (0. The oil ring is a combined ring con· sisting of two rails and a spacer in between.20 . 3·104 Measuring piston ring gap e N mark 1) If piston ring is broken.0. Oil ring rail .Omm (0.040 mm (0.0016 in) Standard clearance between piston pin and hole in connecting rod '---------- ToprlOg D --Rmark Second ring Oil rtng Fig.0002 to 0. cracks.0079 .0.35 mm (0.039 in) 1.073 ~lowerralf f-- 1 2 Piston ring A 5· 296 13. measure the piston ring gap at the bottom of the cylinder.0079 .8265 to 0.0138 in) 0. When installing.009 mm (0.---------------- -- Standard inner diameter of piston pin hole r-----------------------.0. replace piston ring with a new one of the same size as the piston. where the wear is little. "R" or "N" is marked on the end of the top and second rings.35 mm (0. 3) Make sure that piston pin can be inserted into the piston pin hole with a thumb at 20°C (68°F). replace the piston or bore the cylinder to use an oversize piston. 3·105 Measuring piston ring groove clearance Standard Limit I.0. be careful not to make misassembly.004 to 0. Standard clearance between piston pin and hole in piston r---' --------------20. or if its tension is insufficient. .20 .ENGINE 12.0004 in) 0. and wear and the piston ring grooves for wear and damage. 2) Measure the piston-to-cylinder clearance at each cylinder as instructed in 11. When installing the rings to the piston. NOTE: Upper rail Oil ring NOTE: a.8271 in) ---------_. ~Nmark Second ring ~ 3) Measure the clearance between piston ring and piston ring groove with a thickness gauge. NOTE: If the cylinder is not corrected or replaced one.8267 to 0. Piston Ring Top ring Fig. damaged. Fig. clean the piston ring groove and piston ring.0. Replace if defective. Replace if defective.8268 in) ----------20.0079 .0354 in) Piston ring gap Second ring b. face this mark upward. If any of the clearances is not to specification.039 in) I.059 in) As·on Fig.005 to 0. 3-102 Cross section of piston rings (Riken Piston Ring) ' cr ~ ~Rmark Upper rail Spacer AS. 3-101 Mark on piston ring Top ring 0. Fig.0002 to 0. or worn.0.Omm (0. Piston and Piston Pin I) Check pistons and piston pins for damage. 3-103 Cross section of piston ring (Nippon Piston Ring) Ei Before measuring the clearance.

replace the defective bearing with a new one of standard size or undersize as necessary. Replace connecting rod if the bend or twist exceeds the limit. wear. c. do not allow relative movement between the crank· pin and connecting rod.0028 in) 0. (See the table below. place connecting rod if the side clearance exceeds the specified limit.0.15 mm i (0.0059 in) 0 .0012 0. Standard clearance between piston pin and bushing in connecting rod Fig.4 mm (0. 3-107 Measuring side clearance Connecting rod side clearance I Thickness gauge 2 Connecting rod A5-077 Standard Limit 0. 2) Check for bend or twist using a connecting rod aligner. Remove connecting rod and mea· sure the width of the plastigauge with the scale printed on the plastigauge case. Wipe off oil. Cut the plastigauge to the width of the bearing. Also measure the piston pin clearance at the connecting rod small end.15 mm (0.) 6) Inspect bushing at connecting rod small end.0039 in) NOTE: During this measurement.0.04 (0.330 mm (0. etc.-Top ring Clearance between piston ring and piston ring groove Second ring Oil ring ENGINE Standard 0. a. dust.0028 in) 0 _M. melting.0031 in) Limit 0. seizure.10 mm (0.0008 . etc. and install connecting rod. I twist per 100 mm I (3._ 0. place it on the crankpin parallel with the crankshaft axis. 3-108 Measuring connecting rod oil clearance large or small end thrust surface is damaged.0. 30 ft-lb).020 .0059 in) l i I 0. on the surfaces to be measured. if the 3) Install connecting rod fitted with bearing to crankshaft and measure the side clearance (thrust clearance). peeling.0039 in) 1 Connecting rod 2 Thickness gauge Fig.08 mm 0.0016 0.022mm (0 .0. 5) Measure the oil clearance on individual connecting rod bearings by means of plastigauge according to the following procedure. If any oil clearance is not within specification. Tighten connecting rod nuts to 41 N'm (4. Re- Fig. 3·106 Measuring piston ring groove clearance 3-54 . and replace if worn or damaged.070 mm (0.0. i A5·0S0 14.016 in) 4) Inspect connecting rod bearing for scar.0.07 mm (0. b.94 in) in length Limit of bend or 0. i o 0.0028 .10 mm (0. and replace or recondition the crankshaft as necessary. Connecting Rod 1) Replace connecting rod.01 30 in) 0.0009 in) A5-07S Connecting rod oil clearance Standard Limit 0.2 kg-m.070 .03 .

6083 in) 1600 cc 109. bearing and bearing bore ~ Size Standard ~--- Crankpin dianleter Connecting rod bearing thickness at center Connecting rod bearing bore dianleter 44. and correct or replace if it exceeds the limit. Fig. Press bushing with Remover & Replacer (499037000) after apply· ing oil on the periphery of bushing. After completion of reaming. and replace or recondition crankshaft as necessary. and apply a dial gauge to the center journal.12 in) holes in bushing. and replace if defective.0581 .44.05 mm 4.016 mm (0.0.1.0594 in) 0.0012 in) or less 0.7701 in) 1.1. 3-110 Checking wear of crank journal Crankpin and crank journal Out-of· roundness Taper limit 0.0585 in) 1. (See the table . If not to specifica· tions.019 mm (1.0098 in) undersize 48.) Bushing bore 21.95 (4.760 mm (1.05 mm (4.21.0028 in) 0.510 mm (0.07 mm (0.477 .0632 .0020 in) undersize 0.0.3·109 Checking crankshaft bend Grinding limit Dimensions of crankpin.1.745 .485 mm (0.25 mm (0.6043 117.1.8274 in) 1800 cc Distance between big end and small end hole 116.0.7720 in) 44.7616 . 3) Inspect the crank journal and crank pin for wear. place both the front and rear journals on blocks located on a surface plate.1.45.0098 in) Crankshaft bend limit 0. replace bearing with an under· size one. b.8268 .0014 in) AS·OSl Fig.605 .0634 in) . 15.945 .000 .610 mm (0.95 .035 mm (0..110.ENGINE Replacement procedure is as fol· lows.3287 4. finish them to the specified dimensions according to the undersize bearing to be used.505 . NOTE: When measuring.44.25 mm (0.1. Remove bushing from connecting rod with Remover & Replacer (499037000) and press.7695 .8898 .995 . d. clean bushing to remove chips.010 mm (1.7715 . c. Ream the inside of bushing.7622 in) 1.3327 in) e.03 mm (0. 2) Measure the crankshaft bend.0. a.1.960 mm (1.05 mm (0.000 . Make two 3 mm (0.8905 in) 44.0593 . Crankshaft and Crankshaft Bearing I) Clean crankshaft completely and check for cracks by means of red check etc. When grinding crank journal or crankpin.48.

dust. 3-56 .3 . and wear. 3-172 MlJasuring oil cllJaranCIJ of crank journal lOmm 1 Thickness gauge 2 Center bearing part Fig. Measure the plastigauge width with the scale printed on the plastigauge case.7 kg-m.970mm 1.3 mm (O.49.S kg-m.5.4 N'm (0.745 .1642 in) 54.707 . Center and Rear Standard 44.2.ENGINE Dimensions of crankpin.9661 in) 49.03 mm (0.7616 .1636 .4.45 .0037 in) 0.905 .907 (1. 3.1543 in) 49.720 (1.940 mm 2.SOO cc engine Front. and replace or recondition crankshaft as necessary.1. Crankshaft thrust clearance Standard i 0.2. melting. NOTE: During the work.0012 in) undersize 0.0098 in) undersize - 49.9579 in) I 0.720mm (1. Wipe off oil.49.932 mm (1.44.9673 in) Center 49. on the sur· faces to be measured. seizure. c.1.7622 in) 54.9654 in) 44.1624 54.720 mm (2.920 mm (2. replace defective bearing with an undersize one.9668 49.957 (1.1.7720 in) 54.0 ft.9570 .995 (1.970 . 29 35 ft-Ib) 23 26N·m (2.54.0 4.705 .940 mm (1.54.2. 3-111 Checking thrust cllJaranclJ 8mm 5) Inspect individual crankshaft bearings for signs of flaking.960 mm (1.m.095 mm (0.927 .9575 49.44.0. the crankshaft must not be turned nor the crankcase inverted. Bring together the crank· case halves and tighten bolts to the specified torque.010mm 1. Cut the plastigauge to the bearing width and place it on journal parallel with the crankshaft axis.OllS in) limit 6) Measure the oil clearance on each crankshaft bearing by means of plasti· gauge as follows: a.1616 .1537 .600 cc engine Front and Rear 49.760 mm (1.9656 . d. replace bearing. 17 .9654 .49.940 49.010 . crank journal and bearing Crank journal outer diameter Bearing size Crank pin outer diameter I .952 mm (1:9661 .2.945 . If the measurement is not within the specification.s5 kg.955 .9678 in) 49. Be careful not to put it on the oil hole or groove. If the clearance exceeds the limit.7701 in) 44. 6mm .970 mm (2.925 (2.47 N'm (4.0004 .7695 1.732 mm 1.20 ft-Ib) 4.0.1622 in) 54.9658 in) 49. .982 mm (1.0020 in) undersize 0.1630 in) 1.3 .9575 in) 4) Measure the thrust clearance of crankshaft at center bearing. b.9648 49.1.9673 1. Install bearings in crankcase and set crankshaft in position.lb) Fig. etc.0.1.7715 45.54.4 .05 mm (0.920 .49. AS·084 Thread size Torque 39 . Remove all bolts and separate crankcase.25 mm (0.920mm 1.9666 in) 49..

030 mm (0.2.0020 in) 2) Measure the thrust clearance between camshaft and camshaft plate.0799 .0004 .0808 in) 2.030 mm (0.600 cc 0.0843 .0004 .053 mm (0.0014 in) 1.2.0848 in) 2.015 .0022 in) 0.25 mm (0.0.135 mm (0.0801 in) 2.019 mm (0.034 mm (0.0844 in) 2.0.010 .0791 in) 2.055 mm (0.0.0803 .2.0799 . etc.0841 in) 2.0841 in) 7) Inspect the crankshaft gear teeth and the surface on which oil seal slides for wear.122 .05 mm (0.0. and proper fit of woodruff key.040 .0796 .017 .2.153 mm (0.0794 . If it exceeds the limit.2.0793 .0012 in) undersize 0.0799 in) Center 2.140 .0.0.0795 in) 2.0793 .0004 .0. 16.0799 in) 2.045 mm (0.035 mm (0.0789 .2.010 .0805 in) 2.015 .2.010 .030 .030 mm (0. and replace if defective.017 .010 .05 mm (0.0804 in) I .03mm (0.0..135 mm (0.043 mm (0.035 mm (0.2.0798 in) 2.0. and replace if defective.0796 .040 .2.0.008 mm (0.0. NOTE: When the camshaft is replaced.0.025 mm (0.0098 in) undersize 2.0.044 mm (0.2.122 .2.0801 in) 2. damage.0835 .022 .0803 .0020 in) undersize 0.0004 .0835 .2.ENGINE Crankshaft oil clearance Engine Center Standard Front & Rear Center Limit Front & Rear 0. .003 . Fig.0.800 cc engine Front & Rear Standard O.2. remove cam gear and replace plate.140 . and correct or replace if it exceeds the limit.0012 in) 0.2.0843 .0.0. 8) Inspect distributor drive gear for tooth surface damage.0.93 in) 2.0.600 cc engine Front & Rear 2. the valve filters also must replaced.0.0.800 cc 0.0010 in) 1.2. Camshaft I) Measure the camshaft bend.030 .022 .0801 in) Center 2.0012 in) 0.015 mm (0.0788 .028 mm (0.2.0018 in) Dimensions of bearing Thickness of bearing at center Crankshaft bearing size 1.0.07.0794 .035 mm (0.0.0. 3·113 Checking camshaft bend Bend limit 0.001 .030 mm (0.144 mm (0.0.

090 mm (0.600cc Engine: "51" 8) Measure the backlash between cam gear and crankshaft gear.2693 32.22 in) Fig. 3·116 Cam identification .24 (1. and measure the total height of the cam. and replace cam gear if the run-out exceeds the limit.ENGINE I Camshaft thrust clearance Standard Limit 3) Inspect the journals.00 mm (1.0.25 mm (0. lifter: "76" 1. f Specifications of cam lobe height (intake and exhaust) I Imlt at run-ou ! I • 0.3-117 Checking cam gearrun-out 12mm (O. NOTE: a."Ii. 4) Inspect the cam surface for dam· age. if damaged noticeably or worn beyond the limit.5 x 20 mm) in the camshaft key groove and cam gear key groove.15 mm (0.36. Detail "A" for solid valve lifter Backlash between crankshaft gear and cam gear Standard Fig. Replace camshaft.0008 0.. Be sure to retain this taper. and the cam gear tooth surface for wear. 3·114 Measuring thrust clearance L· .. With hydraulic valve lifter 27 mm (1..0035 in) 0.050 mm (0. or correct the key groove.1.2 mm (0.2732 in) With solid Wear limit 35. grind and correct with an oil stone.34 mm 1. 0. If a new cam is used. The cam lobe is provided with taper of 4 minutes to cause the valve lifter to rotate.06 in) 31 mm (1. A5·297 1 Camshaft plate 2 Thickness gauge 3 Camshaft 4 Cam gear Fig.. Replace cam gear if defective.010 .0004 .. A5·685 rn3-58 '" Eog'" .10 mm (0.0020 in) 0. and if defective replace key or gear.0.4134 . Whenever the camshaft is replaced because of its abnormality. 7) Measure the cam gear run-out. check its identification mark and groove. by using Magnet Base (498247001) and Dial Gauge (498247100).4173 in) 0. replace the valve lifters with new ones too.0039 in) b.90 .800 cc Engine with solid valve lifter: "72" l. If damaged only to a minor degree. and replace if damaged or worn. 5) Inspect the fit of woodruff key (5 x 6.0.n) ~ ~ L~~?v~( .47. hyd.3-115 Cam lobe shape Detail "A" for hydraulic valve lifter 0.020 -. 6) Inspect camshaft and cam gear contact surfaces for cracks or other damage. Replace cam gear if the measurement exceeds the specified Iimi t. A5·686 Limit Fig.0098 in) With solid Standard (Dimension "H") i 32.008 in) i c.0059 in) With conventional valve lifter Dimension "D" .

~~J I l 18.0023 in) --f-- . hardening.35 in) 76 x 93 x lO mm (2.35 in) 70 x 87 x 8.3.018 mm (104173 . Oil Seals Inspect oil seal fitted in flywheel housing and the oil seal fitted at the crankshaft front end for lip wear. A5·299 -~~ . Oil seal Front 1. check them for the following items.1. 1) Oil pump drive gear and rotor a. etc.4157 1.66 x 0.25.000 (1.0236 .17 x 0.4180 in) I Oil seal (Front) 1.800 cc 32. (1800 ee) Shaft portion Magnet Base (498247001) 2 Crankshaft gear A5·091 Fig. Reinstallation is performed by using Oil Seal Installer (499061000).2582 .0.018 mm 1.ENGINE -Front & Center Standard inner diameter of camshaft journal bores Rear ---- 1.800 cc AS·01B 1.335 in) A 6.1.975 mm (1.000 .025 . damage. 3-119 Installing cam gear Fig.959 . and replace oil pump drive gear if worn or damaged considerably.600 cc 38 x 55 x 9 mm (LSO x 2.26.600 cc (1.76 x 34.36.0226 in) 35.2598 32.32 x 0.--. and adjust to the specification.800 cc Front & Center Standard outer diameter of camshaft journal Rear 1.1.100 mm (0.975 mm (1.600 cc 31. use Remover Set (899114110).(104 38 x 59 x 9 mm (LSO x 2.0039 in) The oil seal (Front) can be detached by separating the crankcase. . and replace if defective.39 in) Rear -- Fig.5 mm (2.35.31.99 x 3.2605 in) AS-092 26.0220 .959 . Measure the thrust clearance as described in 2) after replacement. Oil Pump Wash the disassembled parts.0.0010 . When replacing the cam gear. 3-118 Measure backlash NOTE: 17..4163 in) 0. 1.0243 in) 36.059 mm (0.1.1 ?1 . and repair or replace if defective.--- Oil seal (Rear) AS·093 Fig.3·120 Oil seal Clearance between camshaft journal and journal bore Standard NOTE: Limit 0.975 mm (1. 3 Cam gear 4 Dial Gauge (498247100) Remove Set (899714110)-. Check the outside diameter of the shaft portion.000 . ~.959 . 1.018 mm .2589 in) 25.3 x 0..

365 .319 in) 38.854 in) 33.05 4L97N (3.972 N (0.1 mm (0. 8.800 cc Free length 37.70 29.5968 in) Thickness gauge 40.405 kg.28 kg. Relief valve spring Free length AS·OOS Drive gear-to· rotor tip clearance Stand· 0. <I> AS-008 1 Oil relief valve 2 ReUef valve SPrina Rotor-tocase radial clearance Stand· 0.1 mm (1.0.53 Outside diameter of rotor (1.0012 . .12 mm 0.0098 in) Fig.0.159 N (0.13 mm aId (0.224 in) 3. d.0.02 ard (0.2 mm (0.164 .56 .25 mm (0. 0.008 in) case clearance Load when installed I 3-60 .9.7mm (1. 11600 cc engine) 2) Oil relief valve and relief valve spring Check the valve for fitting condi· tion and damage.0008 Limit 0.03 .441b) 0. (1800 cc engine) Outside diameter of drive gear 29.1693 .0.0.. I • By·pass valve spring 1.600 cc 40. Check both the gear and rotor and replace if worn or damaged consid· erably.0.1. Replace the parts if defective.893 lb) Installed length Rotor·to· case and gear-toStand· 0.4. Side clearance between pump case and pump rotor and between pump case and drive gear Measure the side clearance and reo place either the rotor or case as necessary if the clearance exceeds the limit.5 mm (1.2 mm (0.988 in) 5.0047 in) 47. 3·122 Measuring drive gear-torotor clearance Fig.528 .15 .0.0051 in) Limit 0.1709 in) 40.602 in) 31.74mm (1. Radial clearance between pump rotor and pump case Replace either the rotor or case as necessary if the clearance exceeds the limit.ENGINE b.1 mm (1.56mm 1.21 mm ard (0.178 6. and the relief valve spring for damage and deterioration..008 in) 1 Straight edge 2 Thickness puge Fig.1.805 . 3-125 Oil relief valve and spring 3) By-pass valve and spring The checking method is as same as that of paragraph 2).5957 A6·021 Fig. Tip clearance between pump drive gear and pump rotor Measure the tip clearance and reo place both the drive gear and rotor as a set if the clearance exceeds the limit.0083 in) Limit 0.580 3.88 .385 Ib) 1.1 mm (1. 1.3·124 Measuring rotor·to·case clearance c.0059 .628 kg.461 in) 25.3·123 Measuring rotor· to-case and gear·ta-case clearance Installed length Load when installed Drive gear Rotor A6-019 e.

a.3 .3-126 Shaftand impeller 2) Inspect the impeller surface that contacts the mechanical seal for wear and damage. NOTE: In the following procedures.Vinyl hose Thermo valve 1 Water pump shaft 2 Water pump impeller A7·063 AS·6B7 Fig. agitate the water for even temperature distribution. Thermo Valve Connect vinyl tubes to output ports of thenno valve. and other surfaces for damage.2. if to be reused. 3) All removed parts. 3) Inspect the other parts for crack. worn rotor chamber. 23":' 26N'm (2. damage. and confinn that the valve opens or closes in response to the specified temperature. Immerse the thennostat and a thennometer in water. IOoC (50°F)] for some time. items wi1l1 * mark should be rechecked.pin upward. Intake Manifold Assembly 1) Hitachi Carburetor Type 1) Install thennostat and thennostat cover with new gasket. The measurement should be to the specification. and operation. 3-127 Temperature test for thermostat 3-8. Soak the valve in cool water [approx. should be reinstalled in the original positions and directions. Fig. Fig. Precautions 1) All parts should be thoroughly cleaned. Raise water temperature gradually. 5) Bolts. and measure the temperature and valve lift when the valve begins to open and when the valve is fully opened. proceed with ASSY work while making rechecks.7 kg-m. 1) Inspect the pump shaft for wear. cracks. 3-128 Fig. Thermostat Replace the thennostat if the valve does not close completely at an ambient temperature or if the following test shows unsatisfactory results. 4) Gaskets and lock washers must be replaced with new ones. Assembly 1. nuts and washers should be replaced with new ones as required. 5) Oil pump case Check the oil pump case for clogged oil passage. pistons and bearings. 3-129 AS·59B 2) Install the following parts. 6) Even if necessary inspections have been made in advance. Torque . 2) Rotating parts and sliding parts such as piston. bearing and gear should be coated with oil prior to ASSY. and other faults. Thenno vacuum valve II. 21. Liquid gasket should be used where specified to prevent leakage. Blow air into the valve through one vinyl tube. (Refer to page 3-5) 20.ENGINE 4) Oil pump holder Check the pump shaft hole for wear. 19.20 ft-Ib) NOTE: Install it wi1l1 1I1e iiggle . and then heat the water. Water Pump NOTE: Clean all 1I1e disassembled parts 1I1oroughly. . During the test. and replace if defective. 2. 17 . wear and damage. paying special attention to the engine oil passages.

Apply liquid gasket (Fuji Bond C or equivalent) on the thread. carburetor protector 2 and hoses. ® .C. valve with gasket and connector clamp. b.A T and Canada I 2 3 4 • 5 6 7 8 9 ·10 ·11 ·12 Fig. solenoid valve I and bracket. valve. valve. Torque NOTE: Be careful not to bend the terminal.7 kg-m. Torque NOTE: 2) CoW Carburetor Type 1) Install thennostat and thermostat cover with new gasket. and vacuum hoses. d.V.: Except 49 states 4WD & 4WD4WJ). NOTE: Be careful not to bend the terminal. Torque 23 (2. thennostat cover. b.ENGINE NOTE: NOTE: a. Solenoid valve I. 17 . Heater hose and purge hose.20 ft-lb) Install thermo valve with its pipe outlet facing fOlWard.2. AS·S89 Fig.R. duty solenoid valves. Thenno vacuum valve I.2. and then clip harness. clip and actuator ASSY (A/C only). connect electric connectors.G. Control air cleaner. NOTE: Install it with the jiggle pin upward.26 N'm (2.7 kg-m. b.20 ft-Ib) 5) Attach electric wmng harness. Thennosensor. Vacuum pipe CP and vacuum hoses. P. Vacuum pipe CP with carburetor protector 3.3 . i. and connect hose. bracket and protector stay.7 kg-m. a. Clip. Apply liquid gasket (Three Bond 1201 -PIN 004403008. and connect hoses. 17 . h. 4) Install E. 3) Install carburetor with two gaskets and an insulator. Thennosensor. 23 . Thenno vacuum valve I. f.3 . 20 ft-Ib) NOTE: 1 EGR valve 2 Connector clamp Install the valve with its pipe facing outside. Stay & clip. and connect hose. 3-62 . Install thermo valve with its pipe oudet facing outside. 3-130 Thermo vacuum valve 11 Thermostat cover Solenoid valve bracket Protector stay Solenoid valve I Thermosensor PCV valve Thermo vacuum valve I Vacuum pipe CP Carburetor protector 3 Duty solenoid valve Carburetor protector 2 AS·S88 Torque 23 (2.V. P. or equivalent) on the thread. Accelerator cable bracket. f. e. P. g.C.V. c. 2) Install the following parts.7 kg-m. d. Gasket. hose. j.3 17 26 N·m 2. 23 . c. 3-131 g.C. 20 ft-Ib) NOTE: Apply liquid gasket (Fuji Bond C or its equivalent) on the thread. Stay & clip.26 N·m (2. e.3 17 26 N'm 2.

370 in) ~ £3 1 2 3 4 Heater hose EGR valve PCV hose ASSY Actuator (A/C only) Mark on spacer (RH) Mark on spacer (LH) RH -LL A5·691 LH Fig.G. connect electric connectors. 3. Before assembling. c. the posi· tion of the spring washers. and connect hoses.R valve with gasket.11 in) 35. p. 3·133 .v.8 mm (1. the number of plain washers. b.e.. and then clip harness. b. 3·132 3) Install carburetor with two gaskets and an insulator. d.9 mm (6.2 mm (1. E.ENGINE S) Attach electric wmng harness. 1. 4) Install the following parts. apply a generous amount of oil to the sliding surface of each part.346 in) 33.409 in) 34. (Ale only) FleD actuator and hose. hose ASSY. a.307 in) RH 180.600 cc 176. Valve rocker assembly Fig.2 mm 0. Valve Rocker Assembly NOTE: 1 2 3 4 5 6 7 Thermostat cover Solenoid valve bracket Solenoid valve I Thennosensor Thenno vacuum valve 1 Vacuum pipe CP PCVvalve A5·690 a.96 in) 34. the difference between the rocker arms. Heater hose. Pay special attention to the direction of the rocker shaft.800 cc ~ 1.6 mm (7. and the marks on the spacer. and hose.8 mm (1.

NOTE: Apply oil to the oil seal prior to pressing. 2) Apply oil to stems of intake and exhaust valves prior to installation.H.) Snap ring Nut Washer Valve rocker screw Rocker shaft spring washer Rocker shaft supporter Valve rocker arm CP Rocker shaft spacer Valve rocker shaft 11 12 13 14 15 16 17 18 19 Valve rocker arm CP 2 Valve rocker ASSY (L.) Rocker shaft spacer Valve rocker shaft Valve rocker Valve rocker arm Valve rocker arm 2 Lock washer (only for hydraulic valve lifter) Fig. After installing all the parts. Cylinder Head 1) Press oil seal onto intake valve guide. Refer to 3-7. c.3-135 Installing valve and related parts 3-64 . tap the spring top lightly with a plastic hammer or the like to give better seating of the valve.4.) Valve rocker ASSY (R.ENGINE A5·692 1 2 3 4 5 6 7 8 9 10 Valve rokcer ASSY (R. Place the inner and outer valve springs with the paint mark toward the valve spring retainer. Take care not to damage the lips of the intake valve oil seals when installing the intake valves. b. 1 Outer valve spring 2 Inner valve spring 3 Retainer key 4 Valve spring retainer 5 Valve stem A5·324 NOTE: a. 3) Install intake and exhaust valves with inner and outer valve springs. 'valve spring retainers and retainer keys on cylinder head by using Valve Spring Press (899724100). or with the close coil side toward the cylinder head.H. Fig.H. 3· 134 Assembling valve rocker parts 4.

Pay attention to the assembling direction of camshaft plate and cam gear. 3-136 Installed direction of valve spring o A5-329 A5·l00 4) Install spacer with gasket for air injection system. Install oil ring spacer. 3-137 Installing connecting rods LH 7. . J _ ~ R mark . Camshaft Install woodruff key on camshaft. b. 14. s. Remove Set (899714110) Oil ring cr < ~ upper rail Spacer Lower feil A5-073 Fig.:... .600 cc engine CI~'{~ A5-326 Side clearance and oil clearance (Refer to 3-7. Piston I) Install piston rings on pistons as follows... _: Rmark Second ring NOTE: Apply oil to 1hesurfaces of the connecting rod bearings.. ring with a piston ring expander. * Only for 49 States (except 4WD & 4WD-AT) 6. c.31 ft-Ib) with oil on threads Torque (Connecting rod nut) NOTE: a. 16. apply oil on the threads. Each connecting rod has its own mating cap.ENGINE 39 -42 N'm (4.----.0 . 1. * For right-hand side (# I & #3) cylinder head * A5·101 Thrust clearance (Refer to 3-7.4. 2) Install connecting rods and connecting rod caps on crankshaft with connecting rod bolts and nuts. . Place the camshaft journal on Remover Set (899114110) when pressing the cam gear.) 8 For left-hand side (#2 & #4) cylinder head Fig.800 cc engine 1 Valve spring retainer 2 Close coil side A5-325 Paint mark ~" + Up NOTE: a. 29 . upper rail and lower rail in this order by hand.3-139 Camshaft plate and cam gear Discrimination mark on spacer 1600 Engine 1800 Engine 7 Matching number b.) Fig. Crankshaft Top ring 1) Install connecting rod bearings on connecting rods and connecting rod caps_ ~ ~. 3·140 Cross section of piston rings (Riken Piston Ring) . Make sure that they are assembled correctly by checking their matching number. ~ .3 kg-m.. Place camshaft plate in position and install cam gear by using Remover Set (899714110). Then install second ring and top. -~ Fig. When tightening the connecting rod nuts. 3-138 Installing cam gear Fig.-~ / ~ -: . Position each connecting rod with the side marked f) facing forward. A5-328 * 1.

Position stopper pins. NOTE: a. Replace the mechanical seal with a new one. Press the bearing outer race. or the bearings will be damaged. 4) Install oil filter. 3-146 PreSSing water pump shaft ((f\Y'-'. 5·84 and 5-85.. correct so that the piston pin can be inserted smoothly into the piston pin hole with fingers. Install oil ring as shown in the figure. b.. drive gear. 3-147 Installing impeller 3-66 . by-pass valve spring and O-ring in pump body. I) Install the water pump shaft into pump body with a press. If the piston pin hole has burrs made by the circlip end during its removal. A7-067 Fig. two washers and plug in pump body. * Ring to groove clearance (Refer to 3-7. 3·142 Piston ring gap position b. Circlip ~~. heat the pump body to 80 to 100°C (176 to 212 F). Position the gaps of the piston rings. 3-145 Installed direction of circlip AS-331 (Nippon Piston Ring) b.. d. The installed circlip should be directed as shown in the figure. 8. Oil ri ng EE .. 0 Fig. 3·141 Cross section of piston rings (Nippon Piston Ring) Fig. install the impeller onto the pump shaft with a press.) Oil ring lower rail AS-330 2) Insert piston pin circlip into the stopper pin side of the piston. Before pressing. 13. 3) With a thin coat of oil on the shaft surface. O-ring and pump body holder in pump body." Piston Lower side rail AS·334 Fig. 3) Assemble oil pump rotor. 3-144 Stopper pin position NOTE: a. NOTE: a. Water Pump Front AS-333 Fig. b. The top and second rings are provided with "R" or "N" mark as shown in Figs. Apply liquid gasket where required. A5·332 Fig.ENGINE C-Nmark Top ring ~Nmark c. 2) Apply liquid gasket (Fuji Bond D or equivalent) to the periphery of the mechanical seal and press the seal into the pump body with the carbon washer of the seal facing the impeller. Stopper pin I . (Riken Piston Ring) NOTE: a. upper rail Spacer Lower rail AS·074 9. 00 not press the shaft. Second ring ~ 2) Assemble ball.Upper side rail A7-06S Fig. Be sure to install the rings with this mark facing upward. 3-143 Installation of oil ring 1) Assemble oil relief valve. Oil Pump NOTE: Replace washers and O-rings with new ones... spring..

1 ··61. 4) Oil seal lips should be coated with grease before reinstallation. if to be reused. items with * mark should be rechecked. paying special attention to the engine oil passages. 2) Rotating parts and sliding parts such as the piston. pistons. 8) If one or both of the cylinder heads are removed in engine disassembly. washers. Check for the following clearance after installation and correct if defective. Engine Stand (399814300) A5-335 Fig. NOTE: In the following procedures. 3-150 L 1800 cc Engine 61. I) Install Engine Stand (399814300) to each crankcase half. bearing and gear should be coated with oil prior to reinstallation. run for about 10 minutes.S . S) Gaskets and lock washers must be replaced with new ones.020 0. Installation 1.429 in) 1600 cc Engine 64.2. 6) Bolts.7 mm (0.524 64.7 mm (0. should be reinstalled in the original positions and directions.547 in) Fig. proceed with reinstallation work while making rechecks. 3-148 Impeller clearances Fig.1 (2. apply oil on the pump shaft.3-151 Installingenginestand .0. cylinder.7 mm 2.5 . 3-149 Checking impeller-to-pump body clearance NOTE: Before pressing.020 . Precautions I) All parts should be thoroughly cleaned. Press Clearance between impeller and pump body O.028 in) L L 3 Impeller A7·089 A7·101 Fig. 7) Even if necessary inspections have been made in advance.0. Liquid gasket should be used where specified to prevent leakage. Clearance between impeller and pump body 4) Support the impeller side of the pump shaft end and insta1l the pulley by using a press until the distance "L" between the pump body surface.028 in) Mechanical seal 2 Pump body 0.0.7 mm (2. and the center of belt groove of the pulley becomes specified value.406 . mounted on the car. and cooled down to ambient temperature.ENGINE NOTE: Apply coolant on the sliding surface between mechanical seal and impeller. which mates with the gasket. cylinders and bearings. 3·9. and cotter pins should be replaced with new ones as required. nuts. perform the retightening of the cylinder head nuts and intake manifold bolts and the adjustment of the valve clearances (except engine with hydraulic valve lifter) as instruct· ed in 2-2 in CHAPTER 2 after the engine has been assembled. 3) All removed parts.

. .. Torque for crankcase bolts and nut 1 Crankshaft gear 2 Large chamfer 3 Punch AS·337 4 Camshaft gear I TortJ. 3·154 Installing D·ring and backup ring AS·338 Insert valve lifters into the lifter in crankcase and hold them on #1 and #3~. apply liquid gasket (Fuji Bond C or equivalent) to the threads of pressure switch body or plug body. 6) Install O·ring and backup ring on the crankcase half having #2 and #4 cylinders.8 kg-m.. Install stiffener (4WD) at this time temporarily. 3. 22 .. 3-156 Tightening ~uence for crankcase bolts and nut NOTE: a. to prevent lifters from dropping off (for solid valve lifter). Install the front hanger at this time. Apply oil to the camshaft and crankshaft bearings before installa· tion. AS·340 Fig.. b..26 N'm (2.stallcranbhaft and camshaft on ?~. 2 i I Crankshaft bearings AS-336 Fig.4 5. 29 . Bend the lock washers to secuflll~ the bolts.. Pull cam gear fully. 2 I 1 6 mm .cr~se half having #2 and #4 ~f!tin~J": NOTE: Before applying liquid gasket."""aft plate on * Oil clearance of crankshaft (Refer to 3-7.20 ft·lb) 4. Whenever the camshaft is replaced because of its abnormality.ENGINE 2) Install oil pressure switch (Vehicle without pressure gauge) or plug (Vehicle with pressure gauge) on crankcase. grease and dust by using thinner or the like. Take out Valve Lifter Clips (only for solid valve lifter).0 ft·lb) 3) Install crankcase.. c. ' NOTE: Apply oil to the valve lifters before instanation. b. case with the two bolts and.. of! NOTE: :-"" .. Before installation.35 ft·lb) 23 .55 kg·m.0 4.2.3·155 Applying liquid gasket 10) So"".. replace the valve lifters with new ones too. Fig.. ~A~' 3-68 . clean the mating surfaces of the crankcase so that they are free of oil. A5·339 Fig.27 N·m (2.) 8) Put Valve Ufter Clips (899804100) between valve lifters in the crankcase half having the #1 and #3 cylinders.15.. NOTE: a. Make sure that the O·ring is installed exactly. 3·153 Aligning crankshaft and camshaft gears IOmm . d.8 kg·m.3 4. 16 .4 N'm (0. working through tbe hOle in cam gear.2..~~linder side by using Valve Ufter CliP 899804100 (only for hydraulic valve lifter). 8mm .0..45 . s) {n. 6 i * Oil passage. One of the bolt holes in the crank· shaft gear has a larger chamfer than others.3 .3·152 Installing crankshaft bearings ""~("'s 1 O-ring 2 Backup ring Fig. e. c.2 . 17 .· ck washers. 4) 7) Apply liquid gasket (Fuji Bond C or eqUivalent) on the mating surface of crankcase.. Install the crankshaft so that the punch mark on the cam gear can be seen through this bolt hole in the crankshaft gear.7 kg·m..ue Thread size Torque 39-47N·m (4.20 ft·lb) crankshaft bearings on 9) Bring together the crankcase halves and tighten the crankcase bolts and nut with a plain washer to the specified torques and in the specified sequence.

16.ENGINE 12) to horizontal whether piston or not by watching AS·278 AS-343 13) Apply liquid gasket (Fuji Bond C or equivalent) on crankcase plugs and tighten them with aluminum gasket.) c. 3-163 Installing oil strainer stay . Fig. nut and spring washer. 11) Install pistons in cylinder as follows. With the #2 and #4 cylinders facing downwards. Install #4 piston. 46 . e. Install piston pin and circlip through the front service hole after aligning the service hole. but carry out this job from the flywheel housing side.56 ft-Ib) Use this shape of wrench AS·346 Fig.) Thrust clearance of crankshaft (Refer to 3-7. 17 .26 N'm (2. Then insert the #2 piston into cylinder by using Piston Guide (398744300). a. circIip into cylinder in the same manner.20 ft·lb) NOTE: When measuring the backlash of cam gear and thrust clearance of crankshaft. piston pin hole. be sure to direct them in the seme way as before they were disassembled. piston pin.3·158 Checking crankshaft thrust clearance Fig. install it with a new O-ring by driving with an aluminum bar. Torque (Oil strainer stay) 23 . and connecting rod small end with Piston Pin Guide (399284300). Torque (Crankcase plug) 62 -76 N'm (6.3·160 Inserting piston pin 14) If oil strainer has been removed.2.3 . Apply oil to the circumference of piston and the inner surface of cyl· inder. 3-159 Installing piston * * Backlash of cam gear (Refer to 3-7. d. 1 1 i 1 Circlip 2 Long nose pliers AS·345 Fig. 1 Oil strainer stay 2 O-ring 3 0 il strainer 4 Bolt 5 6 7 8 Spring washer Nut Oil strainer stay 2 Bolt and washer Fig. turn crankshaft until the #2 connecting rod comes to the bottom dead center. use an appropriate plate as an attach· ment.7. 3·157 Installing camshaft plate Fig.15. 15) Install oil strainer stay with 8 mm bolt.7 kg-m.3·162 Installing crankcase plugs AS·342 Fig.3·161 Installing circlip NOTE: If any of the pistons are reused.7 kg-m. b.3 . Turn the crankcase upside down so that #1 and #3 cylinder face downward and perform the same job as described in a) to b).

800 cc . In each step. lifter 1800 with hydraulic valve lifter Nothing 17) with valve same Install #1 #3 cylinder head a new gasket and push rods and rocker assembly (RH) in the way as instructed in 16).335 in) NOTE: 29 N·m kg-m. b. A5-348 Fig. Do not use washers in installing valve rocker.] II #2 #4 cylinder head. 3-165 Discrimination of push rod a.. 3-167 Installing flvwheel housing NOTE: NOTE: Do not misuse the push rod. #2 . 1. 14 20 ft-Ib) A5·125 Fig.600 cc . Install a new cylinder head gasket. Make sure that the valve rocker is correctly assembled.43 x 0.. grease and dust by usi.#4 cylinder head. NOTE: a. Oil seal dimensions. b.. a.8 kg-m. Apply oil on the circumference of the oil seal prior to pressing. Install the gasket on to the crankcase quickly after applying sealant. 18) Press oil seal (Rear) into the flywheel housing if oil seal has been removed.0 . Take out Valve Lifter Clip 899804100 (for hydraulic valve lifter). Apply head gasket sealant THREE BOND 1201 (004403008) or DOW CORNING #92-024 evenly to both sides of the new cylinder head gasket with a brush. grease and dust by using thinner or the like before applying liquid gasket. retighten the center nut CD to insure it is correct· Iy torqued. When tightening nuts and bolts.. Do not apply excessive sealant.. 19) Install flywheel housing to crankcase with the mating surface coated with liqUid gasket [THREE BOND 1215 (PIN 004403007) or equivalent] . Before installing the cylinder head gasket. 76 x 93 x 10 mm (2. b. valve push rods and also valve rocker as follows.0 kg-m. After tightening all the cylinder head nuts and bolts.99 x 3. Be careful net to damage the oil seal lip and not to detach the spring when installing the flywheel hous· ing. install valve rocker. a.76 x 3. 3-164 Installed position of cylinder heads c. When tightening CD. FRONT t I Torque I 20 . 43 ft-Ib) 64 N'm (6.. Number of 1600 1800 with solid valve . apply oil to the threads and tighten them in two or three successive steps un til the final tightening is at the specified torque.ENGINE 16) Install a new cylinder head gasket. and insert valve push rods in alignment with valve lifters. . b. 3-166 A5-350 Fig.. use Socket Wrench (499987006). b. Clean the mating surfaces of the flywheel housing and crankcase so that they are free of oil. Inst. c.66 x 0. 22 ft-Ib) 2nd step 3rd (final) step 59N·m (6.5 kg-m.39 in) 1. clean the mating surfaces of the cylinder head and crankcase so that they are free of oil. 47 ft-Ib) The cylinder head installing direction is as in the figure. 10 x 81 x 8.2. ® nuts. A5·615 Fig. d.g thinner or the like. tighten them in the specified sequence.5 mm (2. NOTE: d. 3-70 NOTE: a.27 N·m (2.

3-168 Installing oil pan Torque (Oil pan) 4. align the mark on back plate and the hole in drive plate.55 kg·m. d. When using THREE BOND 1215. (4.4. 12 ft-Ib) Fig. 3-171 Installing clutch cover NOTE: Position the clutch cover so that the "0" marks on the flywheel and clutch cover are spaced 120 0 or more.4 . Remove Valve Lifter Clips (899804100) before installing oil pan. 20) Install crankcase oil pan.4 N'm (0. dry the bolts coated with it for 5 to 10 minutes before $l:rewing them in. 23) Install clutch disc and clutch cover with bolts and spring washers.2 . to flywheel housing.5.3 . hose. pipe compi. When installing back plate.0 . (SUBARU 1600) NOTE: Do not misplace the washer. c.39 ft-Ib) 30 .6 kg-m.ENGINE c. (AT) A5-354 Fig. 3-170 Installing drive plate and I' back plate (A T) and crankcase rear hanger.45 0. 24) Install water pump. 3. b. I Transmission cover II (MT) 2 Oil pan A5·271 ConV'erter drive plate 2 Hole 3 Mark 4 Back plate i A5·353 Fig.4 kg-m. (MT) I 2 3 4 5 6 7 8 9 10 11 Nut Bolt Spring washer Crankcase rear hanger Pitching stopper bracket Timing hole hanger Bolt Timing hole hanger Stiffener RH (4WD) Stiffener LH (4WD) Accelerator cable bracket (C-W carburetor) A5·693 Torque (Clutch cover) 16 N·m (1. 22) Install flywheel with O·ring (MT) or converter drive plate with back plate and O-ring (AT) on the crankshaft gear. aligning clutch disc with flywheel by inserting Clutch Disc Guide (499747000) into needle bearing fitted in flywheel. and heater hose as an assembly and install another hose.5. dry the coated surface for 5 to 10 minutes before installation. if it has been removed. The flywheel or drive plate and back plate can be installed only in one position since not all the bolt holes are positioned at equal intervals.33 ft-Ib) . Apply liquid gasket [THREE BOND 1215 (pIN 004403007)) to the threads of the bolts. ~ AT MT NOTE: a. 36 . oil pan gasket and transmission cover II (MT).6 kg-m. 3-169 Installing crankcase hanger Clutch Disc Guide (499747000) I r. install accelerator cable bracket with hanger.0 ft·lb) 21) Install pitching stopper bracket Fig. When using THREE BOND 1215. On CoW carburetor.4. 49-53N·m 41-45 N'm Torque (5.

1. and bracket 3. stiffener 2. After loosening the bolt @ by two Huns or more.33 .37 mm (0. Install the sub·assembled bracket prepared in a onto the engine by tightening bolts @ @ temporarily.013 . 3-173 Installing oil pump 28) Install oil filler duct.J \ . Temporarily connect bracket comp!. Tighten fully the two bolts @ to the specified torque. When installiilll. When tightening the bolt. a. At first tighten fully the two bolts @ and after that tighten the bolt @ to the specified torque. @ until the spring washer is deformed a little. b.3 .om 1 in) 0. 1600 cc: 109 mm (4. the 30) (Except engine with hydraulic valve lifter) Adjust the valve clearances as described in 2-2 Procedures of maintenance services in Chapter 2. tighten it again to the specified torque.. NOTE: Be sure to use die generator bracket 2.@ . and gasket on crankcase. 9 . 3·176 Installing oil filler duct A5-357 Fig.009 .5 47 74 N·m 7.0. Crankshaft pu lIey . Odlen are CD ones. Fig. c. b. _align the rotor shaft with groove in die cam· shaft end. 3·178 Adjusting valve clearance Valve clearance (Cold) Intake 0. install oil fllier duct. Apply engine oil on the thread. c.0. 3·177 Installing generator brackets Fig. insert a screw driver through the timing hole into the hole in the drive plate (A T) or flywheel (MT) to prevent the crankshaft from turning. 64 (6.23 . and liquid gasket (THREE BOND 1215 or the equivalent) on the flange seat. A5-502 Fig. l!J - bolt for die NOTE: .14'ft·lb) A5·694 Fig. Pulley dia. oil filler duct stay and gasket on crankcase.69 in) A5-356 1 BracketCP 2 Bracket 3 3 Bolts 4 Bolt 5 Bolts 6 Bracket 2 A5·696 Fig. 1 Oil filler duct 2 Oil filler duct stay A5·695 Fig. d. install it with O-ring and oil pump gasket.5 kg-m S4ft-lb) on I t Torque 29) Install generator bracket comp!.27 mm (0.29 in) 1800 cc: 119 mm (4. is as follows.ENGINE NOTE: a. a. bracket 2 and bracket 3 as follows.9 kg-m. f. I Exhaust valvelt 2 Intake valves 3 Thickness gauge 4 Valve Oearance Adjuster (498767000) CD .3-175 Installing crankshaft pulley /1 II ) 'I b.oms in) Exhaust 3-72 . Temporarily install bracket 2. e.3-172 Installing water pump 25) After assembling oil filter and oil pump. On 4WD. 3-174 Installing oil seal 27) Install crankshaft pulley crankshaft with flange bolt. 13 Torque ~ 19N·m (1. Use new gaskets and O-rings.

bracket 33) Install the intake manifold as· sembly prepared before as follows.2. seal washers and bolts.S.9 ft-Ib) 34) Tighten E.17 ft-Ib) Fig. 3·180 37) Install E.2 kg·m.V.M. Battery cable bracket 2 A. the tension is 10 mm (0. water hose and P. fuel hose stay. 18-24N·m (1.55 in)! 98 N (10 kg.C. 2. 13 . wiring harness.R.0. pipe cover.G.V.40 kg-m. hose. 221b) hose. bracket {vehicle without power steering for 49 States (except 4WD & 4WD·AT)] or oil pump bracket (vehicle with power steering). secure the bracket. in chapter 15 and Parts Catalogue. Install the intake manifold as· sembly with intake manifold gasket.39 in)/98 N (10 kg.51 . 13 . b. Vehicle 1600 cc CoW carburetor type Except the above Knurling 2 AS-697 Fig.0.s.8 . 35) Install battery cable bracket and A. b.ENGINE NOTE: Use T.2 .C. a. hose to rocker cover and clip it at the upper portion. pipe. marking on pulley. . air cleaner bracket. Connect the P. c.16 ft·lb) AI5-474 NOTE: Discrimination knurling for E. . and EGR pipe. Connect the harness lead to oil pressure gauge or oil pressure switch. Do not forget tightening fully the bolt for generator bracket 2. Torque 18 . After aligning the air cleaner bracket and air cleaner.2.30 . spark plug cord stay and drive belt.3. When replacing with new one. 15-12.9 . Torque 32) Install spark plugs with gaskets. NOTE: a.G.4 kg·m. 22Ib).R.2.S. c. NOTE: a.9N·m (0. (Elec' tronic Control Module) earth at right front bolt AS'69B Fig. 3·181 Torque 38) Install alternator on the genera· " tor brackets with air cleaner bracket.C.R. 3·179 36) Install A.G. and clip it. Fig. pipe.8 .O. For further particulars of vacuum Drive belt tension 13 .S. Be sure to connect E. 3·182 Installing alternator with relative parts 3 Nothing b.V.V. And connect water by-pass hoses.V.14 mm (0. Adjust the drive belt tension as described in 2·2 Procedures of maintenance services in Chapter 2. pipe and A.22 N·m (1.V. refer to label behined engine hood.C. 31) Install valve rocker covers with valve rocker cover gaskets. 2.

g. Install distributor plate on crankcase with bolt. a. Crank· shaft e. [For 49 States (except 4WD & 4WD·AT) and California] 43) Remove Engine Stands (399814300).ENGINE 13-14mm (0. Align the distributor matching marks. 40) Connect spark plug cords to spark plugs and cord supporters and distributor cord to cord supporter.3-183 Drive belt tension Be careful that the holes in the distributor plate and crankcase are correctly lined up. NOTE: OM· tOt Fig.51-0. 41) Install oil level gauge if it has been removed. Fig. Apply oil to the circumference of distributor shaft and gear. Set #1 piston at its top dead center in the compression stroke. b. 42) Install carburetor protector. 3-184 Aligning distributor matching marks d. Clip the distributor lead wire. HITACHI AS·SOS 39) Install distributor as follows. f. 22 Ib) " c. Install distributor into crankcase taking care not to damage distributor gear and O-ring. Connect vacuum hoses to distributor. 3-74 .55 in) 98N (10 kg.

--"- 3) • I 2. I) Improper ignition timing 2) Defective spark plug Improper spark plug gap Fouled spark plug • Defective insulator • • Adjust or replace. over flow. pinion does not mesh with ring gear. Adjust.) See "Troubleshooting of ignition system" in Chapter 15.ignition coil and outer resistor (except 4WD) 5) Malfunction of distributor Inspect. 2) Defective starting system . . Defective engine Bearing seizure on crankshaft. See "Troubleshooting of fuel system" in Chapter 4. See "Troubleshooting of carburetor" in Chapter 4. Replace. etc. etc. stalls 1. 3) Defective cord or wiring • Loose and/or damaged contacts of ignition system connection • Defective cord or wires 4) Defective . • Defective charging system Corrective action Charge or replace. See "Troubleshooting of charging system" in Chapter 15.) 2) Defective ignition system (no con· tinuity ignition current. Starter motor rotates but engine does not start. See "Troubleshooting of starting system" in Chapter 15. repair or replace. 4) Insufficient engine compression pressure Improper engine oil See 3-3. Replace See "Troubleshooting of ignition system" in Chapter 15. 5) 2. Clean or replace. con· necting rod.ENGINE 3-10. Troubleshooting Trouble and possible cause I.) 3) Defective fuel system (malfunction of choke system. Defective igni· tion system Replace with recommended oil. Replace. 1) Defective starting system (starting speed too low. • Piston seizure or sticking Repair or replace. See "Troubleshooting of starting system" in Chapter 15. no flow of fuel. Repair or replace. etc.2 in this Chapter. etc. Engine does not start I. Rough idle. Starter motor does not rotate 1) Defective battery and/or charging system • Over discharged batt~ry.

Repair or replace. etc. Tighten or replace. etc. Inspect. Replace. Replace. PCV valve. centrifugal advance mechanism. ! See "Troubleshooting of carburetor" in Chapter 4. Tighten or replace. 7) Defective ignition control system. • Clogged vacuum lines • Malfunction of operating parts (Thermo vacuum valve I. delivery line. 3. etc. • Loose carburetor nuts or defective gasket • Defective EG R valve.) • Improper air gap or defective pick up coil. check valve etc. S) Seizure of valve stem I 3-76 . • AdjUSt. repair or replace. filter. Adjust. repair or replace. Adjust. repair or replace. damaged or corroded cord contacts. Tighten or replace. I) Improper valve clearance Loose spark plug or defective gasket I 2) 3) Loose cylinder head nuts or defective head gasket 4) Defective valve seat contact Resurface valve and valve seat. Tighten or replace. Refer to Chapter S.) • Malfunction of operating parts (vacuum advance.) Clean or replace. Clean or replace.ENGINE Trouble and possible cause 6) Defective distributor Corrective action • Cap troubles (cracked cap. Defective fuel and air intake system I) Improper idle speed. 7) Malfunction of ECC system. Repair or replace. 2) Clogged air cleaner element 3) Defective carburetor • • • • Improper float level Malfunction of choke system Plugged jets or air bleeds Malfunction of antidieseling switch (Hitachi carburetor) or idle stop solenoid (C-W carburetor) or defective wire connection • Defective metering rod (C-W carburetor) • Others Adjust. S) Vacuum leaks • Leakage from vacuum lin!:s • Loose intake manifold bolts or defective gasket. Adjust. 2. Replace. 4) Defective fuel pump. Insufficient engine compression pressure i Inspect. 6) Malfunction of fuel feed system. repair or replace. Repair or replace. Repair or replace Adjust or replace. See "Troubleshooting of fuel system" in Chapter 4.

poor accelera· tion I. Refer to Chapter 5. Adjust. repair or replace. Adjust. . 5) Vacuum leaks (vacuum lines. etc. hesitation. repair or replace. Replace. 2 in this Chapter. Clean or replace. delivery line. Inspect. I 4) Defective fuel pump. Replace. inspect. Insufficient engine compression pressure 1) Improper valve clearance 2) Loose spark plug or defective gasket 3) Loose cylinder head nuts or defective head gasket 4) Others See 3-3. See "Troubleshooting of carburetor" in Chapter 4. Tighten or replace. • Improper spark plug gap • Fouled spark plug • Defective insulator Adjust or replace. Deterioration or damage of valve spring Seizure or worn piston ring. filter. Defective fuel and air intake system 1) Improper idle speed and mixture Clogged air cleaner element Defective carburetor • Improper float level • Clogged main jet • Defective accelerator pump • Malfunction of secondary diaphragm (Hitachi carburetor) • Defective power valve (Hitachi carburetor) • Malfunction of ECC system • Others 2) 3) Adjust. See "Troubleshooting of fuel system" in Chapter 4. See "Troubleshooting" in Chapter 15. 9) Improper engine oil (low viscosity) 3. Adjust. repair or replace. Lowoutput. Clean Inspect. clean or replace. Defective ignition system I I) 2) Improper ignition timing Defective spark plug.ENGINE Trouble and possible cause 6) Corrective action Replace. etc. Replace with oil of proper grade. piston Improper valve timing 7) Repair or replace. Inspect. 4) 2. cylinder. 8) Disassemble and correct. Tighten or replace. 3) • Defective cord or wiring Loose and/or damaged contacts of ignition system connection • Defective cords or wires Others Inspect. Replace.) 3. repair or replace.

• • --~~ 2) Improper idle speed Adjust. 1) Defective throttle linkage or accelera· tor cable '~-. . ~~r-- . Explosive after· burning in ex· haust system 1) Improper ignition timing 2) Improper idle speed 3) Improper valve clearance Adjust. .. Dieseling 3) Malfunction of ignition control system Repair or replace.. Oil leakage 1) Loose oil drain plug or defective gasket. 5.. Repair or replace. 4) Slipping of clutch ~~"----" Inspect. Clean. Inspect.' . repair or replace.) r-I) Improper ignition timing Adjust. Adjust. Malfunction of operating parts (Thermo vacuum valve I. repair or replace. Replace. Adjust.~-----. check valve. See "Troubleshooting of engine cool· ing system" on page 3-83. adjust or replace. Inspect. 2) Malfunction of choke system Adjust. adjust and repair. 4) Malfunction of choke system S) Malfunction of EGR system 6) Malfunction of AAV system 7. Malfunction orvacuum controller or centrifugal advancer in distributor Inspect. repair or replace..--~~. Others I) Malfunction of EGR system. • Clogged vacuum lines Replace. Adjust. repair or replace.----~--- Corrective action Inspect.ENGINE Trouble and possible cause 4. Adjust. . 3) Malfunction of antidieseling switch (Hitachi carburetor) or idle stop solenoid (C·W carburetor) or defec· tive wire connection 4) Malfunction of choke system 6. . 5) Dragging of brake 4. Tighten or replace. Engine speed does not reo turn to normal idle speed. Inspect and adjust.. Excessive en· gine oil con· sumption 1. repair pr replace. -. 2) Over cooling or overheating 3) Excessive carbon deposit in comb ustion chamber.. repair or replace... etc.

Oil enters com. etc. cylinder. 4) Replace. Adjust. Defective ignition system 1) Improper ignition timing Replace. Replace. • • Inspect. Refer to Chapter S. wiring or vacuum line • Improper float level • Loose main jet or clogged main air bleed • Clogged vacuum pipe or disconnected hose • Others Defective fuel pump. Replace.1) Worn or damaged intake valve oil seal bustion chamber through 2) Excessive clearance between valve valve stem-tostem and guide guide clearance. 2) Defective spark plug • Improper spark plug gap • Fouled spark plug • Defective insulator 3) Defective cord or wiring Loose and/or damaged contacts of ignition system connection Defective cords or wires Adjust. 5) Defective crankshaft oil seals 6) Defective rocker cover gasket 2. 3) Tighten or replace. See "Troubleshooting" in Chapter IS. clean or replace. Replace. Adjust Replace. See "Troubleshooting of fuel system" in Chapter 4. piston 3. Replace. 4) Others 2. Replace. See "Troubleshooting of carburetor" in Chapter 4. 1) Improper piston ring gap 2) Worn or damaged piston ring. Clean or replace. delivery line. Replace. Excessive fuel consumption 1. 8. Oil enters combustion chamber past piston ring. Replace. 4) S) Malfunction of ECC system . filter. Defective fuel and air intake system 1) Improper idle speed 2) Clogged air cleaner element 3) Defective cord. Adjust. Check or replace pipe. Tighten. repair or replace.ENGINE Trouble and possible cause 2) Loose oil pan attaching bolts or defective oil pan gasket Loose oil pump attaching bolts or defective oil pump gasket Defective oil filler sealing Corrective action Tighten or replace.

• Worn valve lifter hole. Sound increases as engine speed increase. Slipping of clutch 3) Dragging of brake 4) Improper air pressure of tire 9. 2 in this Chapter. • • Loose flywheel mounting bolts. Inspect. Overheating. Others 1) Overcooling (defective thermostat) 2) See 3·3. Retighten connecting clamps or replace. fuel pump and fuel lines. Type of sound Excessive . Replace. coolant leaks 10. Insufficient engine compression pres· sure 1) Improper valve clearance Corrective action Adjust. Valve clearance is Broken valve spring. Tighten or replace. Correct. Adjust float level. Bent push rod. overcooling. en$ine noise Regular clicking sound Condition Possible cause Valve clearance is not normal. Oil pressure is normal. Odor of fuel 1) Fuel leakage from fuel tank. adjust or replace.ENGINE Trouble and possible cause 3. 2) Overflow from float chamber in carburetor 3) Leaking evaporative emission lines Check for cracks or cloggings of evaporative emission lines. • • Heavy and dull metallic knock Oil pressure is low • Worn crankshaft main bearing. • Worn connecting rod bearing (big end). See "Troubleshooting of engine cooling system" on page 3-83. filler cap. Damaged engine mounting . • Worn valve rocker arm. Tighten or replace.11. Check for cracks or cloggings. Retighten clamps on connections. Inspect and adjust. 2) Loose spark plug or defective gasket 3) Loose cylinder head nuts or defective head gasket 4) Others 4. Replace if necessary . normal.

Defective • Worn ring ignition starter switch.000 to 2. • Loss of compression. • Worn crankshaft main bearing. Sound like polishing glass with a dry cloth Hissing sound • Loose drive belt. • Ignition timingof carbon inside Accumulation • combustion chamber. High-pitched Sound is noticeable when accelerating metaJlic knock with an overload (Engine knocking) • • Worn cylinder liner and piston ring.distributor vacuum • Improper gasoline. Defective • controJler.000 rpm). gear and starter pinion. Metallic knock Sound is reduced when spark plug in when engine speed noisy cylinder is shortened out. • Wrong spark plug. • Defective alternator brush and rotor contact. Squeaky sound Rubbing sound • Insufficient alternator lubrication. Knocking sound when engine is operating under idling speed and engine is warm. Sound is reduced when spark plug in noisy cylinder is shortened out. • Air leakage in air intake system. connections or manifolds. • Worn bearing at crankshaft end of connecting rod. • Worn cam gear.ENGINE Type of sound Condition Possible cause advanced. is medium (1. • Defective water pump shaft. • hoses. • Worn camshaft journal bore in crankcase. Sound is not reduced if each spark plug is shortened out in turn. • UnusuaJly worn valve lifter. Broken or stuck piston ring. Gear scream when starting engine. J . • Worn piston pin and hole at piston end of connecting rod.

Replace.~-~---~-- Replace.. Check for the same possible causes as listed in 1. Replace_ --- --"--"---- c--~ -~-. Lubrication System Before troubleshooting. 3. Repair.--- Clean or replace. ~-~-~~~---- does not go on.--~-------- Insufficient engine oil ---~~--"~---- ---- 3) No oil pressure Broken pipe of oil strainer Stuck oil pump drive gear and rotor Replace.ENGINE 1. switch failure ~"~ -~---~- ~---~ "~--~- Oil leakage within switch Replace. Clean. 2) Poor contact of switch contact points ------- ----~----------~- 3) Disconnection of wiring 1) Poor contact at terminals Repair. Cracked diaphragm Clogged oil filter Possible cause Corrective action Replace. Replace. Replace. Replenish.. Warning light remains on.. Repair. Warning light flickers momentarily.- 1) Burnt-out bulb 2. 2) Defective wiring harness 3) Low oil pressure . Clean or replace. Clean or replace. Warning light r----~----. pressure Clogged oil passage Excessive tip clearance and side clearance of oil pump rotor and gear "~--"~ Clogged oil strainer or broken pipe r----~-------~--~~ ~--- ----~-. ~rouble I) Oil pressure .-2.. make sure that the engine oil level is correct and no oil leakage exists. r--~--" I.. ~- Malfunction of oil by-pass valve ~~ Malfunction of oil relief valve 2) Low oil .

Replace. c. Repair or replace. d. Replace. Malfunction of electric fan. Clean. Adjust. Improper transmission oil. Inspect and repair fuel system. Defective water pump mechanical seal. Defective drive belt. Adjust. Defective thermostat. Coolant leaks a. Outside temperature extremely low. o. Slipping clutch. b. . e. Defective thermostat. Possible cause Insufficient coolant. Clean or replace. j. i. Damaged or cracked thermostat case. Defective water pump bearing. Adjust. Repair or replace. or replace. Adjust or replace. Leakage from thermo valve. m. c. Adjust drive belt tension. f. Repair or replace. Replace. back pressure in exhaust Corrective action Replenish coolant. e. b. Replace. d. Partly cover radiator front area. d. n. b. Oil on drive belt. Replace. Leakage from intake manifold. Retighten cylinder head nuts or replace gasket. and repair. Damaged or cracked cylinder head and crankcase. Insufficient clearance between piston and cylinder. Leakage from radiator. Replace. Clogged or leaking radiator. Replace. inspect for leakage. Cooling System Trouble Over-heating a. Improper engine oil. Replace. Loose drive belt. k. g. p. Improper valve clearance. Repair or replace. Noise a. Repair or replace. g. Improper ignition timing. Excessive system. Replace. Repair or replace. r. Malfunction of water pump. q. Leakage around cylinder head gasket. Leakage from water pump. Replace. Air-fuel mixture too thin. Dragging brake. Clogged coolant passage. Repair or replace.ENGINE 2. Defective electric fan. f. h. I. h. b. Replace. Over-cooling a. Replace. Loosened or damaged connecting units on hoses. Malfunction of thermostat. Clean or repair. Repair or replace. c.

3-789 A5·l45 Fig. 3-785 AS·14l I Fig. 3·793 A5·l48 Fig. 3-786 Bolt 18995214121 A5·l42 • c._39_9~8_1_43_0_0_____ ~_______ 89_9_7_2_4_1_0_0_____ ENGINE STAND SPRING PRESS l-- I VALVE GUIDE ADJUSTER Exhaust valve guide 8_9_97_6_8_60_2______+-__~_8_9_8_8_7_8_6oo ______~ STUD BOLT WRENCH Crankcase stud bolt ---------·------------~--------------T Crankcase Valve spring . 3·788 All·'. I--------"---------+--------------+- ----t---------------.. Special Tools ~___..200 All·' II' . Fig. 3·197 A5·l52 899524100 PULLER SET _.7 Fig.181! Fig. 3·198 AI5-388 Fig. 3·195 898858600 i 8 Fig._--Crankshaft pulley 899714110 REMOVER SET Cam shaft 899768603 VALVE GUIDE ADJUSTER Intake valve guide 499067000 OIL SEAL INSTALLER Oil seal (crankcase) Puller (899521411) Q Cap Fig.. 3·191 A5·148 899804100 VALVE LIFTER CLIP Valve lifter 899764104 VALVE GUIDE REMOVER Valve guide IFig. Fig.. 399765101 CYLINDER HEAD TABLE Cylinder head 899764105 VALVE GUIDE REAMER Valve guide 398744300 PISTON GUIDE Piston • () ~ A5·143 ~ 0"" Ii :::g Fig. ! f!j 3·194 A5·149 0 Fig. 3·192 AII·' . 3·187 Fig.J ' CD ' A12.. 3·799 AII·11111 AII·1110 399284300 PISTON PIN GUIDE Piston pin OIL SEAL INSTALLER Valve gUide oil seal C _ _ :LP AII·'II' Fig.ENGINE 3·11. 3·790 399094310 PISTON PIN REMOVER Piston pin . 3. 3·196 Fig.

A1()'133 . 3·204 A 5·389 499990100 SOCKET Oxygen (0 2 ) sensor v J. 3·201 ST·030 ~ Fig. 3·202 A11·014 . Fig. Fig. Fig. . 3·205 . 3·203 ST·029 \'. \\ '. .ENGINE 499987006 SOCKET WRENCH Cylinder head nuts 499747000 CLUTCH DISC GUIDE Clutch disc 498767000 VALVE CLEARANCE ADJUSTER Intake and exhaust valves 499037000 REMOVER & REPLACER Connecting rod bushing ~ Fig. .' .

......••••• 4-12.....••. EVAPORATION LINE AND CANISTER •..•....3..•...... FUEL TANK .•... 4. 4-10..... .•..••.. FUEL PUMP •... ....••.•. • ...•.... HITACHI CARBURETOR •....••. VAPOR SEPARATOR ..........•.••.•.. • •• 4..•. .••.•.. •.•..••.•..•••.•.. 4.. ...:_"" " .••••••.••...CHAPTER~ FUEL SYSTEM Page 4.•...•.•.. 4....•. FUEL SEPARATOR ....5 4.. • • . ..• 4-11.• 4..•..•••... • • .•.. 4-45 4-31. .. • .6... • . 4....•.•...2.•.....•......4. 4...•...... TROUBLESHOOTING .•.8...••.. .... FUEL FILLER PIPE ....••. SPECIAL TOOLS .••.......?... • ........... • . ....•••..•••• 4-13.9....•...•..•.•.........•...7..':-:It':'~. COMPONENT PARTS OF FUEL SYSTEM (Except Carburetor) ... CARTER·WEBER CARBURETOR ••. ...•. FUEL FILTER •.~ _. 4-14....••..•.•.. • .... 4-20 4-29 4-31 4-32 4-33 4-34 4-35 4-36 4-:-37 4-.. ....•.••.. .••••• 4.•..2 4.5........ • . SPECIFICATIONS AND SERVICE DATA •...•. . ..•......1.." ..•..••.. FUEL DELIVERY AND FUEL RETURN LINE ...

02 .236 in) () =49 0 4-2 .067 in) I #114 .102 x 0. Recommended Fuel The SUBARU 1600 cc and 1800 cc engines are designed to get satisfactory engine perfonnance and to keep clean exhaust gas by using gasoline no less than 90 octane.7 mm (0.#50 #9S . (Inner dia.8 mm (0.-20. (Inner dia. -S.a a. > ~ . x Outer dia.6 x 40 mm (0.339 in) 2.5 mm (0.138 in) 2. Specifications and Service Data 1.#145 55 x 59 mm (2.#145 #60 .6 x 34 mm (0.91 inHg) I (Plugged) - Accelerating pump nozzle dia.138 in) 2. Hitachi Carburetor All California models and non4WD of non.-20.30 mm (1.575 in) 1.5 x 39.1.5 x 2.0 mm (0.031 in) x 16 #43 #80 #160 #90 O.5 mm (0.vacuum required "'eQ) .8 mm (0.091 x 0.3 x 3. x Length) :::e .#90 til Power jet .5 mm (0.094 xO.#80 #109 .) P S P S P S P S #116 . x Outer dia.S mm (0.california models i I MT 1800 AT DCP306·18 DCP306-19 1800 MT DCP306-21 AT DCP306-22 . -S.0 mm (0. Carburetor DCP306-17 I Air horn dia.california models Vehicle 1600 All Canada models and 4WD of non.142 x 1.020 in) 4.110 x 0.~ 2. number of holes) ~ 0 e ~ Slow jet (P-S) Slow air bleed (P-S) Economizer bleed (p·S) l\l #150 . Octane as selected by Raseareh method.SSS in) 0.j #35 .6 x 3.4 x 3.17 x 2. Weight of accelerating pump injector Type Primary throttle valve opening angle and clearance when secondary throttle valve starts to open 8 a.028 in) x 8 0. 0.s=~ -< -.020 in) x 2.91 inHg) 0.031 in) x 24 Emulsion hole (Dia..5 mm (0.098 x l.18 in) 1. Usa unleaded gasoline only.8 x 4.~ i= ~ 8 = 6.#140 #70 #109 #80 #145 2. of needle valve Main jet (P-8) Main air bleed (p·S) Main nozzle dia. NOTE: a.4 g (0.157 in) 5° 0 0 .0 kPa (-150 mmHg.) Throttle bore (P·S) Inner dia.0 kPa (-150 mmHg.OS9 x 0.142 x 1.094 x 0.. x Outer dia. e -.32 in) 26 .#90 #50 .FUEL SYSTEM 4-1. 2.155 oz) Diaphragm type G~ #150 . b. ~ e 4U Main nozzle end surface angle Emulsion tube (Inner dia.4 x 3.7 mm (0.

98mm (0.0480 in) ~-~ 18. #300 (Safety orifice: # 150) #300 #300 (Safety orifice: # 110) #300 .~ .. P.858 in) e t.M. :s cO . Fast idle opening angle and clearance of primary throttle valve 15· G 1 "'0.50 G 1 '" 1.0528 in) 1.11.0 .8 mm (0.433 .051 . ::s 0 Fuel level from upper mating surface of float chamber r---~ 20.22 mm (0.7 mm (0.5· G1 '" 1.21.) ~ Choke valve angle when fully closed 160 - . tf.5· G 1 = 1.S.. . Inner dia..0528 in) - .3 .795 0..FUEL SYSTEM All California models and non-4WD of non-California models Vehicle I----- All Canada models and 4WD of non-Califomia models 1800 1600 t-----Carburetor DCP306-17 I MT DCP306-18 1800 AT DCP306-19 Automatic choke MT DCP306-21 AT DCP306-22 <I) e l:l Choke system ~-- t. cO fi: 5 H = 11. of auxiliary passage (at nipple) S.5· G1 '" 17. .0386 in) 17..:..5 mm (0.2 .453 in) Clearance between float and upper mating surface on float chamber when front seat comes in contact with valve stem Clearance between valve stem and float seat when float is fully lowered ~~"~----- --~ L = 1.:.34 mm (0.0..34 mm (0.22 mm (0.0480 in) -~ 18..1.0.M.067 in) P...

2201 ± 0.79 mm (0.25 mm (0.(1) e By-pass bleed dia.. (I) Metering rod a -.70 mm (0.0020 16..0240 in) 0.70 mm (0.61 mm (0.0921 in) 0.arbureto r 1 TYF7419S mm (1.~-~------ .. ~L~_ A8·395 2. Choke system Choke-valve closed angle 0.. .59 ± 0.FUEL SYSTEM 3.~.:.( o.0020 1. 4·2 4-4 .05 mm (0.0961 in) -~ ---~ .0276 in) 1.78 ± 0.- :e ~ 'r 0.3701 ± 0.0299 9.55 ± 0.57 mm (0.25 mm (0.34 mm (0.0299 5.. Body bleed dia. 0. -~- ""I :0 c .34 mm (0.76 mm (0.51 ± 0.76 mm (0.:.I (I) (I) Low-speed jet tube dia.J '" ~~ =t~--~--- I ______ a b= c= a' == b' = c' = 0.I 1 I \ b f--..0921 in) Inner dia. c: ~:.44 mm (0. Pump bleed dia.0299 in) in) in) in) in) in) Fig.0803 ± 0. Economizer dia.0311 in) 2.51 mm (0. "' .76 mm (0.6500 ± 0.I:'" u~ '..0020 1. of needle seat -. / -- .04 ± 0.0610 ± 0. Nozzle discharge dia.437 in) 2.~ .0224 in) 0.05 mm (0. 2.0201 in) Automatic choke 15° 8 ..0492 in) I I e '" ~ (I) (I) Main metering jet Main well bleed dia.)~ f:!e(l) E E Pump nozzle dia..0492 in) -- 1. o . Nozzle tip bleed dia. 4-1 OIl -~-~.-.::: 0..':(1) 0_ (I) -- Float setting NO 0" E- E~ ~~ //////////////// A ir horn surface A8·396 ~ Fig. Carter-Weber Carburetor .40 ± 0.0701 ± 0.05 mm (0.0669 in) 1.

..______.1 Imp gal) --._-' _ _ _ . This carburetor has elemental system as follows. 12.45 Liter Hatchback 4WD (11...2 Impga1) a1 15. Discharge volume Current Starting voltage Less than 1. Secondary side p _ _ _ _--i[ste system Main system 4-5 . . 4WD Others _ _ _ _ _..------ + ____________. Provided with fuel return system Slow system Main system 2. I I I Capacity I 60 Liter ( USg. Primary side --------1 Accelerating pump system Power system Choke system 3._2_U_S_~_~I_~.98 in) di~charge head 220 mOl (8.~ c:: Hat:hbaok Others ~--l. nozzle tess than 8 V 4-2. Hitachi Carburetor 1.-------+---------..~-ul ~ ._=_--.. Fuel Tank and Fuel Pump r-T---~cat~:~--Under rear floor 1\ ~ r---.!.9 Imp gal) ~ c.5 US gal.--c----:-:-=-~..--------------.. _-+_____ 55 Liter (14.. One float system is commonly used I..FUEL SYSTEM 4.9 US gal..--__t_---.5 A AT..- -.. primary (normal) side and secondary (high output) side..____.J._-----_•._:t_.. Construction 'nlis carburetor consists of a float system.- Discharge pressure ~-------·---·------------·-r-------~---·-----~ g c. . § u._.~_I_m_p _ _ __ _______-I I u.66 in) mm (0. _ _ _ _ _ _.079 in) dia.. 13 ...9 ----+-----------~---+...~---. 9. Float system for both primary and secondary sides.------~--...------".....~( 13_.----I Type f-... suction head 990 mm (38.

.. '----.. 44 Fuel and air flow in Slow system . {)Primary side Fig.. the float chamber is opened to atmospheric pressure through the vacuum switching valve... When the coolant temperature exceeds the specified level. 4-3 Float system A8-487 All California models and non4WD of the non-California models are provided with a vacuum switching valve.. . ...' I ' ... ic:fJ Primary Side 1) Slow System FUEL AIR r---------. I . I ® l@ ilrr ..------' 1 All California models and non-4WD of non. . -_ _.FUEL SYSTEM • Float System @ I Fuel inlet pipe 2 Fuel return pipe 3 Filter 4 Needle valve 5 Float 6 Solenoid valve III 7 Air vent pipe 8 Air ftlter 9 Vacuum switching valve 10 Thermo vacuum valve 11 Intake manifold ------L~~' California modals and non-4WD of non-California models --------'11 l' rr II.1-_ _. I I I 1'-'. .california models only AS-273 Fig.

.-.. . .::~~H~~.... (mainl I L ________________ ~ :~~3~ I / \~.V. I :[~_I----. non-4WD of non-California models I ---I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I . 'i -U I I I ...-. ..... 4-6 Fuel and air flow in main system AS-490 . .. .FUEL SYSTEM . __ ~_n: All California models and non-4WD of non-California models :7 Fig. 4-5 Slow and step system 2) Main System f ... . : .S.. To D...uk -r---' ..---------j To electronic • control module All California models and .-... I I o I I I I I I I I I I :~~G r-. ~ . _________ J All Canada models and 4WD of non-California models (High-altitude configuration only) 1 Choke valve 13 Step hole 2 Economizer air bleed 3 Primary slow air bleed 14 Spacer 15 Idle mixture adj usting screw 16 Spring pin 17 Secondary diaphragm 18 Diaphragm chamber 4 Secondary slow air bleed 5 6 7 8 Slow control air passage Anti-dieseling switch Primary main jet Secondary main jet 9 Primary slow jet 10 Secondary slow jet 11 Idle nozzle 12 By-pass hole 19 20 21 22 Air vent pipe Control air cleaner Slow duty solenoid valve Intake manifold A8-489 Fig... ~ AIR :[ I C-""~~: / :fTU: : · · · .. ! ~~r~r ___~~ .

.FUEL SYSTEM To electronic • control module ---{ .S. 4-7 Main system (All California models and non4WD of non-California models) . To control air cleaner Non-4WD of non-California models (High altitude configuration only) ® (j) • TOD. (slow) Secondary side Primary side A8-491 1 Primary main je t 2 Secondary main jet 3 4 5 6 Primary throttle valve Secondary throttle valve Primary main nozzle Secondary main nozzle 7 8 9 10 11 12 Primary main air bleed Secondary main air bleed Primary emulsion tube Secondary emulsion tube Check valve Main con trol air passage 13 14 15 16 17 Secondary diaphragm Diaphragm chamber Surge tank Control air cleaner Main duty solenoid valve Fig. .V.

FUEL SYSTEM __ • To air cleaner High altitude configuration only @ Secondary side Primary side @ A8-492 1 2 3 4 S 6 Primary main jet Secondary main jet Primary throttle valve Secondary throttle valve Primary main nozzle Secondary main nozzle 7 8 9 10 11 12 13 Primary main air bleed Secondary main air bleed Primary emulsion tube Secondary emulsion tube Check valve Secondary diaphragm Diaphragm chamber Fig. 4-8 Main system (All Canada models and 4WD of non-California models) .

__ !. ..... Inlet valve IBaUl Primary side Outlet valve (I njector weight) Large venturi A8·378 Fig. Entry of (uel to main system Small venturi (primary) To intake manifold Fig..... 4·9 Fuel flow in accelerating pump system Fig.FUEL SYSTEM 3) Accelerating Pump System (Fuel) Float chamber Inlet valve (Ball) Pump cylinder r . - -- Primary side o A8·428 A8-428 Fig.. Pump nozzle Pump nozzle Outlet valve To intake manifold A8·008 -:. 4-12 Power system 4-10 . 4·10 Accelerating pump 4) Power System (Fuel) Float chamber .-----' AS.()l1 ! l.Power valve Main nozzle (Primary) 1----. 4·11 Fuel flow in power system .. .

I J l Slow air bleed (secondary) I Economizer air bleed (secondary) b. the bimetal is warmed by the heater to adjust the opening of the choke valve auto· matically. the travel of the vacuum piston is reduced when the coolant temperature drops below lSoC (64°F). flow in the step system . and this reduces the travel of vacuum position.. refer to 1) j Step hole Slow system in Primary Side. the vacuum diaphragm is operated by vacuum pressure and the choke valve is opened through a vacuum piston whereby the . . when the engine is started with coolant temperature under ISoC (S9°F). 4-13 • Secondary Side 1) Step System FUEL AIR I Float chamber I I J Main jet (secondary) I I . ~ Slow jet (secondary) r .J t ld_ _ 1 Diaphragm chamber 2 Chocke valve 3 Vacuum piston 4 Connecting rod 7 Choke lever A8-493 8 'Bimetal 9 Solenoid valve III 10 Intake manifold 11 Thermo vacuum valve II 12 ECM 13 Thermosensor S Setting point is one notch to rich side (10 degrees/notch) 6 Heater Fig. J Step system passage I I I I ~ NOTE: As for the construction. On all California models and non-4WD of non-Califomia models.4-14 Fuel and ai. overchoke is prevented. After the engine is started. Air horn . On all Canada models and 4WD of non-California models.FUEL SYSTEM 5) Automatic Choke The choke valve is linked to the bimetal through a choke lever so that the choke valve is kept opened at the degree corresponding to the ambient temperature by means of the bimetal force. l ~ Throttle bore (secondary) I AS·380 Fig. All California models and non-4WD of non-California models To air cleaner r----.. When the engine is started.. solenoid valve III opens the passage to air cleaner until coolant temperature reaches 2SoC (77°F).

refer to 2) Main system in Primary Side.4-15 Fuel and air flow in main system .--_ _ E_m_U_Is_'io_n_tube (se_co_n_d~r_y_)_ I Main nozzle (secondary) Small venturi (secondary) Large venturi (secondary) Throttle bore (secondary) NOTE: As for the construction. A8-494 • Control air cleaner: Non-4WD of non-California models Air cleaner: 4WD of non-California models Fig.FUEL SYSTEM 2) Main System FUEL Float chamber AIR * Control air cleaner or air cleaner Main jet (secondary) Main air bleed (secondary) Auxiliary main air bleed (High altitude configuration only) .

D. 80 Washer 81 Pu 82 Pump Iever spring 83 mp lever 84 Pump lever shaft 85 ~:T. washer I crew &. bimetal CP 86 Sunetal cover 87 Screw &. 4-16 4-13 ..". Sl eeve A Return plate Screw &. ' ~D 'if:. wa h I 6 Screw s er I 1 Sw'tch vent sol I 1 . 2 26 7 28 29 30 31 32 33 34 35 36 w:::: Solenoid valve CP Washer Secondary main jet Pr' main jet Float h Lock pclaamber plug te Throttle ad' Th Just screw rottle adj Idle adj ust spring Idl . ).~":_>'''' @@. washer crew &.FUEL SYSTEM 2. washer F . 22 Plug weight 23 Primary s1 jet 24 Pi ow 25 B~on return spring 16 Fl~' . . washer aphragm chambe 71 Gasket r 72 Float chambe 73 Screw &. washer Lead 88 Blind wire holder 89 . '\ r: Ir I 59 Throttle return spring 60 Thr 61 F ottle lever 62 .~II JliiI\. nvet 90 Connector AB-495 ~ "!- .\.."'" I I I .. S .dJust spring sast Idle lever B crew Washer Pum P connecting d Conn' ro ctmg COlla: lever : I : 4 S oke chamber kit I I 5 Screw &.I.¥:"I' £. ~.J.C.~. ® w 41 @ 11 Float 19 P un~ slow air bl ed 18 Pr' ower Jet e 20 Washer 21 Injector . r washer 74 Se condary slow jet 75 Se condary main . prmg Sleeve Connecung lever . au bleed 76 Prim y main air bleed 77 Gask: 78 SecOndary slow air b leed 79 Spnng washer . ~ I I : I I I I ) I I I I : I I : : 1 I / ////:~l ~ 11 I I . tII <-«. 'I 8 Gasket enOid valve 10 Pi P cover 9 Pum ston 11 Cotter pin 12 Washer 13 Washer 4 Filter 1 I I ~ Ii . Idle a . Component P arts 31 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 " .. ber 69 Di 10 Screw &. <' '~''''. lever Spnng washer 63 Nut 64 Retum sprin 65 Insulator g 66 Gasket 67 Throttle cham 68 "E" nng .( .ust screw e adjust spring Fig. 1 Clip 2Lead' 3 Cb Wlte holder Washer O-ring Washer Screw Cotter pin Washer Adjust plate Fast idle lever A Cam c onnectlng rod .

Inspection Disassembled components should be washed in clean gasoline before inspection. b. 3) Anti-dieseling switch. Air cleaner. 2) Primary and secondary main air bleeds. (All California models and non-4WD of non-California models) a. washer and spring washer. 5) Switch vent solenoid valve. NOTE: Remove spring pin beforehand. Be careful not to cause burr or damage. Particularly small holes and hollows such as fuel passage must be blown with compressed air to remove dust and dirt. 4) Primary and secondary slow air bleeds. pump lever. Be careful not to damage the longest screw. NOTE: Keep the disassembled parts in order. 9) Drain coolant so as to prevent it from flowing out. 3) Cam connecting rod.R. 2) Unclamp harness at two points. Air horn Check for cracks. 8) Disconnect accelerator cable from throttle lever. 4) Lock plate. a. gasket and three screws. 2) Pump lever shaft. Main diaphragm b. (All California models and non4WD of non-California models) 7) Disconnect harness connector. bailor injector weight) may drop off. 3) Primary and secondary plugs and slow jets. in order to prevent dust from entering into the engine. 5. 4) Separating Float Chamber NOTE: Be careful not to lose the 8 mm washer. 6) Disassembling Float Chamber 1) Piston return spring. gasket and five NOTE: Be careful not to lose the 9 mm washers. 2) Keep disassembled parts in order not to mix them up when reassembling. 3) Needle valve.G. Do not use drills or wires to clean the small passages. Disassembly 1) Precautions NOTE: a. Removal 2) a. otherwise the carburetor performance may be adversely affected due to cut or deformation.FUEL SYSTEM 3. Power valve. d. Retard (All California models and non-4WD of non-California models) 4) Disconnect hoses for duty solenoid valves. 3) a. 2) Choke valve Check for deformation and rust. 3) Nut and parts on throttle valve shaft. 1) spring. NOTE: Be careful not to lose the 10 mm washer. Disconnect hoses for fuel. 2) Float shaft and float. Duty solenoid valve (main) 5) Disconnect hoses. 2) Secondary diaphragm. float chamber drain plugs and primary and secondary main jets.2 mm washer. 3) Use clean gasoline and compressed air to clean the jets and fuel passages. and excessive wear of choke valve shaft contact areas. Secondary main air bleed (High altitude configuration only) 6) Duty solenoid valve connector clamp. 3) Separate float chamber and throttle chamber by removing three screws. b. NOTE: Be careful not to lose the 12. damage on mating surfaces. ball and injector weight. NOTE: After removal. 3) Choke valve shaft 1) . 1) Choke Chamber 1) Use wrenches and screwdrivers of proper size to remove nuts and screws. NOTE: Since the choke chamber is fitted with a float. gasket and three screws. 4_14 2) Removing Linkage I) Throttle return spring. 5) screws. Main diaphragm Distributor advance E. and Throttle Chamber 1) Snap ring of secondary diaphragm. Duty solenoid valve (slow) b. Fuel hose Fuel return hose Carburetor air vent hose Disconnect vacuum hoses. 4. 7) Disassembling Throttle Chamber 1) Throttle adjusting Screw and spring. cover the area on the intake manifold where the carburetor was installed. b. take care not to damage the float. c. NOTE: Leave pump connecting rod as it is. 10) Four carburetor attaching nuts and carburetor. Never use a wire or cloth. 2) Idle adjusting screw and spring. cotter pins and washers. 5) Disassembling Choke Chamber I) Accelerating pump piston and pump cover. Be careful when putting the float chamber upside down because some parts (spring. c. 3) Removing Choke Chamber 1) Return spring of return plate. since it has a hole which is vacuum passage for the power valve. 4) Choke chamber. damage on threads.

twist. AS-305 Fig. 4) Piston return spring Check for rust. 7) Accelerating pump piston Check for damage and wear. 6) Needle valve Check for damage and correct con· tact against valve seat. 4) Others 1) Washer Check for deformation and damage_ 2) Linkage Check for wear of each sliding part. 3) I) 1 Switch vent solenoid valve 2 Screw AS·297 I Float shaft 2 Float A8-294 Fig. and adjust the float level. Throttle valve shaft Check for wear. 7) Filter Check for deformation and damage. Float Check for deformation.<over Check for crack and damage. and wear of Ooat shaft hole. 3) Throttle Chamber Throttle chamber body Check for cracks. damage on 6. I Primary slow air bleed AS-296 2 Secondary slow air bleed Fig. 8) Air bleed Check for damage on thread and groove. damage on mating surfaces. 4·21 4-15 . 2) Use new gaskets. Assembly 1) Precautions 1) Wash all parts with clean gasoline before reassembly. 5) Idle mixture adjusting screw Check for damage on tip of the screw. 6) Emulsion tube Check for deformation.FUEL SYSTEM Check for wear and twist. 2) Injector weight Check for damage and proper con· tact against seat. Fig. 3) Passages Check for dogging. 2) Throttle valve Check for deformation. damage of seat and stopper. and wear of accelerating pump cylinder. 4·19 2) Float Chamber I) Float chamber body Check for cracks. 10) Accelerating pump . 4·17 Idle mixture adjusting screw 5) Springs Check for permanent set and rust. Ball Check for damage. 4·20 4) Install float with float shaft. wear of throttle valve shaft hole and damage on thread. wear of auxiliary valve shaft hole. Power valve Check for correct operation and damage on thread and groove. 4) 2) Install primary and secondary slow air bleeds. mm Needle valve II 3) 2) Assembling Choke Chamber AS-496 1) Install switch vent solenoid valve with gasket and three screw & washer assemblies. 4·18 Fig. 5) Jet Check for damage on thread and groove. lock plate and cotter pins. damage on threads. 8) 3) Install needle valve with 10 washer. 4) Power piston Check for correct operation. and damage on thread. 9) Choke spring Check for rust and deterioration. 3) Use wrenches and screwdrivers of proper size to prevent damaging the parts. mating surfaces.

4-30 AS-304 Fig. 4·27 2) Install idle adjusting screw. 2 1 Accelerating pump piston 2 Pump cover AS-429 Fig. 4·25 AS-303 1 Secondary diapbrl!lJll 2 Screw 3 Snap ring Fig. sleeve. 4·22 1 Throttle adjusting screw 2 Spring A8-155 3) Assembling Float Chamber 1) Install power valve with 8 mm washer. 4·26 5) Bringing Float Chamber and Throttle Chamber Together 1) Put float chamber and throttle chamber together with two screw & washer assemblies. 4) Install primary and secondary main air bleeds. etc. 5 mm washer and 0 ring. 2) Install secondary diaphragm together with gasket and connect with snap ring. spring. Primary slow jet 2 Secondary slow jet Fig./ A8·302 I. washer and insulator and gaskets. 1 Primary main air bleed 2 Secondary main air bleed Fig_ 4·29 A8-299 Fig. one screw. lever. Fig. 3) Install throttle adjusting screw and spring. 4·28 Fig.FUEL SYSTEM 5) Install accelerating pump piston 2 and pump cover. I Screw Fig. Power valve . 4) Assembling Throttle Chamber 1) Install adjusting plate. 4·23 2) Install primary and secondary main jets and float chamber drain plugs with 9 mm washers and install lock plate. 4·31 A8-430 . onto throttle valve shaft as shown in the figure. washer..

4·38 4) Install throttle return spring. ball and piston return spring. NOTE: Install return spring with its hook portion facing downward. Fig. Run the harnesses for anti·dieseling switch and for switch vent solenoid valve above solenoid valve as shown in the figure. b. 4·32 3) Install pump lever with pump lever shaft. plain washer. 4·36 spring A8-433 Fig. 1) Install cam connecting rod with cotter pins and plain washers. NOTE: Make sure that all the linkages operate smoothly. f'l 6} Installing Choke Chamber 1) Position choke chamber on float chamber with gasket between them and tighten with five screw & washer assemblies. 4·33 A8·289 Fig. 4·35 A8·2B7 7} Installing Linkage NOTE: a. L Return springlsl Fig. NOTE: Position the acute angle side of the connecting rod upward. 1 Cam connecting rod 2 Pump connecting rod 1 Screw & washer assembly 2 Clamp Fig. I Pump lever 2 Pump lever shaft 3 Spring A8·432 Fig. Tighten the screw near the acceler· ating pump together with harness clamp. . and spring washer. 4·39 2) Connect anti·dieseling switch with 12. 4·34 AB·288 1 Pump lever 2 Pump connecting rod AB·431 3) Install return spring of return Fig. Anti~ieseling switch -. 2} Connect accelerating pump con· necting rod to pump lever by inserting the rod end into hole in pump lever. spring.FUEL SYSTEM 3) Install injector weight.2 rom washer to float chamber. 4·37 1 Ball 2 Piston return spring 3 Injector weight AB·298 Fig.

ow • .--+-.OS28 in) 18. When the current is ON in die solenoid. ~ •ting ".0480 in) 17. die plunger is forced upwards by die spring force to close the passage between ® and @..7 . This angle is called fast idle opening angle. Standard resistance: 1 MO or more. 441 A 10-116 Thermo vacuum valve (II) Fully open below 14°C (57°F) Fully closed above 20°C (68°F) Check the vacuum passage for opening and closing operation while applying electric current on both (+) and (-) terminals. v..J'. Replace YES Fig. 4·40 Fast idle mechanism ~ Clearance G..FUEL SYSTEM 7. Below air into the valve as shown in the illustration.0386 in) ISO DCP306·I8 DCP306·2I 1. . the pri· mary throttle valve is slightly opened from its ~ully closed position by the action of the fast idle cam and the linkage. In this condition. measure the clearance G. Valve . below 10°C (SO°F)] for some time. Fast idle opening angle Spring DCP306·I7 0.s° DCP306·I9 DCP306·22 1. Standard resistance: 32. l. To air cleaner i ~ . die plunger is attracted downwards to open die passage between ® and @.90 NOTE: 00 not allow water to get into die dlermo vacuum valve (II).. and confirm that the valve opens or closes in response to the speCified temperature. Check and Adjustment 1) Automatic Choke Mechanism Adjustment 1) When the choke is closed. Vinyl tube NO YES Check the resistance between (+) or (-) terminal and body. 1 YES ~ .34mm (O.Thermo vacuum valva (II) NO . heat the water. is not to specifi· _~ti()n.. NO NOTE: Usually (when die current is OFF).IIiI"-==-To carburetor Fig. indicated in the figure which should be as specified in the table.22 mm (0.39. adjust by means of the fast idle 1 Fast idle adjusting screw 2 Cam adjusting lever 3 Fast idle cam 4 Cam connecting rod 5 Throttle valve 6 Bend this pawl to adjust choke valve opening angle 7 Choke lever 8 Choke valve AS-170 Fig. After soaking valve in cooled water [approx.5° ~ _ . If the clearance G. At this time. the top of the cam adjusting lever rests on the first (highest) step of the fast idle cam. 442 AS-384 2) Check of Solenoid Valve (III) Check the resistance between (+) and (-) terminals. Check of thermo vacuum valve (II) Connect vinyl tubes to output ports of thermo vacuum valve (II).. Which is suitable for starting the engine in cold weather. .98 mm (0.

4) Install duty solenoid valve connector clamp G).11. Fig. 2) Connect accelerator cable Q) to throttle lever. (4WD of non-California modelsHigh altitude configuration only) 6) Connect hoses for duty solenoid valves. (All California models and non4WD of non-California models) c.051 . a. From thermo vacuum valve (II) to main diaphragm @. From intake manifold to main diaphragm @.High altitude configuration only) 8) Connect vacuum hoses. To diaphragm Plunger Valve stroke AS-497 NOTE: 3) Adjustment for Interlock of Primary and Secondary Throttle Valves The primary and secondary throttle valves are interlocked so that the secondary throttle valve starts to open when the primary throttle valve is opened to a certain degree. From distributor to advance port Fig.453 in) Clearance H 1 2 3 4 26 mm (1. 4-19 . 4-45 1 t Secondary side t Primary side 1) Adjusting float level Remove the choke chamber and turn it upside down.5 mm (0. b. A fuel level within a range of 1. adjust as specified in the following paragraphs 1) and 2). If not. From air cleaner to secondary main air bleed. From duty solenoid valve (slow) to carburetor @. 4-46 '1 1 8. From control air cleaner to secondary main air bleed.067 in) throttle valve interlock (2).3 -1. a. From duty solenoid valve (main) to carburetor 0). Fig• . 11. b. adjust the level by bending the float seat. the effective stroke is normal. (All Canada models and 4WD of non-California models) b. 7) From air cleaner to carburetor 1 1 1 1 Float seat 2 Float stopper 3 Float AB·027 1 G2 6.7 mm (0. If the fuel level is out of this range. (4WD of non-California models . If the clearance H indicated in the figure is as specified below when the float seat comes in contact with the valve stem.0 . From solenoid valve (III) to main diaphragm @. (Non-4WD of non-California models .4-43 . After completion of fuel level adjustment.4-44 Primary and secondary Clearance L 1.High altitude configuration only) d. @. 3) Connect harness connector @. adjust by bending the float stopper.0. This opening angle of the primary throttle valve and the clearance G2 should be as follows.J FUEL SYSTEM To electronic control module 1 1 1 1 4) Fuel Level The fuel level in the carburetor can be checked through the sight glass of the float chamber. (All California models and non-4WD of non-California models) a. Adjust plate Throttle lever Return plate Primary throttle valve AS-175 2) Adjusting effective needle valve stroke If the clearance L between the float seat and valve stem with the float fully lifted is as specified below.02 inl dia. If not.0.2362 in) Fig. Installation 1) Install carburetor with two gasi. confirm it through the sight glass.00 mm (0. (All California models and non-4WD of non-California models) 5) Connect hoses to carburetor.5 mm (0.<ets and an insulator on intake manifold. the float level is normal.059 in) above or below the point mark is normal.(1). t 1 !1 AS-499 .433 .

h.4-48 Float system .R. After reinstallation. b. pOlt Q i».speed system 4. hiel hll~~ Q"2). The carburetor has 5 systems as follows.R.'IlUm .+WD ..FUEL SYSTEM -_.)1 1I1111·Califllrnia models) (1) ('milled lhlses 1'01 fuel. make sure that no leakage exists around the mating parts and that the vacuum system operates correctlv. Perform "Engine idle speed adjustment" and "Engine idle mixture adjustment" .Hd pnrt QU._-_. valve III EG. Low-speed system 3._-_. Construction The carburetor is a ~ingle·barrel downdraft type consisting of 5 systems which enable it to provide the correct fuel and air mixture under various operating conditions and loads. Float system 2. 1. d._-_._-_. a.h the coolaut. A8·385 Fig.wildt (II) 1. F(ont view 'All Calillllllla 11l0dds and non· . h'lll! \'<I._--------_. It also incorporates a pulsing air control solenoid allowing it to interface with an electronic feedback fuel control system. 4-47 4 . NOTE: a. Fuelletlllll'tlOse (r~ L Carburdul air vent host' (i4) 10) Illst:dl all . Carter-Weber Carburetor 1. Choke system 1) Float System A8·387 Fig.._.0 rel._---------_. II J Repl~lli._._-------c.:ica!Jer. High. 3. FrIll\] FJ. Accelerating pump system 5.

4-52 High-speed system .FUEL SYSTEM 2) Low-Speed System Body bleed Duty solenoid valvel By-pass bleed Economizer FUEL AIR Metering rod Low speed jet Low speed passage A8-388 ASS·3S9 Fig. 4-49 Fuel and air flow in low-speed system Fig_ 4-50 Low-speed system 3) High-Speed System FUEL AIR I Float chamber I I I AirhQro I I D"ty !Olenoid valve I Metering rod jet I Main well biud I I I j i I Control air passage I I I Noule tip bleed I I Nonie dischar.e J Metering rod l I Small venturi I I Throttle bore A8-390 A9·391 Fig.4-51 Fuel and air flow in high-speed system Fig.

4·54 Accelerating pump system 5) Choke System Vacuum diaphragm Vacuum piston Bimetal Bimetal housing set at one notch to rich side.FUEL SYSTEM 4) Accelerating Pump System Pump nozzle Anti·siphon passage Cam follower FUEL Pump bleed Check ball (Inlet) Pump chamber A8-392 A8-393 Fig. 4-53 Fuel flow in accelerating pump system fig. (10 degrees/notch I Choke valve Modulator spring Vacuum Hose A8-394 Fig. 4·55 Choke system .

Component Parts 6 Banjo lock screw 7 Banjo lock 8 Banjo fuel bolt 9 Banjo gasket IO Banjo fuel line ASSY 11 Fuel line bracket a ttaching screw 12 Idle stop solenoid attaching screw 13 Idle stop solenoid 14 Fuel line bracket 15 Feedback solenoid a ttaching screw 16 Feedback solenoid 17 Feedback solenoid gasket 18 Bowl vent solenoid attaching screw 19 Bowl vent solenoid 20 Bowl vent armature spring 21 Bowl vent armature 22 Bowl vent armature spring retainer 23 Bowl vent valve 24 Bowl vent gasket 25 Wire support(s) 26 Connector rod 27 Connec tor rod bushing 28 Air horn attaching screw (short) .29 Air horn attaching screw (long) 30 Air horn 31 Air horn gasket 32 Float hinge pin 33 Float 34 Fuel inlet needle pin 35 Fuel inlet needle pin spring 36 Fuel inlet needle 37 Fuel inlet needle seat 38 Fuel inlet needle seat gasket 39 Fuel inle t filter 40 Pump discharge weight 41 Pump discharge check ball 42 Lifter link 43 Metering rod 44 Metering rod spring 45 Pump delivery hose 46 Pump assembly attaching screw 47 Main jet 48 Flange attaching screws 49 Flange 50 Flange gasket 51 Idle mix ture screw 52 Idle mixture screw spring 53 Body casting 54 Metering rod adjustment hole plug 55 Flange a-ring AS-397 ~-~ @ I cb-~ I I I 1 Choke vacuum hose 2 Fuel line clamp screw (outer) 3 Fuel line clamp (outer) 4 Fuel line clamp screw (inner) 5 Fuel line clamp (inner) Fig.FUEL SYSTEM 2. 4-56 .

4) Banjo lock. 3) Main jet. 8) Choke break diaphragm Check for cracks or other damage. otherwise the carbUretor performance may be adversely affected due to cut or deformation. Disconnect hoses for fuel. 4) Air horn gasket. damage on threads and excessive wear of choke shaft and countershaft contact areas. Air cleaner. 6) Banjo fuel line assembly and two gaskets. 3) Float by pulling out float hinge pin. 3) a. c. II) Modulation bushings and spring Check for excessive wear and insure parts more freely. needle pin spring and needle. 4) Tamper·proof pin. Particularly small holes and hollows such as fuel passage must be blown with compressed air to remove dust and dirt. 5) Disconnect accelerator cable from throttle lever. gasket and mter. 8) Two carburetor attaching nuts and carburetor. Be careful not to cause burrs or damage. 9) Choke coil Check for rust. b. metering rod and spring. 4) Disconnect harness connectors. 5. Inspection Disassembled components should be washed in clean gasoline before inspection. do not put any plastic or rubber parts into the carburetor cleaning solution. 2) Fuel line clamp (outer). 5) Removing Air Horn I) Connector rod. Distributor advance I) Feedback solenoid and gasket. 4) Countershaft Check for wear. 3) Removing Idle Stop Solenoid I) 2) I Cam 2 Fast idle lrver 3 I'ast idle adJusting screw Idle stop solenoid. I) Warm up the engine sufficiently. Ensure that the auto-choke is fully open. On-car Service Fast Idle Adjustment NOTE: Prior to adjustment of fast idle.000 rpm. S) Banjo fuel bolt. 2) Choke valve Check for deformation and rust. 4) Pump housing ASSY. . I) lise wrenches and screwdrivers of proper size to remove nuts and screws. 2) Air horn by removing seven screws. 6) Removing Metering Rod and Accelerating Pump b. (cold parts cleaner) 7) Separating Body Casting and Flange I) Pump discharge check ball and weight. 3) Use clean gasoline and compressed air to clean the jets and fuel passages. 6) Needle seat. Disassembly 1) Precautions I) Lifter link. NOTE: Use Main Jet Driver (498167100).FUEL SYSTEM 3. 7) Drain coolant so as to prevent it from !1owing out. Removal I) 2) a. 3) Fuel line clamp (inner). 4-57 4. E. 3) Choke shaft Check for wear and twist. S) Float Check for deformation. S) Idle mixture screw and spring. 6) Vent hose and connector with carburetor spacer and gasket. 7) Filter Check for deformation and damage. 2) Bowl vent solenoid and gasket. 5) Fuel inlet needle pin. I) 4) A8·422 Fig. 2) Keep disassembled parts in order so not to mix them up when reassembling. 2) Separate body from flange by removing four screws. 3) Pick-up armature and spring from b()wl vent solenoid. Do not use drills or wires to clean the small passages. Removing Feedback Solenoid and Bowl Vent Solenoid 1) Air Horn Air horn casting Check for cracks or damage on mating surfaces. ensure that idle speed and idle mixture have been adjusted properly. 6. 6) Needle valve and seat Check for damage and correct contact between needle and seat. wear or set. excessive wear on needle contact area. 2) Pump hose.R. 3) Adj\lst the fast idle adjusting screw \llltil idle speed is 2. 2) Removing Fuel Line I) Choke vacuum hose. damage or cracking. Fuel hose Fuel return hose Carburetor air vent hose Disconnect vacuum hoses. 3) Flange gasket. wear or damage. 2) Engage the fast idle lever with 3rd cam latch. Never use a wire or cloth. 10) Accelerator pump cam Check for cracks. 4) When cleaning carburetor. 12) Fast idle cam bushing Check for excessive wear. Fuel line bracket.G. float pin hole and pin.

twist or damage to threads. 3) Use wrenches and screwdrivers of proper size to prevent damaging the parts. 2) Assembling Flange and Body Casting 1) Install idle mixture screw and spring in flange. 3) Accelerating discharge weight Check for wear. 11) Metering rod Check for wear or bends. 2) Throttle valve Check for deformation. S) Springs Check for permanent set or rust. 4·58 A8·402 A8·398 Fig. 4·63 3) Assembling Body Casting I) Install pump housing ASSY. 4·64 A8-404 . 7. 2) Passages Check for clogging. 3) Throttle valve shaft Check for wear. 1 Main jet 2 Main Jet Driver (498167100) Fig. 4) Install lifter link. 8) Accelerating pump seal Check for wear or damage. S) Mainjet Check for damage on thread. metering rod and spring. 4-61 A8·401 3) Install main jet by using Main Jet Driver (498167100). Fig. 4) Others 1) Washers Check for deformation and damage. 3) Linkage Check for wear of all moving parts. groove and seat and for wear on guide. 7) Accelerating pump diaphragm Check for cracks or damage. 9) Accelerating pump delivery hose Check for cracks or damage. Pump hose I) Wash all parts with clean gasoline before reassembly. 6) Low·speed jet tube Check for deformation. 4·60 Fig. 4) Idle mixture adjusting screw Check for damage on the tip of the screw. 10) Lifter link Check for wear or warpage.FUEL SYSTEM 2) Main Body I) Body casting Check for cracks or damage on mating surfaces and damage on threads. damage on threads and wear of throttle valve shaft holes. 2) Use new gaskets. Assembly 1) Precautions 2) Install pump hose. 4·59 A8·399 1 Lifter link 2 Metering rod 3 Spring A8-403 Fig. 4·62 2) Position flange on body casting with gasket between them and tighten with four screws. 2) Accelerating check balls Check for damage and proper con· tact against seat. 3) Throttle Flange Flange casting Check for cracks or damage on mating surfaces. 4) Accelerating pump and metering rod springs Check for rust or damage. 1) Fig. Pump housing assembly Pump discharge check ball 2 Weight A8·400 Fig. connector link bushing and pump hose.

Needle seat 5) Put air horn gasket on air horn. A8-405 (. feedback solenoid with 1 Float 2 Float hinge pin A8·407 Fig. 4-73 5) Installing Feedback Solenoid and Bowl Vent Solenoid 1) Put bowl vent annature.:. 4·66 Connector rod 2 Rod bushing AS-410 A8-413 Fig. 4·69 AS-412 Fig. NOTE: Refer to 8 "Check and Adjustment". n Air horn gasket Fig. 4) Install gasket. 2) Put spring and bowl vent armature into bowl vent soleassembled in noid. Bowl vent solenoid 1 Fuel inlet needle 2 Spring 3 Needle pin A8-406 Fig. and Bringing Air Horn and Body Casting Together 1) Install needle seat with fuel filter and washer. I Bowl vent armature 2 Spring retainer 3 Valve AS-411 AS-414 Fig. Fig.FUEL SYSTEM 4) Assembling Air Horn. 4-70 3) Install float. 3) Install bowl vent solenoid assembled in 2) with gasket. 4·74 . 4·65 I Bowl vent armature 2 Spring 3 Bowl vent solenoid 2) Install fuel inlet needle with spring and needle pin. 4·68 A8-408 6) Position air horn on body casting with gasket and tighten seven screws. 4-72 7) Install connector rod with rod bushings. 4·67 4) Check float adjustment. 4-71 Fig. Fig.:..' @ ~ \ ~ \ ~ ~~:. spring retainer and valve together.:~" Screw Fig.

8. 2) Turn the top side of the air horn down to free the float. I Idle stop solenoid 2 Fuel line bracket A8·415 Fig. 4·80 A8-420 9. 4-75 E[ Torque 34-40N. 4-82 A8-423 Fig. Fig. measure the distance shown in the figure below.R.1 kg·m. bend portion (A) to adjust the distance. 3) Connect accelerator cable to throttle lever. Make sure that all the linkages operate smoothly. 4·76 Fig. connector and spacer with gasket. banjo fuel line assembly and second banjo gasket on air horn. Installation 1) Install carburetor with two gaskets and an insulator on intake manifold. 2) Install vent hose. Carburetor air vent hose 7) Install air cleaner. 4-79 A8-419 1 Banjo fuel line assembly 2 Banjo gasket A8-416 3) If the distance is outside the specifications. a. then position the float at the air horn. At this pOint. Choke vacuum hose A8-417 Fig. 4) After the distance has been ad· justed properly. 4·81 A8·421 Fig. . Fuel hose b. Fig. 5) Connect vacuum hoses. a. E. 4) Connect harness connectors. Distributor advance b. 25 . A8·418 Fuel line clamp (outer) 2 Fuel line clamp (inner) Fig.4.5 . 6) Connect hoses for fuel. 7) Install choke vacuum hose.m (3. 8) Replenish the coolant. 4·77 NOTE: 4) Install fuel line clamp (outer) and fuel line clamp (inner).30 ft·lb) 2) Position banjo gasket. turn the air horn right side up to lower the float. bend portion (B). If necessary.G. Fuel return hose c. 4·78 5) Tigh ten banjo bolt to the specified torque. 3) Put banjo bolt on banjo fuel line assembly and tighten lightly. Check and Adjustment Float Setting 1) Detach the air horn gasket. and then connect hoses.FUEL SYSTEM 6) Installing Idle Stop Solenoid and Fuel Line 1) Install idle stop solenoid with fuel line bracket. Measure the distance from the lower surface of the air horn to the tip end of the float to ensure that it is more than 38 mm (LSD in). The needle must be free while adjusting the distance.

After reinstallation. A8-425 1 Vent hose 2 Connector 3 Spacer 4 Carburetor air vent hose 5 Accelerator cable 6 Harness connectors 7 Fuel hose 8 Fuel return hose Fig. Perform "Engine idle speed adiust· ment" and "Engine idle mixture adjustment" . 4-83 .FUEL SYSTEM NOTE: a. b. make sure that no leakage exists around the mating parts and that the vacuum system operates correctly.

_~' 9 8 " " ' :!J q/l' 'I 9 . I. __ 20 .-~02' 9 r' '6' .-" 9' 17 1'8~ 18 ·']'1"'''''' b~-. while p.FUEL SYSTEM 4-4. J. 4·84 A21·183 2. o "r" iI e -. 4-29 . 8) Deta NOTE: Be careful 9) Disc breath!' Fig.. E~ Sedan and Hardtop I Other than BRATI IFuel separator I BRAT I.'. Component Parts of Fuel System (Except Carburetor) 20 --". 7) oS.~:: '.~.

FUEL SYSTEM @t11t!~ tha~ BRAT] 1 2 3 5 6 7 8 9 10 Clip 14 Clip delivery Clip A Flange bolt Fuel hose clamp Purge hose Purse lock clip Carburetor evaporator hose Clip8-5 Delivery hose Tapping screw Fuel hose clamp Evaporation tube Evaporation pipe CP Carburetor vent hose Pipe canister hose Hose spring Clip Pipe canister hose Fuel mter holder Vapor separator hose Vapor separator Return hose Band Valve pipe hose Return hose clamp Valve ASSY Filter pump hose Pipe ASSY center (L..) Clip 11 Pipe hose Return clamp Tapping screw Clamp Return hose Purse lock clip Flange bolt Clamp Clip Fuel clip Delivery clip Canister bracket Pipe canister hose Spring hose Cab vent hose Clip Canister ASSY Pipe canister hose Purge hose Cab vent hose Pipe CP Tapping screw Fuel mter holder Vapor separator hose Vapor separator Delivery hose Return hose Band Valve AY Filter pump hose IFuel separator I 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Fuel separator Fuel separator Separator bracket PipeCP Packing Joint hose Air breather hose Pipe separator hose Clip Clip Tapping screw Separator bracket Separator cover CP Pipe protector CP Flange screw Pipe separator hose Pipe separator hose Air vent clip Washer Flange nut Flange screw Separator bracket Air breather pipe (L..) Air breather pipe (R.) Return hose Del hose Tapping screw 2-way valve bracket Hose 2-way valve Screw grommet BracketCP Clip Canister Clamp Fuel pipe ASSY Pipe lower clamp Pipe upper clamp Bolt Fuel fIlter holder Flange nut Fuel mter ASSY Pump bracket Grommet Fuel pump ASSY Washer Pump bracket Coating clip Filter-pump hose Pump pipe hose Pipe fIlter hose Clip [BRAT! 1 2 3 4 5 6 7 8 9 10 Pipe ASSY Clip 8 . A . ..H..H.H..H..) Air breather pipe (engine) Grommet Clamp Separator hose Air breather tube Separator hose (engine) Fuel system clip Fuel system clip Tapping screw Flange screw Clamp Tapping screw Washer Spring nut Separator bracket Tube Air breather pipe Air breather pipe Tapping screw Pipe protector Air breather pipe Hose Tube 1 2 3 4 5 6 7 8 9 10 11 12 Purse lock clip Air breather hose Filter hose Brake pipe clamp Clip Air breather hose Clip Air breather pipe Air breather tube ClipC Tank-pipe hose Washer Bolt ASSY Drain packing Flange screw Filler packing Filler cap packing Filler cap ASSY Fill pipe packing Fuel meter unit Packing Clip Fuel system clip Bolt & washer AY Clip fuel system Air breather hose Flange bolt Fuel meter unit bolt Hose protector Clip Air breather clamp Tapping screw Washer Air vent clip Fuel tankCP Filler pipe CP Air vent hose Return hose Hose protector 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 33 34 35 36 37 39 40 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 65 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 33 34 35 36 37 38 39 40 41 43 44 45 50 51 52 53 54 55 57 58 59 13 14 16 17 18 19 20 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 22 23 24 25 26 29 30 31 32 33 34 35 36 37 38 40 41 42 44 45 : ~.5 Air breather tube Air breather hose Valve bracket 2-way valve Bolt Grommet Fuel pump ASSY Filter holder Fuel mter Clip 14 Filter pipe hose Pipe filter hose Nut Washer Pump pipe hose Fuel pump bracket Return hose Pipe ASSY center-R Pipe ASSY center (L.

Air-breather hoses from air-breather pipes. I the inside of fuel tank by gaso)r by blowing compressed air. 2) Uft up vehicle and detach rear right tire and wheel. ""'"". After all gasoline is completely drained. Return hose.1 ± 5. c. securely tighten drain bolt. Installation I) Insert the front flange of fuel tank into opening between reinforcement and vehicle body./ '''. 3) Tighten seven bolts installing fuel tank to body.1 2) Slide fuel tank to left or right until mounting holes on its rear are aligned with those on vehicle body. Remove filler cap for quick draining. ~l \ ' 11" t. '. Fig. Fuel Tank 1. Fig~ 4-85 5) Detach protector from filler pipe. Inspection 1) Check leakage.FUEL SYSTEM 4·5.r"'~.9 ft-lb) NOTE: Keep open flames away from all working areas. hose 2 to the highest pipe and hose 3 to the lowest pipe at wheel apron and tighten them with clips. 4) Drain gasoline by removing drain bolt. 6) Connect air breather hoses as follows.4 kg-m. 18. a. and remove it while pulling down backward. Air-breather hose. 9) Disconnect air-vent hose and airbreather hoses from fuel tank. ± 2. Then install and temporarily tighten the rear of tank with four bolts. If necessary. f.7 kg-m.1 ft-lb) L ---:-1----·····. Removal and Disassembly I) Disconnect ground cable from battery. Torque 25 ± 7 N·m (2. 2S 111m (0. Fig. which is attached to fuel filler pipe. 3. 4-86 Connecting hose and hoses 4. For All Models Except Station Wagon Connect hose I to the middle airbreather pipe. ~.. hose 2 to the lowest pipe and hose 3 to the middle pipe at wheel apron and tighten them with dips .7 ±' 2. rust. Air-vent hose from air-vent pipe.2 ± 0. 2) Connect air-vent hose and airbreather hoses to fuel tank. b.5 ± 0. Filler hose from fuel tank.~ ~'~'l. 6) Disconnect hoses. /-' ® I ! I 1 Air-breather hose 1 2 Air-breather hose 2 3 Air-breather hose 3 4 Air·vent hose @ i [ A21·190 Jj1=J I For Station Wagon : ~ Ll2 t-----1l NOTE: Be careful not to damage gasket.9 ft-Ib) A21·159 4) Insert fuel filler hose into fuel tank pipe until it stops and then fasten it with clips. crack. 1 Fuel tank 2 Reinforcement 3 Bracket A21·080 Connect hose 1 to the highest airbreather pipe. 4·89 Connecting air-breather hoses A21-062 Fig. and then fasten it with clips. Tighten nuts diagonally one after the other. e. Assembly I) Assemble fuel meter unit and gasket to fuel tank by nuts.4 kg-m. 7) Support fuel tank. ~~~ Fig. S) Insert air-vent hose by approx. clean the inside of fuel tank or replace. · · _I-~orque 10. 8) Detach fuel meter unit and gasket. 4-88 Connecting air-breather hoses 2. 2) When fuel filter is easy to be logged resulting from accumulation dust or foreign matter in fuel tank. d.98 in) into air-vent pipe. 8. pipes and tubes as follows. Torque 12 ± 4 N'm (1./ ~"'-~ __ i . )4 ±4 N·m (1. 4-87 Inserting front flange of fuel tank .4 ± 0. or dust adhered. 3) Disconnect electric connector for fuel meter unit. Delivery hose.

NOTE: When filler packing edge is folded inward. Installation 1) Insert filler pipe to the hole in saucer through the inside of wheel apron and install fllier packing to filler pipe by tightening three screws. 11) Fill fuel tank with gasoline and check for any leakage.38 in) and tighten them with clip. more than 20 mm (0. and detach following parts. more than 15 mm (0. 12) Connect ground cable with battery. straighten it with a flat-blade screwdriver. NOTE: Overlap at connection For delivery hose and return hose. 4-90 Installing protector 4·6. ensuring that they do not interfere with filler pipe protector or wheel apron. 3) Insert filler hose into filler pipe by approx. Filler cap.98 in) and tighten them with clip. 6) Install rear right tire and wheel.FUEL SYSTEM 7) Connect delivery hose. Removal 1) Disconnect ground cable from battery. and temporarily tighten it using only the rear upper bolt. 8) Connect ground cable with bat· tery. 4) Insert air-vent hose into air-vent pipe by approx. 1 Fuel filler hose 2 Air-vent hose 3 Clips A21-164 Fig. 7) Remove filler pipe downward. A21-162 Fig. a. 7) FilI fuel tank with gasoline and check for any leakage. Screws installing filler pipe.79 in) For air-breather hose. . Filler packing. Fuel Filler Pipe 1. 25 mm (0. 5) Install protector to fllier pipe and tighten them with bolts. 35 mrn (I. 2) Align holes on filler pipe bracket with those on wheel apron bracket. 10) Connect electric connector for fuel meter unit. 9) Install rear right tire and wheel. 4-92 Tightening hose clip A21-163 2.59 in) 8) Align protector with wheel apron at mounting holes. b. 2) Open filler flap. 6) Disconnect filler hose and air-vent hose from filler pipe. return hose and air-breather hose to fuel tank and tighten them with clips. 4) Drain gasoline by removing drain bolt. 5) Remove protector from filler pipe. 4-91 Installing filler pipe NOTE: Fasten clips. c. Fig. 3) Lift up vehicle and detach rear right tire and wheel. then install protector on filler pipe.

Sedan and Hardtop 1) Removal 1) Detach back rest of rear seat and rear quarter trim. 3) Install separator onto body with cover and protector. then disconnect hose between separator and pipe. 2) Connect air-breather hoses to pipe assembly under rear floor.FUEL SYSTEM 4· 7. 4) Disconnect air·breather hoses under rear floor. b. b. 2) Remove fuel separator installing screw from rear bulkhead side. 7) Take out separator by expanding the band. 4-93 Connecting hoses A21·089 . Fig. NOTE: Be careful not to damage separator noule. 15 mm (0. 5) Bend the joining portion of cover and protector toward first the center of vehicle and then its rear while removing separator from floor. 4) Remove screw securing band to separator. 15 mm (0. Hatchback 1) Removal 1) Detach rear trim and rear quarter trim. 6) Remove two screws securing pipe assembly to floor. The hoses should be inserted approx.g. 6) Remove screw securing band to separator. 2) Disconnect hoses from separator. 25 mm (0. NOTE: Be careful not to damage separator nozzle. 3) Fit band onto separator with screw. The hoses should be inserted into separator nozzles until they reach the bases of separator noules. NOTE: a. Connect the "L-bend" small hose between separator upper noule and the pipe situated in front of large pipe. The . The hose small end should be inserted approx.hoses should be inserted into separator nozzles until they reach the bases of separator nozzles. Fuel Separator 1. c. 3) Remove separator from body. :. and take out separator by expanding the band. and pull it out while inclining it rearwards. and fit band to separator. 1 Separator 2 Screws A21-091 Fig. Connect hoses to separator and pipes as before .59 in) into pipe. 5) Disconnect air-breather hoses under rear floor. 3) Remove screws and nut installing fuel separator in trunk room. I 2) Connect air-breather hoses to pipe under rear floor. A21'092 NOTE: Ensure to tighten fuel separator instal· ling screw from rear bulk-head side. 4-96 5) Connect hoses to separator. 6) Attach rear trim and rear quarter trim as before. NOTE: a. 2) Installation 1) Connect hoses between separator and pipe. Before installing band on separator insert "L·bend" small hose pro· jected from separator upper nozzle into concave portion at the corner of separator. 1 Screw A 2 Nut B 3 Screw C 4 Screw D A21'087 Fig. The hose large end should be inserted approx. 4) Install separator in position with 2 screws.59 in) into pipes.98 in) into pipe. 4-95 Removing pipe compl NOTE: Be careful not to damage pipe ends. 4-94 4) Attach rear quarter trim and back rest of rear seat as before. 2. 2) Installation I) Attach pipe assembly with 2 screws.

Inspection NOTE: The fuel filter has a cartridge design and cannot be disassembled. 3) Disconnect hoses from separator. 1) Place "No fire" signs near the working area. Fig. b. Before starting the job. 2) Disconnect ground cable from battery. 4) Remove screw securing band to separator. Fig. pinch the delivery hose on the fuel tank side (as viewed from the fuel filter) with a pinch cock. 4-98 Non-BRA T . If water is in the fuel filter. 4) Remove screw securing band to separator. 2) Remove separator from rear quarter panel. to block the discharge of fuel. 2) Installation 1) Fit band to separator with screw_ 2) Connect hoses to separator with clips. Replacement NOTE: Before removing the fuel filter. 3) Install separator onto back side of rear side panel with 2 screws. and take out separator by expanding the band. Front BRAT A21·185 r I Fig. point the fuel outlet down and shake the fuel filter to remove water. If dust or dirt is noticed. 2. 4WD BRAT 1) Removal 1) Detach rear side panel cover on right side of rear cargo space. 4) Attach rear side panel cover as before.. 1) Unfasten the clip which connects the fuel hose to the fuel filter and disconnect the hose. be sure to carry out the following. replace the fuel filter. and take out separator by expanding the band. etc. Station Wagon 1) Removal I) Detach rear trim and rear quarter trim. 2) Installation 1) Fit band to separator with screw. and pull it out through side panel hole. 4·99 BRA T Pipe assembly d Front Non-BRAT A21·1B4 NOTE: The fuel filter has a cartridge design. 3) Disconnect hoses from separator. 2) Remove the fuel filter from the holder. 2) Detach separator from back side of rear side panel. Check the interior of the fuel filter for any indication of dust or dirt. b. Be careful not to spill fuel on the floor. 4·97 A2H65 4·8. 3) Install separator onto rear quarter panel with 2 screws. 4) Attach rear trim and rear quarter trim as before. Fuel Filter NOTE: a. 4.FUEL SYSTEM 3. 1. 2) Connect hoses to separator with clips. a.

endurance of the pump will be short· ened. Fuel Pump 5) fuel 6) fuel Remove three (3) nuts. 2) Disconnect clip ( except BRAT) and connector of electric wiring for fuel pump. A '21: . So. Installation 1) Attach cushions to fuel pump as follows. 3) Release clips. 5) Connect delivery hoses to pipe ASSY (or pipes) with clips. 1) Check the hose connections for leakage by operating fuel pump. 3) Check performance of fuel pump as follows.76 . don't operate pump without fuel. Removal 1) Pinch the inlet side hose of fuel pump with a pincher to stop gasoline leakage in hose disconnection. 8. Inspection In principle. 2. 3) Connect delivery hoses to fuel pump. c. 4) Remove three (3) screws.3 .09 .33 inHg) 1 Nuts 2 Fuel filter 3 4 5 6 Screw Pipe assembly Fuel pump Fuel pump bracket 7 Screws a~~*=~~~~~ b-l-'-I-. 4·102 Fig. 4) Install fuel pump bracket along with fuel pump to vehicle body with three (3) screws. 2. and take out fuel pump bracket along with fuel pump. Replace fuel pump ASSY if abnormal when checking pump. NOTE: If pump is operated without fuel. 4-100 Non-BRA T Front ® @ Discharge pressure: A21-187 1 Fuel pump bracket 2 Nuts 3 Screws 4 Fuelpump 5 Fuel fllter 2) Fit fuel pump to fuel pump bracket in position. Suction pressure Disconnect fuel hose (filter to pump) from filter and also put a finger on the hose end and check if the fmger is sucked..FUEL SYSTEM 4·9. Discharge pressure Disconnect fuel hose from carburetor and connect it to pressure gauge or manometer. 1. and disconnect delivery hoses from pipe ASSY (or pipes). fuel pump should not be disassembled.7kPa (0. Disconnect delivery hoses from pump.J a< b A21·188 A21-186 Fig. Measure discharge pressure while operating fuel pump. a. 4-101 BRAT 1.14. Operating sound Confirm that the operating sound of fuel pump is generated while engine is running. and detach pump from fuel pump bracket.0. and tighten three (3) nuts with washers. 6) Connect electric connector and clip ( except BRAT) for fuel pump.0 psi) or 9. 2) Check connections of fuel pump wiring for looseness. b.7 kPa (70 Ito mmHg.14 kg/cm 2 . 3.3 .2.4.8-13. Fig.

Inspection I) Inspect vapor separator if the foreign matter exists in it. and disconnect hoses from vapor separator. and water will be removed. Removal and Installation 1) Release clips. Front t To carburetor To fuel tank 2. so it should not be disassembled. Vapor Separator (Engine compartment I 1. shake it with its outlet downward. A21·189 Fig.FUEL SYSTEM 4·10. 3) Installation can be carried out in the reverse order of removal. 2) Pull out vapor separator from holder. 4-36 . 4·103 NOTE: The vapor separator is a cartridge type. 2) If water is found in it. Replace it if it will interfere with running.

Air cleaner. Delivery hose (between fuel pump and pipe). Connect delivery hoses and fuel return hose to fuel tank. Clamp from suspension bracket reinforcement. Installation NOTE: A21·139 Fig. 7) Under body floor. Fuel Delivery and Fuel Return Line 1. fuel pump. 8) Attach fuel delivery hoses with clips between fuel filter and pipes. and return hose to pipe. b.18 in). d.98 to 1. 4-37 . I) Connect fuel delivery hose and fuel return hose to carburetor. Connect delivery hose to delivery pipe with overlap 25 to 30 mm (0. c. c. 2) Install their hoses along with purge hose onto stay with clamp. 6) Install air cleaner in position. 2) In engine compartment. Clamp from fuel hose stay. 4) Connect fuel delivery hose to fuel pump. 1 2 3 4 5 Vacuum hose Carburetor vent hose Fuel delivery hose Fuel return hose Purgehose 2. Return hose (between fuel tank and pipe). b. Removal 1) Under body floor. detach fuel delivery and return line as follows. Delivery hose (between fuel pump and carburetor). e.41 in) from hose ends.FUEL SYSTEM 4-11. 5) Attach fuel delivery hose between fuel pump and pipe. 9) Attach fuel delivery hose and fuel return hose between fuel tank and pipes. 4·105 A21·168 NOTE: Ensure to inspect hoses and their connections for no leakage of fuel. 3) Attach their hoses with clamp at suspension bracket reinforcement. Return hose (between carburetor and pipe). Clips should be positioned with their center 12 mm (0. CD @ 1 2 3 A21·138 1 Fuel delivery hose 2 Fuel return hose Fig. Delivery hoses (between fuel ftlter and pipes). 4-104 a. Delivery hose (between fuel tank and pipe). detach fuel delivery and return line as follows. and fuel filter until they reICh the bases of eech pipe. d. f. a. b. Return hose (between pipe and pipe). attach fuel return hose with clip between pipes. a.

1 EVaporation tube 2 Clips Fig. a.59 in) and position a clip with approx. vacuum hose etc.FUEL SYSTEM 4-12. 8 mm (0.. Evaporation Line and Canister 1. 4. 4-107 A21·171 Fig. Evaporation tube (between pipe at bulkhead and pipe complete). 2. 3) Remove pipe complete. canister and canister bracket from wheel apron. 4-106 Fig. b. Installation NOTE: r \ \ Insert air-breather tube into airbreather pipe by approx. 5) Install 2-way valve with screw. and set canister by operating clip of bracket.t 10 1 Canister bracket 2 Canister A21·169 1 Pipe complete 2 Canister 3 Carburetor 4 Hose clamp 6) Attach air-breather tubes with clips between fuel tank and air-brea· ther pipe. and attach air-breather tubes with clips between 2-way valve and air·breather pipes. a. (from rear end of pipe complete). Hoses (between front end of pipe complete and canister). Removal I) Under body floor. 4·108 A3·258 4-38 . NOTE: Install 2-way valve with its "TO ENGINE" mark facing downward. 4) Attach evaporation tube between pipe at bulkhead and rear end of pipe complete. b. c. Air-breather tubes (between fuel tank and air-breather pipe).31 in) from hose end. Air-breather tubes (between 2-way valve and air-breather pipes). detach hoses and tube as follows. c. and connect purge hose. 2) In engine compartment. 15 mm (0. I) Install bracket with four screws. 2) Install pipe complete in position with two screws. with clips to rear end of pipe complete. U\j A21·119 Fig. 4·109 3) Attach hoses with clips between canister and front end of pipe com· plete. detach evaporation line as follows. vacuum hose etc. Fig. 2-way valve. \®-~ -. Purge hose.

by·pass hole. Readjust float leveL Replace float. Improper opening of secondary throttle valve. Replace. Ovedlow. Clean or replace. Inspect and adjust. Clean. Overflow". I) 2) 3) Corrective action Clean or lap contact surfaces. Worn throttle valve shaft. Clogged air bleed. or damaged contact surfaces. Loose plugs or jets. Worn Iloa t shaft. Improper throttle valve opening. Damaged or improperly tightened gasket under carburetor. Worn float seat or float stopper. Inspect and repair linkage. I Replace gasket or retighte. or replace. I Inspect and repair or replace lie pump. Clogged slow jet.JL-_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _. Inspect and repair or replace. 4) 5) 6) 7) 8) I 4. . High fuel pump discharge pressure. _ _ _ _ _ _ _. Overflow. Leaking vacuum hoses. Replace. .- I Inspect and repair linkage. Defective power valve or vacuum leaking from power valve system. Replace. 3. ." Replace. Clean. Improper number of main jet or slow jet. Trouble and possible cause Overflow Poor contact between needle valve and valve seat. Hitachi Carburetor Before troubleshooting. Overflow. Improper opening of choke valve.' --. Clogged idle hole.-.FUEL SYSTEM 4-13. Defective accelerating pump injector weight seat.. Inspect and replace. Damaged !loat chamber gasket or loose screw. Improper Iloat level adjustment. Retighten or replace. [[ 2) 3) )~Ogged main jet. Damaged idle mixture adjusting screw. Troubleshooting 1. See items for" 1. Excessive fuel consumption. or slow system passage. Inspect and adjust.- 4-39 . make certain that the ignition system and fuel line function correctly. Replace or retighten. See items for" 1. . Clean. Inspect and repair or replace. Rough idle -~-- Improper idle adjustment.. or damaged gaskets. Low output Adjust. Improper choke valve opening. ~ _ .

FUEL SYSTEM Trouble and possible cause Corrective action I 5. 4) Improper float level. 6) Malfunction of power valve piston. Replace. 7) Improper float level. 1) Clogged slow jet. Adjust float level. Inspect and adjust. 4) Improper adjustments of automatic choke. Poor high. Adjust. 4) Malfunction of secondary throttle valve. Hesitation Clean. 4) Malfunction of accelerating pump linkage. 4-40 . 7. 2) Improper throttle valve opening. 3) Improper fast idle opening. Clean.speed performance 1) Clogged main jet. Adjust. Adjust. Adjust. 2) Malfunction of choke linkage. main jet. 8) Malfunction of throttle valve. 2) Malfunction of accelerating pump inlet valve or outlet valve. Adjust float leveL Adjust. Inspect and replace. 3) Improper idle adjustment. Clean. 2) Clogged by·pass hole or slow system passage. Replace. 5) Damaged gaskets. Replace. Repair. 8. Poor acceleration 1) Defective accelerating pump piston or piston return spring. Difficulty in starting at low temperatures Adjust. Replace. 6. Replace. I) Malfunction of choke valve. 3) Worn throttle valve shaft. or emulsion tube. Adjust. 3) Clogged pump nozzle. 5) Defective power valve. Clean.

Replace float. Re-tighten bolts or replace gasket. Inspect and replace. Make sure wire connections are clean and tight. Make sure E. Check to make sure that power supply to bowl vent solenoid is good. Poor contact between needle valve and seat. c. Leaking vacuum hoses. Check to make sure choke coil assembly has electric supplied. d. inspect and repair or replace fuel pump.FUEL SYSTEM 2. e. g. d. Flange to body gasket defective. Make sure electronic control module is operating correctly. Improper idle adjustment. check feedback pulse solenoid for continuity and for shorts or grounded wires . f. Check to make sure choke coil assembly does not have an open circuit . f. Clean. Excessive fuel consumption a. c. Make sure anti-Siphon passage in body and air horn are open. e. d. Adjust idle. Improper float level adjustment. Dirt in low speed jet or in bleeds or passages. See section" I Flooding". Accelerating pump nozzle feeding. Flooding Possible cause a.R. Worn float hinge or damaged float. Make sure fuel return line is open and that restriction is not clogged. Rough idle a. Worn float hinge pin. Clean carburetor. Check solenoid for continuity and for shorts or grounds.G. b. Corrective action Clean or replace needle valve and seat assembly. Re-tighten bolts or replace gasket.replace if damaged. Replace hinge pin. 3. Damaged E. b.R. Choke valve not opening fully. valve closes fully with no vacuum applied. Flange to manifold bolts loose or damaged O-ring. or damaged surface. c. Readjust float level. b. g. Check to make sure choke valve does not bind.if so replace. Intake manifold to head bolts. valve.G. Re-tighten screws or replace gasket. Flooding. Bowl vent solenoid not functioning. Connecting rod not installed properly. Dirty air bleeds. Make sure connecting rod is attached at both ends and that bushings are in good shape. . Carter-Weber Carburetor Trouble I. e. Check discharge ball and weight. 2. High fuel pressure. Feedback pulse solenoid not functioning.

b. h. i. Check feedback pulse solenoid· for continuity and for shorts or grounded wires replace if damaged.replace if damaged. Check solenoid for continuity and for shorts or grounds. Damaged or disconnected accelerating pump fuel delivery tube. check feedback pulse solenoid for continuity and for shorts or grounded wires . Possible cause Corrective action See section" I Flooding". Improper float level. Inspect exhaust system replace any faulty parts. h. Clean.if so replace. Make sure connecting rod is attached at both ends and that bushings are in good shape. Check to make sure choke valve does not bind. See section "2 f". Check to make sure that power supply to bowl vent solenoid is good. Dirty fuel filter. Dirty or damaged intake or discharge check balls for accelerating pump. 4. f. Make sure wire connections are clean and tight. Bowl vent solenoid not functioning. Low fuel pressure. Low power output a. Dirty or clogged main jet or main system. Replace fuel filter. Damaged accelerating pump diaphragm. Choke valve not opening fully. Re-adjust idle settings. Make sure wire connections are clean and tight. Inspect and replace. Clean. d. d. Dirty or clogged main system. Inspect and re-adjust float level. e. Repair or replace fuel pump. Inspect and replace. Flooding. • 4-42 . g. Rough idle h. Hesitation and/or poor acceleration a. Clean or replace. Check to make sure choke coil assembly has electric supplied. i. Feedback pulse solenoid not functioning. b. Clean. carefully and j. Check to make sure choke coil assembly does not have an open circuit .FUEL SYSTEM Trouble 3. Improper throttle valve opening. Make sure electronic control module is operating correctly. Make sure electronic control module is operating correctly. Replace. Re-connect or replace delivery tube. Improper idle adjustment. e. S. Restriction in exhaust system. Damaged choke break diaphragm. Fuel nIter dirty . g. Inspect and adjust throttle cable. c. Connecting rod not installed properly. c. f. Feedback pulse solenoid not functioning. Clogged accelerating pump nozzle. Feedback pulse solenoid not functioning. j.

g. Inspect exhaust system replace any faulty parts. Feedback pulse solenoid not functioning. Improper throttle valve opening. Poor high-speed performance a. f. carefully and 6. Check solenoid for continuity and for shorts or grounds. Bowl vent solenoid not functioning. b.FUEL SYSTEM Trouble S. Feedback pulse solenoid not functioning. Vacuum supply hose to choke break diaphragm clogged or cracked. e. Clean. 7. Make sure electrailic control module is operating correctly. I.. Inspect and replace. Restriction in exhaust system. Fuel pump pressure low. c. Improper adjustment of choke system. Damaged choke break diaphragm. f. Make sure electronic control module is opera ting correctly. Improper float level. Adjust fast idle. Inspect and replace. Make sure valve does not stick and that valve closes fully. Hesitation and/or poor acceleration Possible cause k. Difficult starting at low temperatures a. 4-43 . Check feedback pulse solenoid for continuity and for shorts or grounded wires replace if damaged. Dirty or clogged main jet or main system. Check solenoid for continuity and for shorts or grounds. c. . Make sure all adjustments are correct. Improper fast idle speed. Check to make sure that power supply to bowl vent solenoid is good. Inspect and adjust throttle cable. d. Repair or replace. Bowl vent solenoid not functioning. b. Malfunction of choke valve and linkage. Corrective action Repair or replace. e. Fuel pump pressure low. h.. Check to make sure that power supply to bowl vent solenoid is good. Make sure wire connections are clean and tight. Make sure wire connections are clean and tight. Dirty fuel filter. q./J Check feedback pulse s~noid for continuity and for shorts or grounded wires replace if damaged. Replace. Adjust float level.

To prevent water condensation. and tighten securely. especially ground. etc. c. air bent tube and fuel filler pipe. Replace fuel filter. mountainous areas.FUEL SYSTEM 3.--~. correct or replace air breather tube or air vent tube. Cracked fuel separator Retightening Correct or replace packing. Cracked fuel pipe. Inspect or retighten each connection part. Defective drain packing of the fuel tank. Clogged or bent fuel pipe or hose. Other Components Trouble and possible cause I. top off the fuel tank or drain the fuel completely. Leakage or blowout fuel I) Loosened joints of the fuel pipe. correct or replace fuel pipe or hose. (i) Water may accumulate in the fuel tank. 2) 3) 4) Inspect connections. When the vehicle is left unattended for an extended period of time. Clogged or bent air breather tube or pipe 5) 6) 2. skiing areas. In snow-covered areas. correct or replace air breather tube or pipe Lowering of fuel pump function. Replace fuel pump. Gasoline is smelling inside of compartment -------~. Replace fuel pump. Clogged dust or water in the fuel filter. (ij) Also drain water condensation from the fuel filter. Defective welding part on the fuel tank. 2) 3) 4. o Trouble in electromagnetic or electronic circuit parts. Protecting the fuel system against freezing and water condensation. Defective packing air tighteness on the fuel saucer.--. 4-44 . Noise 1) Large operation noise or vibration of fuel pump Replace NOTE: a. Clogged or bent air breather tube or air vent tube. clean or replace fuel tank. 2) 3) 4) 5) 3. Refilling the fuel tank. b. hose and fuel tank. Retightening Replace Replace Replace Clean. Clean. Replace separator. Insufficient fuel supply to the carburetor Corrective action 1) Fuel pump will not operate 0 Defective terminal contact. Clean. (i) Refill the fuel tank while there is still some fuel left in the tank. (i) Cold areas . Air is mixed in the fuel system. where ambient temperatures drop below oDe (32°F). Defective fuel meter indicator 1) 2) Defective operation of fuel meter unit Defective operation of fuel meter Replace Replace 5. "---- 1) Loosened joints at air breather tube.

etc. drain water which may have accumulated in the fuel filter and fuel tank in the manner same as that described under the Moderate Areas. Special Tools 498167100 Main Jet Driver Main jet (C-W) Fig. Refueling will also complement the effect of anti-freeze solution each time the fuel level drops to about one-half. use an anti-freeze solution in the cooling system..FUEL SYSTEM throughout the winter season. 4·111 A8-426 4-45 . indicated on the label affixed to the anti-freeze solution (water removing agent) container before use. 4-14. (ii) Moderate areas When water condensation is noticed in the fuel filter. After the winter season. • Observe the instructions. drain water from both the fuel filter and fuel tank or use a water removing agent (or anti-freeze solution) in the fuel tank. notes.

5-22 5-4......... 5-10 4....................2 1............•............. 5-48 1.••..... 5-48 3..... General Precautions ............... EVAPORATIVE EMISSION CONTROL SYSTEM ...•....... Inspection ...............••.. Inspection ..••.... 5.............. Schematic Drawing .•...........4 5-3..........3 2. Wiring Diagram ....................8 3...... Description ...•.........•.................... 5...................•.•......• 5-49 5-5. 5.............•.......3 1...•..•••.•. Description ............ 5......•.......... System Application .. Schematic Drawing ..........................• 5......4 1..•...•.•......3 EXHAUST EMISSION CONTROL SYSTEM ..... 5-49 SlIBARU ... CRANKCASE EMISSION CONTROL SYSTEM ....•..CHAPTER ~ Page GENERAL DESCRIPTION EMISSION CONTROL SYSTEM 5-1.. 5-48 2. 5.....•.•..•.....•.........•.............•... 5.. 5-18 5......•••.••......... 5...2 2....................... Inspection .. 5.......•••.. 2............ Troubleshooting for ECC System ......... SPECIAL TOOL ... Description ..2 5-2..•..••.

System Application There are three emission control systems which are as follows: 1) Crankcase emission control system 2) Exhaust emission control system 3) Evaporative emission control system Destination U. vd correct. a. Always make sure that connections' are s~ure and '. '~ays b.EMISSION CONTROL SYSTEM 5-1. Abbreviations used ECC: Electronically Controlled Carburetor EGR: Exhaust Gas Recirculation AI Air Injection 2. Failing to do even one item can cause the engine to run poorly and increase exhaust emissions. To disconnect vacu'um hoses. pull on the end. Specifications for each system may differ depending on the destination area. General Precautions 1) Know the importance of periodic maintenance services.'1 a. 4) Avoid coasting '. 3) Check hose and wiring connections first. " .t 5-2 . 5) D~not damage parts. troubleshooting. 2) Determine if you have an engine or emission system problem. When check the engine and the ignition system first. Every service item in the periodic maintenance schedule must be performed. b.A. a. .with the ignition turned off and prolonged Itngine braking. Engine problems are usually not caused by the emission control systems. b. General Description 1. The most frequent Cause of problems is simply a bad connection in the wiring or vacuum hoses. Non-California California Item Crankcase emission control system Three-way catalyst attended with ECC system Oxidation catalyst EGR system Exhaust emission control system Al system Ignition control system Anti-afterburning system Shift-up control system High-altitude kit Evaporative emission control system Canada 4WD Non4WD • • - • • • • • - • • • • • - • • • • • • - • • • • • • - i I i • • • • • • • NOTE: a.S. not tnt::tniddle of the hose.

The system consists of a sealed oil filler cap. See the "Vacuum connections label" under the hood. To intake manifold 1 Case 2 Valve 3 Spring A10-oS6 Fig. When disconnecting vacuum hoses... e.. air cleaner. the test bar should be inserted carefully to prevent terminals from bending. Disconnect the hose from the PCV valve. a. When steam cleaning an engine.V. use tags to identify how they should be reconnected. the connecting hose between air cleaner case and connecting hose of rocker cover on #2-#4 side reduces the vacuum to prevent this. double check to see that the vacuum hoses are properly connected. d. Fresh air . then lightly open and close the throttle valve (increase and decrease the engine speed a little). a. and drawn to the intake manifold through PCV valve together with the blow-by gas.060 10 Crankcase 11 Fig. not the wire. in this case. Blow-by gas Mixture of air and blow-by gas 1 Connecting hose 7 9 Oil filler cap (Sealed) 2 P. When checking continuity at the wire connector. carburetor from water. With a finger attaching top of the valve. the intake manifold vacuum is not so strong as to introduce all blow-by gases increasing with engine speed directly through the PCV valve. @ @ @ -@ ® . It is normal when you hear it move. or relays. The valve alone may be checked by shaking it. Under this condition. Crankcase Emission Control System 1.. 5-2 . valve 3 Carburetor 4 Air cleaner 5 Air filter 6 Connecting hose 8 Connecting hose Rocker cover on #2 . If they are dropped on a hard floor. To pull apart electrical connectors. replace the valve. The hoses may be cleared with compressed air. rocker covers with an emission outlet and fresh air inlet. coil. Inspection I) Check the positive crankcase ventilation hoses and connections for leaks and clogging. At the wide open throttle. because under this condition. After completing a job. c. 6) Use SUBARU genuine parts. the fresh air is introduced into the crankcase through connecting hose of rocker cover on # 1-#3 side. protect the distributor. Under the special operating condition. 3) Check the PCV valve as the following procedure.#3 side A10. However. b.. d. the blow-by gas in the crankcase flows into the intake manifold through the connecting hose of rocker cover on #2-#4 side and PCV valve by the strong vacuum of the intake manifold. 2) Check the oil filler cap to insure that the gasket is not damaged and the cap fits firmly on the filler cap end. connecting hoses. 5-1 2.C. The valve is in good condition if a vacuum is felt by the finger. engine oil sometimes blows up into connecting hose of rocker cover on #2-#4 side and flows into the intake manifold by the force of the vacuum. If not. they should be replaced and not reused. a part of blow-by gas flows into the air cleaner through the connecting hose of rocker cover on # 1-#3 side and is drawn to the carburetor. 7) Record how hoses are connected before disconnecting. such as sensors.. Be careful not to drop electrical parts.#4 side Rocker cover on #1 . b. c. 5·2.EMISSION CONTROL SYSTEM b. Description The positive crankcase ventilation (PCV) system is employed to prevent air pollution which will be caused by blow-by gas being emitted from the crankcase. Replace it if it fails to move. pull on the connector itself. PCV valve and an air cleaner. At the part throttle. such as steep right turn driving.

I:: : . *. .r:----------:-. ~. Without leak ---- [Under hood temperature Vacuum switch(H 27°C(81"F): OFF] [0.-1.7(0..::..-1.-:. _. .7 mm (0.. ....039)dia.a '~ t ATC r~" .- --Q-' l : I r-SO~~id I : I I I _ _ _ _ _ _ _ _ _ -' I Orifice I [0.. ::I =.J (10 advance system) L 0 -----"0 L r -· ~ Thermo valve (1m [Water tem· perature over 60"C(140°F): ON] Vacuum switching Choke break diaphragm valve Battery IG switch To I I I ---t-_ I ~ kic~-d?Wn Relay --. : . - - n o o Ut en ~ n Z r :::I .::.39)dia.f.-13.'iii' :'1'1 ...-26.. J I I IG.. OFF] . o Unit: mm (in) .-----.--.I 11'11 II nnn Air cleaner fl~?rifICe Mfi.:J:=~j Duty solenoid valve (Slow) IG.] ® +~ ®®..0(0..-7.-----~ I solenoid via relay-"""1 (AT only) I Relay~ L ijJ :: L I I EGRvalve : L I r ~----- r--------:...020)dia.9(0.. i -.----.1-. .t-<t> I 'I J1-::1 i.. ---.0751 dla..(-11-) (Wall ec va. ~ .028)dia. . ve SW"'-~ I To fuel pump I L-t:.------.-100mmHg.. (!).ACC : I CD ~ 5..... :r :. J w· ch Onf.. . 0 Solenoid valvem Thermo valveu~r -C-h -k. / l _______ Thermo valve ~ MT except4WO Other than the above L .. . .. 0--3.J valve lUll r-r----=-=====::. Distributor To fuel tank ... . Fuel return onflCe [0. ® I :+ : IPTCautochoke I In' II .. ....87InHg).. CD a en ~ -< m 3: ~ir Canister suction valve I (With cut valve) Vacuum switchUII [0.I ! LEil Silencer' 1600 Model Orifice only [0...--l~ I I I I r--I r (Digital) ! . ~ ~ 3: • '" !!....94inHg): ON] ~ ~ - (9) - !'fP\r---------l » . I --l l J/ n PCV valve 10iO. a n _.-200mmHg..7kPa(0.. a: :r 8. .] I t I I : L I I L_ ~ ECM OUT IN j:- t::=~~ .:-:-® t [1.. :::: 1:.ce I s It [~. • Orifice S/L 0.3kPaI0. I Duty solenoid' I valve(Main) Orifice U ~ i --+@ L~.. 0.....\ ECS light (On dashboard) To temperature gauge -I ::D 0 r- Heat shield temperature)~. n n I» C9 I: i -- I t® U"I 1'1.5(0... :I D:I (II • • n en W !!. .028 in) dia. 3: o_ _ en m .. I . ...::::...7(0. r ... ] . s : _. '< (b)_____ (i!) ..028)dia...] I r::c--------lI Surge tenk L~ ~J_.. n • ..

O P for H/Avehicle till till n :J To fuel pump Anti after burning valve L.[ ~-~ 1 &>:: I .. . f •• 1I:!!Jnr br~. li H/A I I I II II PTC auto choke ~ t=uel return orifice Thermo valve (II) (Water temperature over 18°C(64°F): OFF) !!.. I L T - ' L-ll____. - :.~ 9:J 'GRwl~ @l !Ii z 0 0 ~ j' • .~. . ~ I AT 4WD .4 (0.055) dia.) OrifIce 3!: 0 a.028) dia.051) dia... Orifice S/L MT except 4WD 4WD MT 0. 0 :J Silencer -___ I -@ Orifice [1.5(0."1 ! hSii" c 0 ~ ~ ..) ~ ..7(0... CD 3!: n X . Choke break diaphragm 0 [1... .3(0. . Orifice 1.. 0. 3!: 0 Z 0 Z 0 m ~ ~ iii' I t t~:.) ~ r:. Unit: mm(in) *1. Without leak Without leak 0.510...7(0...:!..039) dia._.' n till ~ -f ::D Thermo valve (f) (Wall temperature) ~ C" .028) dia.010..:j... "'rI IG ATC ~ Idle compensator [55-65°C(131-149°F)) ~ ...039)dia. • ~ Distributor To fuel tenk .7{0.. II I !: ~ i I ---@ till a. 1 AT . except4WD 4WDMT AT & 4WD AT _ -- Thermo valve (Under hood temperature over 2PC(Sl° F): OFF) » . - Unit: mm (in) ... Unit: mmlin) *2.. :J n . 8..---~ .020)"'.en ~ m 3!: -< 0--.020) dia. 1._____ -.f~r [0.r till CD a.051) MT dia.e ~I ~I t " [0. __ ...0{0.028)dia. 1.3(0..

1 .----T @).810...J I I L"Orifice[1.. L -J..075} dia.--=--=-.J r-": . Silencer @ ®.. CD :::J: ii' ::::I s: 0 2 m = .7 Bowl vent solenoid Surge I tank Duty solenoid r:::!:0rm. .tiS· .O"~ : ._----1I ..028)dia.710...-'ii" ~ L ' Thermo valvelIlI) [Water temper· ature over SO°C . Duty solenOid I valve lSI ow} L . 1.067) dia .0311dia.7kPato. '1 Silencer . s: en -< en -f m nister ...[1." z: ~.O~I~..-13.0[O.) .. Catalyst IPt:Rh=9:1) Unit: mm (in) h) . ...--._ -.":..3kPa(0.. I 2 Air filter . ~IL ' I.7 I IG tto.. . .-20OmmHg 0..) 0 Relay 2 ::::I .. _ _ _." [~5!..- E - : -·iS~S~~..f. system) I Orifice I.87inHg}: OFF] ..!.."!"S\ IG switch .j-_U---G) -------. EGR valve only I ~ f I ~ __ _ (10 advance I I 0 .n-... I i r i L--------r..910.94inHg): ON] IG coil n » 9 .~ ) I Vacuums.028)dia.. ~_ ~ ~ (fr--.---.l IHigh altitude configuration only) To temperature gauge Thermosensor LL~~- ~J--::..----.....0391 dia .~. ... Check valve UI --:.e_I' [0.." s: 8.Ll® j _. 'L-G) II I --+0 l To fuel pump ~.--j-h.c-.010.. L [0. ... '~F:e-.. .J Orifice .=-_ :/' I I I I I I _ ~~ • I - ---- ::- rPi!l Relay~ iMd ~~-=-::-'::-'::-~-"~-i"i" --. cr c ~ n C» ~ 8 2 -f ::D - ~ .. Without leak H/A [Unter hood temVacuum switchll) peratu re over [0.. Thermo valve ~ /'ii»..:v .-7.-1 Unit: mm Un) • Orifice SIL 0..... 0 ... ~}J-"'--11 t-.. 27°CI81°F): OFF] 0. I 1....d:: fl I I fr r·-t.710. ~ \ \ \ L ~ Lf.-.__ J II' Q.4-J.' Klck-O?w~ OP for H/A vehicle Battery IG switch Co.+ valve Hm - 1600 Model r .-.) n----1 : I L::l:4Lj'1 ...I " i.l'rr ~[1.. ~ c 20 . 1140"F): ON) Vacuum switching valve Choke break diaphragm I I ---..itch(II)~ [0--2S.==:'::l I _ _..-100mmHg. n L ___ IDigitall .. r----ID' =':1 :~I sOllenOid via reay IATonlyl ____ _ .---[0. .----+------:---n (TI J" ::i " :: II 1£:.028) dia... > _____ . valve IMainl • 10...067in)diaJ'1 switch IMT at SIL only) I I I : L_ --_ 'I'I I L-I ECM T IN OU ::::I !!.... I • I r ATC Air cleaner Orifice -.n..710. ECS light Secondary main air IOn dashboard) bleed ICarb.":[J _..:.

.-11.j .c-. Relay I ______ .~~-11-1rt t-:":=':--: I 0 I I ~ EGR valve . ."~.-300mmHg.-:LJIL'Silencer ::r 0 h - .~-J ~[l.-.: I m::Jl " ..:::!. I I • i! ~ :'::f~~ ~~ ~ ~ =-=--~=-~-::-----~' .7(0." ~ ~ i~ ATe i J: ~____ t. 1'Wi.."h ECM !!."_" I I . CD ~ tr :D E! 0 r- o t Vacuum switch 1111 [0. 0. LEl - • ~ \. . ..J I L OP for H/A vehicle Battery I G switch Z 0 ::r 0 0 0 ::E J::. (0) ! Sll~h).-----. ~ ECS lamp IOn dashboard) Z .810.3kPa(0.~.. i I J t. A .--~ ~~ I :------=-:.:::....____ ____ 0 0 I o Distributor To fuel tan k ~ _ : canister '" :::. ..0671 dia._-__ ___ . ~ ~ 0 Z 0 Z -t 0 0 s: temperaturer 0 ..'Ti. 0.0311 dia. .0kPalO.':'! ACC '" I 0""" 'd 0 WIW" I:D"~I ~ T pump ii" Q. '" 0 Do".---0 ------ @C-· 10 ---- '-_~w.~ Unit: mm (in) ____ ..:. -~ ---.r----' -.orificel : I I 0 .-3.~i~--J r-~':.n! fl.:. (j).94inHgI: ON) IG coil ~ 9 .-100mmHg.11 1. .. Thermo valve Air suction [Under hood temperature valve II over 27"CI81°FI: OFF] Catalyst (Pd:Rh=5:11 ----~ I ~ Vacuum switch III [0.flf' ~ fJ8i'---® S.:::. . A.. 0 .. 1 .81inHg): OFF]-- Dol • ~ ..51)dia.tP" .@ __ __ ____ 0 .~IJ 0 • ____ •• 0 0 I • 0 0" ..U.-13.l . m 'r-- en '0 I» . ::r :::.I.r:. n --- . tr C en -< en -t m s: j-J Unit: mm lin) • Orifice ~lF---~ Ai r suc tion valve I IWith cut valvel S/l 0. ! ~ .-. '0 I» .-40.J'Ijl.. H/A 1.00 wlwlll i .'to! 1 . CD OUT IN s: 0 tl +1-+1-l. r~~=k=----1 ~ Selection signal for carburetor ~~ To dashboard temperature meter 131O. _ _--.

. 9 ~ . CD m c -e' "D 8.......1jQ]I{7 m "" • . en < IG ..' ~ o.So .~- 3: . ~ ~a I I F/P r----Icontrol &.. ... --:::I N • Cleek * 0'1 gJ I~ I 1111111 II! II.."~. .OY~ ....... .. ' .. monitOf" Sub input (I) Input carburetCM" setection Input 0" sensor PTCcontrol Sub input (2) GrOlmd fOf" control Duty monitor 0 r- ::D -f en m Sub OUtput (3) Shield Sub output (2) Trouble code OutPUt solenoid wive 11 Sub output 111 Warni"9 leCS) ~ -< 3: InputH/Asw Input VAC ow I Input VAC sw II Output solenoid wive III Input thennosentOf' J. ...r... '" .I J. .....::....relay =CD 3 I~ rg 0 Z Z (") 0 J:...-/ LOn{ L ~ ::r m " a .... " .":=:~C hold Output KID .. iJI .J Output solenoid velve I Output duly Modee_ ~: l> LO : t PC. w:: ~ Ground for control 10pul".(") (") KID hold relay! . ... _'. w .....a " • . KID switch IG source 0.. -a Y'I "'EIiE switch Ignition-startar - I. ...

.~'" » . CD 3: 3L 28W D m Fuse box Distributor 2BW 2B vme 0.B5 LR 2BW ~EFf) YB 2B 0.85LR c=r:r"/ .>- I ell .85 LR LB o F/P control unit (") o ::0 2 -t .. g: :E g -< &/10 (I) m m 3: ~ (5 2 /' J..8 0.2 8.85L BW PTC\'U -::-:::- Anti-dieseling solenoid harness ~ 0.ciS' '"rI <tt CO 3W$ 2B \ N 1..85 L Y ~ m 3: If To rear YG BW LY~Y~ y~0.JI III >.25 L 22B .85~ 8 0. Check AiR S 3 U'I 0..85 LR 'a -e" C !.85 L 2B 0.~ terminal 0.. . .t YB to fTEllfl~ 0..85E] LR -F! C .. 9 IJI Oil Thermo pressure switch switch F/P .

. -~ TIrr . The catalyst is used to reduce HC. To avoid damaging the catalyst. : ' ~ A10-177 Fig.JI _____ @ : I I I ----- -----..--. .. Oxygen (0 1 ) sensor b. and a thin film of their mixture is applied onto honeycomb or porous ceramics of an oval shape (carrier). ECC system is mainly made up of following component parts.91O. Duty solenoid d. CO and NOx. and permits simultaneous oxidation and reduction. Carburetor They compose a feedback system to control the air-fuel ratio during operation by supplying a measured air into air bleeders of the carburetor. To avoid application of feedback during certain driving conditions.J . These concentrations vary with the air-fuel ratio. ---. I . I 1 I I I I I I I I I ( I 1 I ® ~--. I I ® :--~--: - ' ~ ... only unleaded gasoline should be used.J I I -. ... a. I High altitude configuration only "'-----_ . 5·10 High altitude configuration only A10-178 5-10 . 5-9 2) Non-4WD of non-California models (C-W carburetor) To temperature sensor of air temperature control . Electronically Controlled Carburetor (ECC) system is employed with threeway catalyst for this purpose. CO and NOx in exhaust gases. Unit: mm (in) I I I I I I I I I I l-----I1~' @ [-r I J _I _____ .07S)dia. Electronic control module (ECM) c.---_--=. a thermosensor and an engine speed sensing circuit are also provided in this system. For high altitude configuration..EMISSION CONTROL SYSTEM 3. I) Component layout I) California models and non-4WD of non-California models carburetor) 2 To temperature sensor of air temperature control I Control air cleaner 2 Intake manifold 3 Duty solenoid valve (main) 4 Duty solenoid \~Iifornia valve (slow) \odelOnlY 5 Carburetor 6 Surge tank 7 Thermosensor 8 Oxygen sensor 9 Vacuum switch I 10 Vacuum switch II 11 Exhaust manifold 12 Electronic control unit 13 Ignition coil Orifice 1. 1 I I . The air-fuel ratio needs to be controlled to a value within the very narrow range covering around the theoretical (stoichiometric) air-fuel ratio to purify the components efficiently. Description 1) Three-way Catalyst Attended with ECC System The basic material of three-way catalyst is platinum (Pt) and rhodium tRh).=1. 7 ' 1 Fig.. a balance should be kept among the concentrations of the components. the Hitachi carburetor is also provided with a circuit to supply air to the secondary main air bleed. vacuum switches.. To obtain an excellent purification efficiency on all components HC.--iI I I I 2 3 4 5 6 7 8 9 10 Intake manifold Duty solenoid valve Carburetor Thermosensor Oxygen sensor Vacuum switch I Vacuum switch II Exhaust manifold Electronic control unit Ignition coil I I :0": '-- I I I I I - .

ECM issues signals to duty solenoid valves to let a little air into carburetor so that the air-fuel ratio will be changed toward rich mixture. ECM judges whether the exhaust gas at the manifold is made from rich or lean mixture against the stoichiometric. Duty solenoid valve has a construction as shown in the illustration. A 10-181 A5-679 Fig_ 5-11 Fig. that is. the acceleration rate beyond a certain engine speed is changed in steps to obtain greater acceleration at higher engine rpm. The average flow rate of air passing through this valve to carburetor changes depending upon the period of time during which the valve is opened. This allows the valve to sensitive· ly respond to the Rich-Lean mixture as measured by the O2 sensor. 1 cycle ~ 1) Oxygen (0. sensor. 0. The force is larger on the rich side (smaller air-fuel ratio) and smaller on the lean side (larger air-fuel ratio) of the mixture. · ON-duty time x lOOot o It Dut y rat 10 = . The status that a voltage is applied to solenoid. As the result. sensor is higher than the specified level. 5-15 . the air-fuel ratio maintains at around the stoichiometric value. In steady-state operation [where the vacuum switch (II) is on]. sensor is installed on exhaust manifold. concentration in air to that in exhaust gases. [ON duty Open I tJ r- r- A10-t)93 Fig.) sensor 0. one duty solenoid valve is unified in the carburetor as shown in the figure. while on CoW carburetor. On the other hand.5-12 O 2 sensor 2) Electronic control module (ECM) According to the signal from 0. The current air-fuel ratio is judged to be rich mixture when the 3) Duty solenoid valve On Hitachi carburetor. Cycle I Duty solenoid valve (main) 2 Duty solenoid valve (slow) 3 Connectors Al0-141 (C-W) I Feedback: solenoid valve 2 Connector A10-142 Fig. According to these feedback operations. ECM issues signals to duty solenoid valves to let much air into carburetor. The light-weight valve (A) repeats opening!closing at a short cycle according to the signal output from ECM. 5-14 The ON-duty duration varies at a fixed acceleration. and has a characteristic that the electromotive force is changed drastically with respect to the stoichiometric airfuel ratio. the valve is lifted is called "ON-duty". and issues signals to duty solenoid valves. and duty ratio is given by the follOWing equation.5-13 Electronic control module tEeM) (Hitachi) Contact plate c /Louver ~/Zirconia tube A10-180 Fig. two duty solenoid valves are installed on the intake manifold. thereby the air-fuel ratio is varied. with the Rich-Lean mixture as measured by the O2 sensor.. the air-fuel ratio is judged to be lean mixture when the electromotive force is lower.EMISSION CONTROL SYSTEM 2) Component parts of ECC system electromotive force of 0. sensor is a kind of concentration cell that generates electromotive force according to the ratio of 0.

Q94 S 6 5-12 .5-19 Thermossnsor 3) Determination of the duty ratio is as follows.5-17 Vacuum switch Is O2 sensor activated or not? Engine rpm Vacuum Sea level or high altitude? 4 A10. thermosensor and engine speed sensing circuit These are additionally provided in the ECC system so that better driveability is assured by avoiding the application of feedback.. To low speed circuit or high speed circuit control module A10-146 (C-W) A10·143 Fig. To intake manifold or carburetor Diaphragm A10·145 Thermistor element 1 Thermistor element 0 Fig. 5-18 Vacuum switch A10-148 A10-o92 (Hitachi) Fig. 5-20 Thermossnsor (C-W) S) Vacuum switch (II) The acceleration (increasing/decreasing rate of the ON-duty duration) increases for several seconds immediately after this switch is turned off. After a lapse of S seconds.EMISSION CONTROL SYSTEM (Hitachi) To electronic control module Spring For ECM For temperature gauge • Lead wire Solenoid . A10-147 Fig. the acceleration returns to the steadystate operating condition. To control air cleaner • To carburetor.. allowing the valve to sensitively respond to the Rich-Lean mixture as measured by the O2 sensor. I~ 1 Item Carburetor Water temperature Device ECM Thermoser O 2 sens6r Engine speed sensing circuit Vacuum switch (I) Grounding wire (Optional) 2 3 1 Connectors 2 Vacuum switch (0) 3 Vacuum switch (I) Fig. 5-16 4) Vacuum switch (I).

039) 1. The vacuum signal to control the EGR valve is picked up from the port near the slightly up stream portion of throttle valve after being modulated with the atmospheric pressure through the orifice (EGR leak orifice equipped models). \. c·w ct Fig.EMISSION CONTROL SYSTEM 2) Oxidation Catalyst The basic material of the oxidation catalyst is as follows: Canada models and 4WD of non· California models: Platinum (Pt) and Palladium (Pd) Non4WD of non-California models: Palladium (Pd) and Rhodium (Rh) A thin film of their mixture is applied onto honeycomb or porous ceramics of an oval shape (carrier).. only unleaded gasoline should be used. .0 1.«10) Non"'W HUadd """. Thermo vacuum} valve I I I LEGR valve Thermo vacuum EGR pipe valve I EGR pipe 3) Exhaust Gas Recirculation (EGR) System Exhaust gas recirculation (EGR) system is aiming at reduction of NOx by reducing the top combustion tempera· ture in cylinders through recirculating a part of exhaust gas into cylinders. To avoid damaging the catalyst. EGR leak orifice mm(in} US.028) 4W1> SlL - 0. Cafifomi. Additionally for non4WD of non· California models."" 0.7 (0.020) GaRb " w' / ct * 1 #1-#3 . the vacuum signal is modulated with the atmospheric pressure through solenoid valve II at the specified driving condition.5 (0. 5·22 NOlt. EGR pipe .1 (0..7 (0. . the vacuum signal is modulated with the atmospheric pressure through the thermo vacuum valve I.. l'" QR.ll39) - - A10·182 . .1 (O. At the specific wall tempera· ture of intake manifold or below.067) - - - - 0. I EGR valve ..1 (0."" 0. #3 Cylinder head OM-721 \#1..1 (0. The catalyst is used to reduce HC.028) (O..5 (0.cWO 0.A. ... The EGR valve opens in response to the engine driving conditions and a part of exhaust gas flows into cylinders through the intake manifold. California models and 4WD of non·California models (MT) rAir cleaner (AT) I .021) AT .061) 1. r A10·183 NT H/A AT - 1..7 NT (0..#1. Canada models. EGR valve L---D--~i ECM : L"-D"'~ ECM Thermosensor Thermosensor Non-Califomi4 ~ #1-#3 pipe c. #3 Cylinder head OM·722 Fig. I .028) 0.oJI) D.wo . .0 (0. . 5-21 INon4WD of non-California models I (MT) Solenoid valve II (AT) .qt> . CO in exhaust gases.

~Electronic control unit rThermosensor rI : U ------------~ Check valve II : I I ~ AI. Under such driving condition as wideopen-throttle acceleration. 1) California models 1) Component parts • Air suction valve I (ASV) with cutoff valve • Silencer • Air suction pipe • Air introduction hoses • Air cleaner • Thermosensor • Solenoid valve I • Check valve II • ECM Secondary air is supplied to the exhaust port on the #2-#4 cylinders side by ASV. the reeds of air suction valve are opened and simultaneously fresh air from the air cleaner is sucked by itself into the exhaust passage. the reeds are closed to prevent the adverse flow of exhaust gas. the positive pressure reaches the ASV. the ECM gives a command to close the vacuum passage of the solenoid valve and open the atmospheric pressure passage. After the period.. the check valve closes the vacuum circuit to confine the vacuum so as to hold the cutoff valve open for that period. 5-23 AI system 5-14 . the reeds of air suction valve are opened and simultaneously fresh air from the air cleaner is sucked by itself into the exhaust passage.. whereby the cutoff valve being closed to deactivate the ASV. When the negative pressure of pulsation is transferred to the ASV. 5·24 ASV I with cutoff valve (Nippon Denso) CD 4 1 2 3 4 5 6 Diaphragm Vacuum inlet Secondary air inlet Reed Stopper Secondary air outlet ® A10-18G Fig. then the vacuum in the vacuum chamber of the cutoff valve goes out through the solenoid valve I. pipe Air suction valve I with cutoff valve A10·184 Fig. the reeds are closed to prevent the adverse flow of exhaust gas. the positive pressure reaches the ASV.. When the negative pressure of pulsation is transfered to the ASV. on the other hand. The AI system is controlled both by coolant temperature sensed by the thermosensor and time governed by the ECM. ? Air suctiOn}. Secondary air outlet A10-185 Fig. on the other hand. reed valves) through the air suction pipe. When.EMISSION CONTROL SYSTEM 4) Air Injection (AI) System The AI system is a major emission control system whose purpose is to promote oxidation of hydrocarbons (HC) and carbon monoxide (CO) while the engine is cold. When the coolant temperature is below 35"C (95°F). whereby the cutoff valve being opened by the diaphragm vacuum actuator to operate the ASV. When. the ECM gives a command to open the intake manifold vacuum passage of the solenoid valve I for the period of 123 seconds. 5-25 ASV I with cutoff valve (NOK) 2) Canada models and 4WD of non· California models I) Component parts • ASV III without cutoff valve • Silencer • Air suction pipe • Air introduction hose • Air cleaner Secondary air is supplied to the exhaust port on the #2-#4 cylinders side by ASV. Exhaust manifold ~. 2) Operational principle The exhaust gas pulsation is transmitted to the air suction valve (a kind of check valve having reed valves) through the air suction pipe. 2) Operational principle The exhaust gas pulsation is transmitted to the air suction valve (a kind of check valve having.

After the period. whereby the two cutoff valves being closed to deactivate the two ASV s.188 mitted to the air suction valve (a kind of check valve having reed valves) through the air suction pipe. the positive pressure reaches the ASV. Under such driving condition as wideopen-throttle acceleration. the reeds are closed to prevent the adverse flow of exhaust gas. Also the secondary air is supplied to the exhaust port near the up stream portion of oxidation catalyst by ASV without cutoff valve that is installed on rear exhaust pipe. When the negative pressure of pulsation is transfered to the ASV. then the vacuum in the vacuum chambers of the cutoff valves goes out through the solenoid valve I. the ECM gives a command to close the vacuum passage of the solenoid valve and open the atmospheric pressure passage. When the coolant temperature is below 35°C (95°F). the ECM gives a command to open the intake manifold vacuum passage of the solenoid valve I for the period of 123 seconds. 5-28 AI system . On the other hand.EMISSION CONTROL SYSTEM Air cleaner Air induction hose A10·187 Fig. two ASVs with cutoff valves are controlled both by coolant temperature sensed by the thennosensor and time governed by the ECM. 2) Operational principle The exhaust gas pulsation is trans- 1 Electronic control mod ule 2 Solenoid valve I 3 Check valve II 4 Air ind uction hose 5 Thermosensor 6 Air cleaner 1 Silencer 8 Air induction hose 9 Air suction valve I with cutoff valve 10 Air suction pipe 11 Air suction valve II 12 Silencer 13 Air suction pipe 14 Silencer 15 Air induction hose 16 Air suction valve I with cutoff valve A10-189 Fig. 5-27 ASV III without cutoff valve 3) Non4WD of non-Califomia models 1) Component parts • Two ASVIs with cutoff valve • ASV II without cutoff valve • Air suction pipes • Air introduction hoses • Silencers • Air cleaner • Thennosensor • Solenoid valve I • Check valve II • ECM Secondary air is supplied to the exhaust ports on # 1-#3 and #2-#4 cylinders sides by ASV with cutoff valve. whereby the two cutoff valves being opened by the diaphragm vacuum actuator to operate the two ASV s. the reeds of air suction valve are opened and simultaneously fresh air from the air cleaner is sucked by itself into the exhaust passage. When. 5-26 A I system Secondary air inlet Secondary air outlet A1o. on the other hand. Fig. An ASV without cutoff valve always operates regardless of coolant temperature and ECM signal. the check valve closes the vacuum circuit to confine the vacuum so as to hold the cutoff valve open for that period.

Actual ignition timing is controlled by the combination of a centrifugal advancer and a vacuum conSecondary air inlet A10·190 troller (advancer) of distributor. At temperature other than the above-mentioned. 5·30 5-16 .JPIII". Distributor". CO and NOx emission through the whole operating conditions. Operational and constitutional description of the centrifugal advancer is performed in "Chapter 15. the vacuum passage is opened to atmospheric pressure through the thermo vacuum valve I.oCI valve I I---tt-Intake manifold ==n I---H-Intake manifold Thermo v8Cuum--. the vacuum passage is opened to atmospheric pressure through the thermo vacuum valve l. 1600 cc 1800 cc 11800 cc I To EGR valve ._ valve I Orifice OM-726 OM-727 Fig..EMISSION CONTROL SYSTEM 5) Ignition Control System Ignition control system is aimed to reduce HC. Between 15 to 35°C (59 to 95°F) of the intake manifold wall temperature... and the vacuum passage is connected to above-throttle ported vacuum due to the check valve being closed when the engine is running at speed above idling. Fig. so here is described how to controll the vacuum signal for the vacuum controller (advancer).. the vacuum passage is connected to above-throttle ported vacuum. the vacuum passage is connected to below-throttle ported vacuum through the check valve when the engine is idling. 5·29 ASV II without cutoff valve NOTE: ASV I with cutoff valve is the same as mat for California models. Thermo vacuum----. At temperature other than the above-mentioned. (Vacuum signal for the vacuum controller) Vacuum signal (Advance signal only) Between 15 to 35°C (59 to 95°F) of the intake manifold wall temperature.

as the vacuum pressure in the intake manifold increases. 5-31 Anti-afterburning system 7) Shift-up Control System Shift-up control system is provided on automatic transmission vehicle only and is used to reduce CO emission due to rapid warm-up. Electronic control module Kick-down switch Relay I Air passage \ ® A 10-191 2 Anti-afterburning valve 3 Orifice 4 Intake manifold Kick-down solenoid valve 5 EGR valve 6 Vacuum line Fig. 5-33 . ® To battery ------'1'------. After that. This prevents afterburning in the exhaust system. ECM keeps the automatic transmission in a kick-down state for a certain duration of time. the pressure in chamber ® gradually becomes equal to that of chamber @ as the air flows through the orifice. The anti-afterburning system prevents this heavy concentration from occurring by introducing air into the intake manifold at this time. The diaphragm is then pushed up by the spring. If the engine is started while the coolant is in the preset temperature range. the valve is closed because chambers ® and @ are at the same pressure. In deceleration (when the throttle valve is closed). During constant-speed running. the vacuum pressure in the intake manifold increases and the pressure in chamber @ decreases. 5·32 Anti-afterburning valve To ignition-starter switch ~.-------~------------~-------. This permits outer air to be drawn into the intake manifold through the filter.EMISSION CONTROL SYSTEM 6) Anti-afterburning System During rapid deceleration the air-fuel mixture becomes heavily concentrated temporarily. Ignition coil Intake manifold r6 LJ-A10-193 Fig. The diaphragm is forced down to open the valve. causing fuel residue on the inside wall of the manifold to vaporize and to enter the combustion chamber. which in turn closes the valve to stop the suction of air. Orifice To intake manifold Air A10-192 Fig.

When a vehicle modified to highaltitude specifications is principally used at altitudes below 1. A3·277 Fig. please restore the relative parts to their original specifications. and clean or replace the EGR valve. Troubleshooting for ECC system". please refer to the modification instruction sheet enclosed in the high altitude kit.7 kPa (-200 mmHg. -7. 5-34 Either engine rough idling or engine stall occurs when vacuum [about -26.082-30 of EPA regulation). here is described how to inspect component parts of the other systems.) .082-30 of EPA regulation). Yes Both EGR valve and vacuum passage to EGR valve are normal.7 kPa (-200 mmHg. EGR valve cleaning. On non-4WD of non-California models: Mter a lapse of 8 minutes or more of engine start with engine warming up. Exhaust gas passage cleaning. Therefore.7 . No r--_ Check if EGR valve moves when vacuum [about -26. (Refer to a. . ~ Yes Check and repair vacuum passage to EGR valve. 1) EGR System 1) EGR wive and EGR flow passages (Vacuum and exhaust gas) Remove EGR valve.000 ft) (areas prescribed in the paragraph (a) (5) of section 86. Regarding the remodification. check if the valve shaft moves when the engine speed reaches 3.000 ft) (other than areas prescribed in the paragraph (a) (5) of section 86. the emission control system must be remodified to the original specifications.EMISSION CONTROL SYSTEM 8) High-altitude Kit When principally operating the vehicle at altitudes above 1. Regarding the modification.87 inHg) is applied to EGR valve by hand vacuum pump.200 m (4. (Refer to b. No 1----1 Clean or replace exhaust gas passage parts.200 m (4. Inspection Check the ECC system as a whole system. On non-4WD of non-California models: After a lapse of 8 minutes or more of engine start with engine warming up.) No Viewing through an opening in the EGR valve body.87 inHg)] is applied to EGR valve by hand vacuum pump after engine warming up. the emission control system requires minor modification to meet the emission standards at high-altitude.000 to 3.500 rpm under no-load condition after engine warmiAg up. and its description is performed in the next section "5. 4.

-----1 • NOTE: To air cleaner To E.A. DO NOT USE AN ELECTRIC DRILL. 5-36 Vinyl tube CAUTION: Do not wash valve ASSY in solvents or degreaser as permanent damage to valve diaphragm may result. (5) Blowout small particles and dust remaining with air hose. and plug the output port to distributor with a cap. 5-37 1 Wax A10·107 2 Valve 3 Spring 4 Valve seat A10-105 Fig. (l) Hold the valve ASSY in hand. DO NOT PUT IN A VISE. remove EGR pipe.. Reassemble EGR pipe. and plug the output port to air cleaner with a cap. b. Empty loose particles.J()~- Thermo vacuum valve HI A10·106 2) Thenno vacuwn valve (I) 1) Connect vinyl tubes to output ports to air cleaner and EGR valve.EMISSION CONTROL SYSTEM a. and confirm that the valve opens or closes in response to intake manifold wall temperature as specified.. Tap lightly on the sides of the EGR pipe with a small plastic hammer to loosen exhaust deposits. (4) Look for exhaust deposits in the valve outlet. Vinyl tube • .:. If out of specification. If valve and/or seat are not completely clean. -7. If valve does not open completely.~r.To Jrr=::::i distributor Thermo vacuum =:. Blow air into the valve as shown in the illustration. EGR valve cleaning present. buff the exhaust deposits from the mounting surface and around the valve. (6) Check EGR valve operation by applying -26.5-35 Thermo vacuum valve (I) Thermo vacuum valve (I) should be open above 20°C (68°F) completely and close below 10°C (50°F) completely.:e:= valve m (j)----\lt+_ Fig. Thermo vacuum valve (I) should be open below 30°C (86°F) completely and close above 40°C (l04°F) completely.G. replace it with a new one. Cap <. and confirm that the valve opens or closes in response to intake manifold wall temperature as specified. Blow air into the valve as shown in the illustration. (more than 5 to 10% blockage of the passage). NOTE: Do not allow water to get into thermo vacuum valve (I). (3) Depress the valve diaphragm and look at the valve seating area through the valve outlet for cleanliness. 2) Connect vinyl tubes to output ports to EGR valve and distributor. replace EGR valve gasket with a new ORB. (2) With a wire wheel or deposit cleaning tool. EGR valve cleaning). (4) Inspect and clean EGR valve as required (See a. Exhaust gas passage cleaning (1) Inspect EGR gas inlet to intake manifold for presence of deposits. Fig. (3) Examine EGR Gas Inlet for ex· haust deposits. If excess deposits @ valva Cap --Hl--:lIIrI /I ~r-t- . Remove any deposits present with a hooked awl taking care to minimize the amount of material falling into the intake manifold. then tap lightly on the sides and end of the valve with a small plastic hammer to remove the exhaust deposits from the valve seat.87 inHg) vacuum with hand vacuum pump. (2) Remove all deposit material using a vacuuming device. Remove built-up deposite with a screwdriver. repeat Step (1). .. When reassembling EGR valve.7 kPa (-200 mmHg. Remove loose exhaust deposits by blowing through EGR pipe using compressed air. replace EGR valve with a new part.

b) A cracked or broken pOint of the reed valve. (2) Remove the reed valve ASSY and gasket from the inside of the valve cover. Inspection (I) Control valve ASSY Apply a vacuum to the vacuum inlet pipe to determine if the con· trol valve operates normally. Disassembly (I) Separate the control valve ASSY. b. Inspection (1) Control valve ASSY Apply a vacuum to the vacuum inlet pipe to determine if the con· trol valve operates normally. YES NO To air cleaner NOTE: Usually (when the current is OFF).spring force to close the passage 'between ® and @. (2) Reed valve ASSY and gasket • Gasket Check for damage and cracks. the plunger is attracted downwards to open the passage between ® and @. 1 2 3 4 Screw Control valve ASSY Reed valve ASSY with gasket A10.9il YES 1 Screw 2 Control valve assy 3 Valve seat 4 Reed valve assy with gasket 5 Reed valve cover NO Check the resistance between (+) or(-) terminal and body. 5-39 ASV I with cutoff valve (Nippon Denso) Check the vacuum passage for opening and closing operation while applying electric current on both (+) and ( -) terminals. and reed valve cover by removing 3 screws. Disassembly (I) Separate the control valve ASSY and reed valve cover by removing 3 screws. 5-40 ASV I with cutoff valve (NOK) . check the ASSY to ensure that it is free of the following defects: a) Waves. (2) O-ring Check for scratches. Assembly Assemble in the reverse order of disassembly. valve seat. YES NO 6 D·ring A10·156 Fig.195 Reed valve cover Fig. c) A rusty stopper. or dents in the reed valve seat. cracks. (3) Reed valve ASSY and gasket • Gasket Check for damage and cracks. (3) Remove the O-ring from the control valve ASSY. 2) ASV I with cutoff valve (NOK) a. cracks.7 39. b. c. To ECM A10·194 Fig. • Reed valve ASSY After washing with gasoline. Standard resistance: 1Mil or more. or dents in the reed valve seat. • Reed valve ASSY After washing with gasoline. (2) Remove the reed valve ASSY and gasket from the inside of the valve cover. When the current is ON in the solenoid. etc.EMISSION CONTROL SYSTEM 3) Solenoid valve II Check the resistance between (+) and (-) terminals. c) A rusty stopper. check the ASSY to ensure that it is free of the following defects: a) Waves. the plunger is forced upwards by the . b) A cracked or broken point of the reed valve. Assembly Assemble in the reverse order of disassembly . Standard resistance: 32. cracks. c.5-38 Solenoid valve II 2) AI System 1) ASV 1) ASV I with cutoff valve (Nippon Denso) a. vacuum valve I @E~~ .

the p unger IS attracte down. ASV case A10-197 Fig. (2) Remove reed valve ASSY and gasket from the inside of outlet case.7 . . and to close the passage between @ and ©. Inspection (l) Inlet case and outlet case Check for damage and cracks. cracks.'''' valve Check the vacuum passage for opening and closing operation while applying electric current on both (+) and (-) terminals. b. the plunger is forced upwards by the spring force to close the passage between @ and @.90 So' NOTE: NO YES Check the resistance between (+) or (-) terminal and body. c) A rusty stopper. ~ I Fig. 542 ASV II without cutoff valve (NOK) ASVcase Screw & washer~ A10-196 f. or dents in the reed valve seat. 543 . and to open the passage between @ and ©. c. J NO Standard resistance: IMO or more. (2) Reed valve ASSY and gasket • Gasket Check for damage and cracks. 541 ASV III without cutoff valve (NOK) 2) Solenoid valve I Check the resistance between (+) and ( -) terminals.EMISSION CONTROL SYSTEM 3) ASV II and III without cutoff valve (NOK) a. YES NO Valve seat l Normal J Al0-1S7 Fig.: wards to open the passage b~n' @ and @. "t Standard resistance: 32.. • Reed valve ASSY After washing with gasoline. check the ASSY to ensure that it is free of the following defects: a) Waves. When the clurrent ~s ON in thde solenoid. Assembly Assemble in the reverse order of disassembly. b) A cracked or broken point of the reed valve.39. Usually (when the current is OFF). YES J I Replace J To intake manifold ®t Valve seat ® Plunger To cutoff k~=illi! Spring To electronic ll1l'diL''''=. Disassembly (1) Separate inlet case from outlet case by removing 3 screws.

then run the engine. Replace it with new one. 545 Anti-afterburning system 3) Ignition Control System 1) Thermo vacuwnvalve (I): Refer to "EGR system". It is automatically changed over to the test mode by connecting the test mode connector. Note that the duty changes from time to time. Accordingly. If the paper is sucked at this moment.) * Test mode is a special mode pro· vided for the dealer to perform selfdiagnosiS quickly. I) Self-diagnosing function This system has a self·diagnosing func· tion. 2) Changeover from regular mode to test mode CD To distributor . being controlled by various sensors. 3) AAV Holding a paper under the AAV. and O2 monitor lamp [~ ECS lamp O2 monitor lamp Diagnosis in progress OFF O2 monitor Diagnosis result on display Regular mode OK OFF O2 monitor NG ON Trouble code Test mode OK Flickers O2 monitor NG ON Trouble code . 1) Disconnect the vacuum hose from AAV. If not. 5. replace it with new one. The self. run engine up to 3. some malfunction occurs in the car. 2) Confirm that air is sucked into the vacuum hose. the ECS (Electric Control System) lamp is illuminated and the trouble code is displayed on the O2 monitor lamp in Morse Code. 3) Relations between self-diagnosis. When trouble occurs. if the duty for the duty solenoid valve is improper.11=== A10-108 1 Valve 2 Spring 1 Intake manifold 2 Air passage 3 Anti·afterburning valve 4 Vacuum line 5 Ball A10-198 Fig. I ®@@ \ duty ratio according to the operating condition. Troubleshootinc for ECC System 1) Outline The air-fuel ratio in the carburetor is compensated by turning ON or OFF the compensation air circuit of the duty solenoid valve at an appropriate 4) Anti-afterburning System 1) Air passage hose Check hose and its connection for leakage and looseness. 544 Check valve Fig. If leakage is found. the AAV operates normally. the AAV is defective.diagnosing function is available in two modes: Regular Mode and *Test Mode. 2) Vacuwn line Check vacuum line for leakage and looseness as foJlows. ECS lamp.EMISSION CONTROL SYSTEM 3) Check valve II I) Confirm that there is no air flow from the carburetor side to the distribu tor side. (The test mode connector must always be disconnected after tests. Described below are the main points of troubleshooting the ECC system. 2) Check valve (II): Refer to "AI system".000 rpm then close the throttle valve quickly. 2) Confirm that there is air flow from the distributor side to the carburetor side. 3) If not. vacuum line is defective.

NOTE: ao Before performing the troubleshooting. (NG) Vacuum switch I remainlOFF Vacuum switch I remains ON Vacuum switch II remain. IV) with it connected or disconnected. ~-_'~r. monitor lamp A10-200 Fig.--_"'1'0_--. Be lure to turn OFF the ignition· starter switch before replacing a defective part. .. 1) A circuit tester a. 2) Requisites for Checking and Their Usages Remarks Carter carbo (sea level mode) 12 11 22 21 23 32 14 41 24 42 13 31 25 52 15 . air hollS and vacuum hollS are connected property.EMISSION CONTROL SYSTEM 4) How to see trouble code Example: 23 10th digit Unit digit Paule Repetition . 5-47 Mflllwring voltage fir. Fig.. or damage. monitor) OFF A-0. When multiple probleml have oc· 5) List of trouble codes Trouble code Item curred. sensor sY" (NG) Thermo sensor 'YI.... passenger room} ...3 8-0. end also check all Plrts and electric wirings for scratch.up control system are not provided..... are displayed repeatedly in numerical order.t mode only } I. OFF Auto choke power remaina ON Main Iystem in feedback system (NG) In te. check if the raspective connectorl. OFF SOlenoid valve III remain& ON Auto choke power remain..l NOTE: L The trouble code is displayed repeatedly.2 (Unit: sec..-.. -------"A. ON (0.. 5-46 MeaBuring voltage (in engine room) 51 34 43 33 6) The self.... So one must carry out checks and make repairs according to the troubleshooting flow chart contained herein. OFF Vacuum switch II remains ON Duty solenoid valve remains OFF Duty solenoid valve remains ON Solenoid valve I remainlOFF Solenoid valve I remains ON Solenoid valve III remain. (NG) (En&tne in OFF) ~ Carter carbo (hlah altitude mode) Hitachi carbo (sea level mode) Hitachi carbo (blah altitude mode) i- 0 .. r. requisites for checking and their usages are as follows. b..------. 1 Check connector (III) 2 Check connector (IV) 3 Test mode connector 4 ECM S 0 . . b. ignition pulse IYS. ell their trouble cod. and reconnect the hOlD and connectors completely after that... I. mod••"" In the section "3) Troubleshooting chart"...diagnosing functions for the EGR system and shift. A circuit tester is used to measure voltage and resistance between terminals of check connectors (I .

. A circuit tester is used to measure resistance of duty solenoid valves after disconnecting their connectors. A10-141 Fig.::-$-. A circuit tester is used to measure resistance of vacuum switches after disconnecting their connectors. 549 (Brown) b.()94 1 To solenoid valve II (Y IL) 2 To high altitude signal (G) 3 To auto choke (0. 5-50 Duty solenoid valves and connectors Duty solenoid valve (main or slow) Vacuum switch UI To ground (S) (+) (B/W) To ECM (Y/R or Y/GI A10-12S To ECM (R/Y) A10-127 to Fig.'..85-B/W) 17 solenoid valve II (Y /L) 18 To selection for carburetor (L/B) 19 To duty monitor (L/W) 20 To thermosensor (W/B) 21 To kick-down solenoid valve (0.5-53 Vacuum switches and connectors Fig. b... sensor monitor (R/W) 24 To vacuum switch (1) (R/Y) 25 To vacuum switch (II) (G/B) 26 To solenoid valve III (L/R) 27 To auto choke relay (R/G) 28 To kick-down relay (L/G) 29 To solenoid valve I (L/Y) Duty solenoid" valve (main) 2 Duty solenoid valve (slow) 3 Connectors ...5-51 Connector terminal of duty solenoid valves • CoW carburetor Vacuum switch lB.. Be sure to insert test bars fr 1IIe harness side of the connect" c.85-L/B) 22 To power supply for ECM (B/Y) 23 To 0.85-L/R) 8 To duty solenoid valve (Y /R) 9 To thermo sensor (W/B) 10 To ground (B) II To ground for control (B/R) 12 To ground (B) 13 To trouble code (R) 14 To warning lamp (R/L) 15 To test mode (G/W) 16 To ignition switch (0. ~ ~ (Pink) A10·202 Check connector (III) Fig..ITj tiliJ (Pink) Check connector (II) Be sure to insert test bar from the' harness side of the check connector.. . (Wrong) a..85-B/W) 7 To kick-down solenoid valve (0... To ground IS) 30 A10·201 To ECM (GIS) 1 Feedback solenoid valve 2 Connector A10-142 A10-128 Fig.85-L) 4 To fuel pump (O. 548 Temrinals of check connector Fig.-'---~A': EMISSION CONTROL SYSTEM Check connector m NOTE: NOTE: f.85-L/R) 5 To selection for carburetor (LIB) 6 To ignition switch (O.. 5-54 Connector terminals of vacuum switches 5-24 . Connector terminal for the CoW solenoid valve is the same as that for Hitachi'.. 5-52 Duty solenoid valve and connector Fig. • Hitachi carburetor Check connector (IV) (Pink) \ 1 Connectors 1 Vacuum switch (0) 3 Vacuum switch (I) A 10.

3. Check the connector while itia connected unless specified oUter· wise. Be sure to check again from the beginning in order to prevent secondary trouble caused by repair work. remove or tighten it by using a special tool (Socket. 0. Fig. 2) A stethoscope or a vinyl tube A stethoscope or a vinyl tube is used to check if there is operating sound from duty solenoid valves. 2. sensor cord A5-680 A10·203 Fig. be the hose. hose disconnected from the vaclltmEl switch at EtG on. 5·56 Fig. When checking with the vacuum . 5·55 3) A dry cell A dry cell. • NOTE FOR TROUBLESHOOTING CHART: 1. is used to check O2 sensor and its wiring for defect. . 499990100). 5·57 Rep/acing O2 sensor A10-129 NOTE: When replacing oxygen (0 2 ) sensor.EMISSION CONTROL SYSTEM NOTE: Be sure to insert test bars from the harness side of the connector. connecting plus (+) terminal of it to O2 sensor wiring and minus (-) one to earth instead of O2 sensor.

EMISSION CONTROL SYSTEM 3) Troubleshooting Chart Wann up engine until coolant temperature rises to about 70°C (158°F). YES .

E/GOFF Disconnect test mode tenninal. Keep idling for over 1 second Make kick-down twice YES Wann up engine at over 2. E/G OFF (AT or non4WD NO (Non4WDof non-California vehicle only) YES Confinn trouble code.EMISSION CONTROL SYSTEM E/GON NO (AT or non4WD >----1 F of non-California vehicle only) Check if voltage between eck connector's kick· down signal tenninal (i?~) and earth tenninal for drive (8) is below IV. Make sequential checks of trouble code. (Non4WDof non-California vehicle only) YES.~- .500 rpm YES Check if voltage between check connector's solenoid valve II tenninal IL) and earth tenninal for drive (8) is over lOY. of non-California vehicle only) Check if voltage between check connector's kick· down signal tenninal i?~) and earth tenninal for drive (8) is over lOY. (AT vehicle only) . System OK Check if voltage between check connector's solenoid value II tenninal IL) and earth tenninal for drive (8) is below 2V. IG ON.

Check if voltage between check connector's warning lamp terminal (R/L) and ground terminal for drive (B) is over 7V NO Replace ECM. IG relay. Check power source. Check if voltage between check connector's carb selection terminal (LIB) and ground terminal for control (B/R) is over 2V. YES Replace ECM. YES IGON Repair shorted carb selection (LIB) circuit harness. rt Check if resistance between check connector's carb selection terminal (LIB) and ground terminal for control (B/R) is below lOll. Check if voltage between check connector's carb selection terminal (LIB) and ground terminal for control (B/R) is below 2V. Replace ECS lamp_ . and harness. NO IGOFF Check if resistance between check connector's ground terminal for drive (B) and body is below lOll. NO Repair open warning lamp circuit harness.EMISSION CONTROL SYSTEM IGOFF Check if resistance between check connector's ground terminal for control (B/R) and body is below lOll. Repair open carb selection (LIB) circuit harness. NO >----11 NO Repair open harness. NO Repair open harness. -' h Check if voltage between check connector's ECM power supply terminal (B/Y) and ground terminal for drive (B) is over IOV. YES NO Replace ECM.

Repair. II Check if voltage between check connector's high-altitude signal tenninal (G) and ground tenninal for drive (B) is below 2V. IGON ECSlamp comes on. . Check if fuel pump operates. Disconnect ECM connector. -~I Replace ECM. or replace ECM. repair. YES Repair open high-altitude signal (G) circuit harness. NO YES IGOFF Check if esistance betwee check connector's high-altitude signal tenninal (G) and ground tenninal for drive (B) is below IOn.EMISSION CONTROL SYSTEM Check if voltage between check connector's high-altitude signal tenninal (G) and ground tenninal for drive (B) is below 2V. YES Warning lamp (R/L) circuit harness shortcircuited. YES E/GOFF NO Repair open IG pulse (Y) circuit harness. NO Improper installation of high-altitude kit. Replace ECM. Repair. YES High-altitude signal (G) circuit harness shortcircuited.

EMISSION CONTROL SYSTEM Check if voltage between kick-down relay connector (L/R) line and car body is over lOY. YES Kick·down (L/R) circuit harness short-circuited. NO Check power source. Repair. YES ick-down relay IGOFF YES Replace ECM. Check if voltase between kick-down relay connector (L/G) line and car body is below 2V. YES Repair broken kick-down (L/R) circuit harness. Check if voltage between kick·down relay connector (B/W) line and car body is below IV. . YES Disconnect kick-down relay connector. NO Check if resistance between kick·down relay connector (L/G) line and car body is below In. 5-30 . Repair. Kick-down relay (L/G) circuit harness broken .

Check if resistance betwee check COMector's solenoid valve II (YIL) and sround tenninal for drive (8) is below Solenoid valve II (YIL) circuit harness shortcircuited. I""l . Check if voltase between kick-down relay connector (L/G) line and car body is below 2V. Disconnect solenoid valve II connector.EMISSION CONTROL SYSTEM NO Disconnect solenoid valve II connector. X YES Kick-down relay (L/G) circuit harness shortcircuited. Check power source.f NO DiSCOMect ECM connector. NO Replace kickdown relay. NO Replace ECM. Repair. YES Replace solenoid valve II. NO Replace ECM. 1On. Repair. NO NO Replace ECM. Repair. YES Replace solenoid valve II. Solenoid valve II (YIL) circuit harness broken. . Disconnect ECM connector.

YES O2 sensor cord short· circuited.EMISSION CONTROL SYSTEM Trouble code 23 E/G OFF IGON Disconnect cord from O2 sensor. Check if voltage between check connector's 0 1 monitor (R/W) and ground terminal for control (8/R) is below 1V. . Repair.. .. YES Remove dry celL Check if resistance between O2 sensor cord and car body is below IOn. Replace.. r'" % ! Check if voltage between check connector's O2 monitor (R/W) and ground terminal for control (8/R) is over 2V. Connect dry cell <±l pole to O2 sensor cord and e pole to car body. NO Replace ECM. YES 0 1 sensor defective.. NO Repair open 0 1 sensor cord.

YES Connect check connector (U)'s thermo sensor (W/B) to ground terminal for drive (B). NO Thermo sensor (W/B) circuit harness shortcircuited. Check if voltage between check connector (III)'s thermo sensor terminal (W/B) and ground terminal for control (B/R) is over IV.EMISSION CONTROL SYSTEM Trouble code 32 Check if voltage between check connector (IIIrs thermo sensor terminal (W IB) and ground terminal for control (B/R) is over IV. NO Check if voltage between check connector (Il)'s thermo sensor terminal (W/B) and ground terminal for drive (B) is below O. NO Repair open thermo sensor (W/B) circuit harness. Check if resistance betwee check connector (IIl)'s thermo sensor terminal (W/B) and ground terminal for control (B/R) is over IOn. NO Disconnect thermo sensor connector. YES NO E/GOFF [ Replace thermo sensor. . YES Replace ECM.2V. Repair.

OK .. NO Check if voltage between check connector's Vlaw (I) (R/Y) and terminal (B/R) is below IV. YES Repair open V/lw (I) (R/Y) circuit harness. NO Replace VI sw (1). NO Check if voltage between both terminals of Vlaw (I) connector is below IV. r h Replace ECM..EMISSION CONTROL SYSTEM Trouble code 14 Disconnect vacuum switch (I) (V/sw (I) hose and stop it with blind plug. 5-34 ..

NO II Replace ECM. Ion.. Replace. YES VIsw (I)(R/Y) circuit harness short-circuited. . YES NO E/GOFF YES NO Check if resistance between check connector's V/sw (I) tenninal (R/Y) and ground tenninal for control (8/R) is below Check vacuum hose line.. r- X ..EMISSION CONTROL SYSTEM Trouble code 41 Disconnect V Isw (I) connector..

. YES fteplace V/sw (II).. .. . Replace ECM. 5-36 . Repair open VIsw (II) (G/B) circuit harness..EMISSION CONTROL SYSTEM Trouble code 24 Check if voltage between check connector's V Isw (II) terminal (G/8) and ground terminal for control (8/R) is below IV. % Check if voltage between both terminals of V Isw (II) connector is below IV. Check vacuum hose line.

.. Check if sistance between check connector's V/sw (II) tenninal (G/B) and ground tenninai for control (B/R) is below 100.. Replace V/sw (II). % NO Replace ECM. OK NO Disconnect VIsw (II) connector. YES V/sw (II) (G/B) circuit harness short-circuited. Repair.EMISSION CONTROL SYS"rEM Trouble code 42 Disconnect V/sw (II) hose and stop it with blind plug. E/GOFF r-t .

. ---~-.. YES Replace duty solenoid..._.. YES Replace solenoid valve I.- EMISSION CONTROL SYSTEM Trouble code 13 IGOFF Trouble code 25 IGOFF Disconnect duty solenoid connector. Trouble code 15 IGOFF Disconnect solenoid valve III connector. Disconnect solenoid valve I connector. 5-38 ..... Replace HeM... NO NO Replace HeM.... YES Replace solenoid valve III.~. NO ·R. _ _-----. .eplace ECM.- ---~- .

EIG OFF Disconnect duty solenoid connector. IGOFF Check if resistance between both terminals of duty solenoid is over lOOn. Check if voltage between duty solenoid connector (B/W) line and car body is below 2V. NO Duty solenoid (Y/R) circuit harness is broken. Repair.EMISSION CONTROL SYSTEM Trouble code 31 IG ON. [I I Im~l ~ 5-39 . duty solenoid terminal and car body is below IOn. YES Replace duty solenoid. NO >---------. NO YES Check power source. YES !' Check if resistance between .

Check if resistance between duty solenoid connector (Y/R) line and car body is below YES Ion. NO Replace ECM. 5-40 .EMISSION CONTROL SYSTEM Disconnect ECM connector. Repair. Duty solenoid (Y/R) circuit harness short· circuited.

EMISSION CONTROL SYSTEM
Trouble code 52

IG ON, EtG OFF

Disconnect ECM connector.

,..,
Check if voltage between check connector's solenoid valve I terminal (LtY) and ground terminal for drive (B) is below 2V. YES Check if resistance between both terminals solenoid valve I is below YES

......

NO Disconnect solenoid valve I connector.

X

IOn.

Replace solenoid valve I.

NO

Replace ECM. Check if voltage between solenoid valve I connector (LtY) line and car body is below 2V.

NO Solenoid valve I (LtY) circuit harness broken. Repair.

Check if voltage between solenoid valve I connector (BtW) line and car body is below2V.

>----------.
rr=================~

NO

EMISSION CONTROL SYSTEM

Disconnect solenoid valve I connector.

YES

Check power source.

Check if resistance between solenoid valve I tenninal and car body is below

YES
Replace solenoid valve I.

Ion.

NO
Solenoid valve I (L/y) circuit harness short· circuited. Repair.

5-42

EMISSION CONTROL SYSTEM Trouble code 5 I

IG ON, E/G OFF

Disconnect ECM connector.
1""1

..

Check if voltage between check connector's solenoid valve III terminal (L/R) and ground terminal for drive (D) is below 2V. YES

X
NO Disconnect solenoid valve III connector.

Check if resistance between both terminals of solenoid valve III is below

YES Replace solenoid valve III.

IOn.

NO Replace ECM. Check if voltage between solenoid valve HI connector (L/R) line and car body is below 2V.

NO Solenoid valve III (L/R) circuit harness broken. Repair.

Check if voltage between solenoid valve III connector (D/W) line and car body is below 2V.

NO Replace solenoid valve III.

EMISSION CONTROL SYSTEM

Disconnect solenoid valve III connector.

YES Check power source.

NO

YES Replace solenoid valve III.

NO
Solenoid valve III (L/R) circuit harness short· circuited. Repair.

5-44

EMISSION CONTROL SYSTEM
Trouble code 34

Check if voltage between check connector's auto choke tenninal (L) and car body is over lOY.

YES
Replace ECM.

Check if

voltage between PTC relay connector (L) line and car body is over lOY.

YES
PTC (L) circuit harness broken. Repair.

Check if voltage between PTC relay connector (B/W) line and car body is over lOY.

NO
Disconnect PTC relay connector.

Check if resistance between PTC relay connector (L) line and car body is below SU.

YES
PTC (L) circuit harness short-circuited. Repair.

NO
Check power source.

EMISSION CONTROL SYSTEM

Check if voltage between PTC relay connector (RIG) line and car body is below 2V.

YES
Replace f'I'C relay.

NO
-,

,...

IGOFF

%
Check if resistance between PTC relay connector (RIG) line and check connector's f'I'C relay tenninal (RIG) is below 100.

NO
f'I'C relay (RIG) circuit harness broken. Repair.

YES

Replace ECM.

5-46

EMISSION CONTROL SYSTEM
Trouble code 43

IG ON, E/G OFF

Check if voltage between check connector's auto choke terminal (L) and ground terminal for drive (B) is below IV. NO

Replace ECM.

EEEEB

Check if voltage between check connector's PTC relay terminal (RIG) and ground terminal for drive (B) is below 2V. NO

Replace PTC relay.

IGOFF

Disconnect ECM connector.

Check if resistance between check connector's PTC relay terminal (RIG) and ground terminal for drive (B) is below IOn. NO

YES

PTC relay (RIG) circuit harness short-circuited. Repair.

Replace ECM.

Trouble code 33

I
Main duty system malfunctioned. Repair.

EMISSION CONTROL SYSTEM

5-4. Evaporative Emission Control System
1. Schematic Drawing
The carburetor vapor line, connecting between the carburetor float chamber and the canister, is employed in addition to the tank vapor line. Gasoline vapor evaporated from the float chamber is inducted into the canister through solenoid valve (II) at all positions except "ON" and "START" positions of ignition-starter switch. I) Canister The purge control valve on the canister is controlled by carburetor vacuum. When the purge control valve is opened, the adsorbed vapor is introduced from the canister into the intake manifold. When the engine is not running, the purge control valve is closed by the return spring. Gasoline vapor does not purge to intake manifold within the specified temperature [IS to 35°C (59 to 95°F)] because the carburetor vacuum is leaked. 2) Two-way valve The two-way valve is located in the fuel vapor line and functions to control the pressure in the fuel tank. When the fuel tank pressure is positive above a certain point, the valve A is open to permit the fuel vapor to the canister, and when the fuel tank pressure is negative below a certain point, the valve B is open to introduce fresh air into the fuel tank.

Carburetor vapor line Fuel separator

Vapor volume Tank vapor line Fuel tank

Tank fuel volume
A3-257

Fig. 5-58

2. Description
The evaporative emission control system is employed to prevent evaporative fuel from being discharged into ambient ~tmosphere. This system includes a canister, a two-way valve, a fuel separator, their connecting lines etc.

Gasoline vapor evaporated from the fuel in the fuel tank is introduced into the canister located in the engine compartment through the tank fuel line, and is absorbed on activated carbon in it. A two-way valve and a vapor separator are also incorporated on the tank vapor line.

From carburetor Purge vent Vacuum release orifice 0.4 mm (0.016 in) dia. From fuel tank Vacuum vent

To canister Orifice 1.5 mm (0.059 in) dia. Purge control valve Activated
Al0·084

Fig.5-60 Two-way valve

carbon
Filter
A3-259

Fig. 5-59

3) Fuel separator The vapor separator is to prevent liqUid fuel from flowing into the canister in case of abrupt cornering, etc.

5-48

EMISSION CONTROL SYSTEM
All models except Hatchback Hatchback
To canister"

@

4) Fuel filler cap with vacuum relief valve The relief valve is adopted to prevent the development of vacuum in the fuel tank which may occur in case of trouble in the fuel vapor line. In normal condition, the filler pipe is sealed at @ and at the packing pressed against the filler pipe end. As vacuum develops in the fuel tank, atmospheric pressure forces the spring down to open the valve; consequently air is led into the fuel tank controlling the inside pressure.

A1G-078 A1G-079

1 Fuel tank
2 Breathefhose

3 Vapor separator

Fig. 5-61

1 Seal 2 Filler cap 3 Spring 4 Valve 5 Packing

A10-205

Fig. 5·62

3. Inspection
Inspect evaporative emission control system in accordance with chapter 2, 2-2, 11.

5-5. Special Tool
499990100

SOCKET
Oxygen (01 ) sensor

j j j j j j j j j j j j j j j j j j j

CHAPTER@
MANUAL TRANSMISSION AND

DIFFERENTIAL
6-1.

6-2.

6-3.

6-4.

6-5.

6-6.

SI BARI'

SPECIFICATIONS AND SERVICE DATA ................... 1. Specifications .................................... 2. Service Data ..................................... CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1. Component Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2. On-car Service ................................... 3. Rem oval . . . . . . . . . • . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. 4. Inspection....................................... 5. Installation...................................... MANUAL TRANSMISSION AND DIFFERENTIAL ............ 1. Cross Sectional View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2. Component Parts .......•.......................... 3. 0 n-ca r Service .. . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4. Dismounting..................................... 5. Removal........................................ 6. Disassembly...................................... 7. Inspection....................................... 8. Assembly ....................................... 9. Installation...................................... 10. Remounting ..................................... TRANSMISSION CONTROL SYSTEM ...................... 1. Component Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2. Removal and Disassembly .........................•.. 3. Inspection....................................... 4. Assembly ....................................... 5. Installation...................................... TROUBLESHOOTING ................................. 1. Clutch ......................................... 2. Manual Transmission and Differential .................... SPECIAL TOOLS .................................... 1. Clutch ......................................... 2. Manual Transmission and Differential ....................

Page 6- 2 6- 2 6- 3 6- 7 6- 7 6- 7 6- 8 6- 9 6-12 6-13 6-13 6-15 6-24 6-25 6-26 6-29 6-32 6-34 6-42 6-59 6-62 6-62 6-64 6-65 6-65 6-67 6-70 6-70 6-73 6-75 6-75 6-76

MANUAL TRANSMISSION AND DI·FFERENTIAL

6·1. Specifications and Service Data
1. Specifications

~~
Type Dimension (Outer diameter )( inner diameter x thickness) Facing Clutch disc Surface area Material

1600 5-speed 4-speed 5-speed All models except Station Wagon Station Wagon

1800

4WD

4WD Dual-range

Dry single plate 200)( 130)( 3.5 mm (7.87)( 5.12)( 0.138 in) lSI x 2cm ' (2S.1 x 2 sq in) Woven asbestos 7.8 mm (0.307 in) 8.8 mm (0.346 in) 225 x 150 )( 3.5 mm (8.86 )( 5.91 x 0.138 in) 220 x 2 cm' (34.1 x 2 sq in)

i

I

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Clutch cover

Disc

Compression thickness Free thickness Type

8.5 mm (0.335 in)
21.5 )( 21 x 1.0 Diaphragm 168 mm (6.61 in)

Hub spline Outer diameter Plate thickness Setting load Driving type of pressure plate Clutch play At the nut center located on the clutch fork end 2 4-forward speeds with Iynchromesh and I-reverse lst 2nd Transmission gear ratio (Tooth number of gear) 3rd 4th 5th Reverse Auxiliary transmission gear ratio (Tooth number of gear) Front reduction gear High Low Type of gear Gear ratio (Tooth number of gear) Type of gear Gear ratio (Tooth number of gear) Type of gear 3.666 (44/12)
2.157 (41/19)

Spring

1.96 mm (0.0772 in) 2,942 N (300 kg, 662 Ib)

2.04 mm (0.0803 in) 3,432 N (350 kg, 772lb) Strap plate type 3 mm (0.08 0.12 in) 4-forward speeds with synchromesh and I-reverse 4-forward speeds with synchro· mesh and I-reverse (dual-range)

,
Type

5-forward speeds with Iynchromesh and I-reverse 3.666 (44/12) 2.157 (41/19) 1.266 (38/30) 0.885 (31/35) 0.725 (29/40) 4.100 (19/10 x 41/19)

5-forward speeds with synchromesh and I-reverse

(43/13) 1.950 (39/20

3lOH{101

(43/13) 1.950 39/20)

3.636 (40/11) 1.950 (39/20) 1.193(37/31) 0.769 (30/39)

1.266 (38/30) 0.885 (31/35)

1.266 (38/30) 0.885 (31/35)
0.725 (29/40)

1.266 (38/30) 0.885 (31/35) 0.725 (29/40)
3.583 (23/12 x 43/23)

~
4.100 (19/10 x 41/19)

3.583 (23/12 x 43/23)

-------3.889 (35/9) Helical
1.000 (34/34)

3.583 (23/12 x 43123) 1.000 1.462 (22/19 x 24/19)

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0

.~

~

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Hypoid 3.700 (37/10)

Filial

Transfer Rear , reduction : gear Final

Hypoid 3.900 (39/10) Straight bevel gear (pinion: 2, Side gear: 2) 14 10 Straight bevel gear (Pinion: 2, Side gear: 2) 16 10

Front differential

Gear ratio (Tooth number of gear) Type and number of gears Side gear Tooth number Pinion gear Type and number of gears

18 13

Rear differential

Tooth number

Side gear Pinion gear

Transmission oil capacity Rear differential gear oil capacity

2.72 (2.9 US qt, 2.4lmpqt)

3.02
(3.2 US qt, 2.6 Imp qt) 0.8(> (0.8 US qt, 0.7 Imp qt)

-

6-2

MANUAL TRANSMISSION AND DIFFERENTIAL

2. Service Data
Clutch pedal full stroke Pad surface position of clutch pedal Release fork stroke Play at release fork center Depth of rivet head (5.08 5.39 in) 129 ~ 137 mm Above brake pedalleveJ by 15 mm (0.59 in) (0.67 - 0.71 in) 17 - 18 mm 2.0 ~3.0mm (0.079 - 0.118 in) (0.055 in) 1.4mm (0.012 in) 0.3mm

.:::: ..... .E! u

<..}

STD Sinking limit

Aluminum gasKet thickness (Neutral position adjustment) Part No. Remarks 803922021 Neutral position approahces reverse gear side 037022000 Standard 803922022 Neutral position approaches 1st/2nd gear side 803922023 Neutral position approaches lst/2nd gear side Dimension 'C' of reverse accent shaft Part No. Mark Contact clearance for 1600 442747001 1 becomes smaller 442747002 2 442747003 442747004 4 5 442747005 442747006 6 becomes larger for 1800 Part No. Mark 442747101 I becomes smaller 442747102 2 442747103 442747104 4 442747105 5 becomes larger 442747106 6 Transmission main shaft snap ring (out-22) thickness Part No. 805022010 805022011 805022012 805022013 805022014 805022015 805022016 805022017 805022018 805022019 805022030 805022031

O.5mm 1.0mm L5mm 2.0mm

(0.020 in) (0.039 in) (0.059 in) (0.079 in)

16.2 16.6 17.0 17.4 17.8 18.2 12.2 12.6 13.0 13.4 13.8 14.2 -

16.4 mm 16.8mm 17.2 mm 17.6 mm 18.0mm 18.4 mm 12.4 mm 12.8 mm 13.2mm 13.6 mm 14.0 mm 14.4 mm

(0.638 (0.654 (0.669 (0.685 (0.701 (0.717 (0.480 (0.496 (0.512 (0.528 (0.543 (0.559 -

0.646 in) 0.661 in) 0.677 in) 0.693 in) 0.709 in) 0.724 in) 0.488 in) 0.504 in) 0.520 in) 0.535 in) 0.551 in) 0.567 in)

.5: '" .~

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ca

e .....
~

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2.45 mm 2.48mm 2.51 mm 2.54mm 2.57mm 2.60mm 2.63 mm 2.66mm 2.69mm 2.85mm 2.42mm 2.39mm

(0.0965 in) (0.0976 in) (0.0988 in) (0.1000 in) (0.1012 in) (0.1024 in) (0.1035 in) (0.1047 in) (0.1059 in) (0.1122 in) (0.0953 in) (0.0941 in)

6-3

MANUAL TRANSMISSION AND 01 FFERENTIAL
Washer thickness (Washer to case wall clearance adjustment) Part No. 803015081 803015082 803015083 803015084 803015085 Main shaft rear plate thickness Dimension 'A' for 1600 3.50 - 3.63 mm (0.1378 0.1429 in) Part No. 441342112 Stamp T71-2 T71-3 Stamp T81-1 T81-2 STD 0.6 1.0 1.4 1.8 2.2 0.8mm L2mm 1.6 mm 2.0mm 2.4mm (0.024 (0.039 (0.055 (0.071 (0.087 0.031 0.047 0.063 0.079 0.094 in) in) in) in) in)

5.0mm 5.13 mm

(0.197 in) (0.2020 in)

441342113 3.37 3.50mm (0.1327 0.1378 in) for 1800 Dimension 'A' Part No. 4.50 4.63mm 441347001 (0.1772 0.1823 in) 441347002 4.37 4.50mm (0.1720 0.1772 in) Synchronizer ring face to gear facing gap

5.0mm 5.13 mm

(0.197 in) (0.2020 in)

1.5 mm (0.059 in) 1.0mm (0.039 in) ... High-low synchroring of 4WD Dual-range 0.5 mm (0.020 in)

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1::1 0 u 1::1 0

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Limit Part No. 841968601 841968602 841968603 841968604 841968605 841968606 841968607 841968608 for 1800 Part No. 441967101 441967102 441967103 441967104 441967105 441967106 441967107 441967108 Input shaft cotter thickness (4WD Dual-range) Part No. 447257000 447257001 447257002 Snap ring (In-56) thickness (4WD Dual-range) Part No. 805156020 805156021 805156022 Drive pinion shim thickness for 1600

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.... .....
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0.140 0.190 0.240 0.290 0.490 0.165 0.215 0.265 -

O.l60mm 0.210 mm 0.260mm 0.310mm 0.510mm 0.185 mm 0.235 mm 0.285 mm

(0.0055 (0.0075 (0.0094 (0.0114 (0.0193 (0.0065 (0.0085 (0.0104

-

0.0063 a.0083 0.0102 0.0122 0.0201 0.0073 0.0093 0.Ql12

in) in) in) in) in) in) in) in)

0.15 mm 0.175 mm 0.20mm 0.225 mm 0.25mm 0.275 mm 0.30mm 0.50mm

(0.0059 in) (0.0069 in) (0.0079 in) (0.0089 in) (0.0098 in) (0.0108 in) (0.0118 in) (0.0197 in)

2.43 mm 2.51 mm 2.59 mm

(0.0957 in) (0.0988 in) (0.1020 in)

1.75 mm 1.83mm 1.91 mm

(0.0689 in) (0.0720 in) (0.0752 in)

6-4

MANUAL TRANSMISSION AND DIFFERENTIAL
Input shaft holder shim quantity (4WD Dual-range) Dimension'D' 50.39 mm (1.9839 in) or more 50.38 - 49.89 mm (1.9835 1.9642 in) 49.88 mm (1.9638 in) or less Reverse shifter rail arm remarks (4-speed) Part No. 842004101 842004102 842004103 lst-2nd shifter fork remarks for 1600 Part No. 842024121 842024122 842024123 842024124 842024125 Part No. 442027001 442027002 442027003 442027004 442027005 3rd-4th shifter fork remarks for 1600 Part No. 842014121 842014122 842014123 842014124 842014125 Part No. 442017001 442017002 442017003 442017004 442017005 5th shifter fork remarks for 1600 Part No. 342031711 342031712 342031713 342031714 for 1800 342031715 Part No. 442037011 442037012 442037013 442037014 442037015 Mark 1 No mark 3 4 5 Mark 1 2 No mark 4 5 Mark 1 No mark 3 4 5 Mark 1 2 No mark 4 5 Mark 1 2 No mark 4 5 Mark 1 2 No mark 4 5 Moves 0.4 mm (0.016 in) toward gear side Moves 0.2 mm (0.008 in) toward gear side Center Recedes 0.2 mm (0.008 in) from gear side Recedes 0.4 mm (0.016 in) from gear side Moves 0.4 mm (0.016 in) toward gear side Moves 0.2 mm (0.008 in) toward gear side Center Recedes 0.2 mm (0.008 in) from gear side Recedes 0.4 mm (0.016 in) from gear side Moves 0.4 mm (0.016 in) toward 4th gear Standard Moves 0.4 mm (0.016 in) toward 3rd gear Moves 0.2 mm (0.008 in) toward 4th gear Moves 0.2 mm (0.008 in) toward 3rd gear Remarks Moves 0.4 mm (0.016 in) toward 4th gear Moves 0.2 mm (0.008 in) toward 4th gear Standard Moves 0.2 mm (0.008 in) toward 3rd gear Moves 0.4 mm (0.016 in) toward 3rd gear Moves 0.4 mm (0.016 in) toward 2nd gear Standard Moves 0.4 mm (0.016 in) toward 1st gear Moves 0.2 mm (0.008 in) toward 2nd gear Moves 0.2 mm (0.008 in) toward lst gear Remarks Moves 0.4 mm (0.016 in) toward 2nd gear Moves 0.2 mm (0.008 in) toward 2nd gear Standard Moves 0.2 mm (0.008 in) toward 1st gear Moves 0.4 mm (0.016 in) toward 1st gear Mark Nothing 1 2

1
No mark 3

Moves toward case wall (L.H.) Standard Recedes from case wall (L.H.)

for 1800
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for 1800

6-5

MANUAL TRANSMISSION AND DIFFERENTIAL
Reverse shifter lever remarks for 1600

for 1800

Part No. 340621701 340621702 340621703 Part No. 440627101 440627102 440627103

Mark 1 No mark 3 Mark 1 No mark 3 Color Colorless Colorless Yellow Color Colorless Blue Colorless Color. Colorless Red Colorless STD STD Recedes from the case wall Center Moves toward the case wall Recedes from the case wall Center Moves toward the case wall

Shifter rail spring free length for 1600 Reverse/5th 3rd/4th 1st/2nd for 1800 (Except 4WD)

32.1 mm 32.1 mm 33.6mm 32.1 mm 33.8mm 32.1 mm 32.1 mm 33.3mm 32.1 mm 0.05 0.13 0.15 mm 0.18 mm

(1.264 in) (1.264 in) (1.324 in) (1.264 in) (1.331 in) (1.264 in) (1.264 in) (1.311 in) (1.264 in) (0.0020 - 0.0059 in) (0.0051 - 0.0071 in)

:;-

.= ....

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= 8 = = •
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Reverse/5th 3rd/4th 1st/2nd for 18004WD Reverse 3rd/4th 1st/2nd Side gear to pinion backlash (Differential) 1600 1800 Washer (35.1 x 45 x t mm) thickness Part No. 803135011 803135012 803135013 803135014 803135015 Pinion shaft to axle drive shaft tip clearance Snap ring (Out-26) thickness Part No. 805026010 031526000 Drive pinion to crown gear backlash 1600 1800

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STD

0.925 - 0.950 mm 0.950 - 0.975 mm 0.975 1.000mm 1.000 1.025 mm 1.025 - 1.050 mm 0-0.2mm

(0.0364 - 0.0374 in) (0.0374 - 0.0384 in) (0.0384 - 0.0394 in) (0.0394 - 0.0404 in) (0.0404 - 0.0413 in) (0 - 0.008 in)

1.00 - 1.10 mm 1.15 1.25 mm SID STD 0.1 0.18mm 0.13 0.18mm

(0.0394 - 0.0433 in) (0.0453 - 0.0492 in) (0.004 - 0.0071 in) (0.0051 - 0.0071 in)

1. Component Parts

2. On-car Service
CLUTCH CONTROL
1) Adjustment of Clutch

Play

1) Remove release fork return spring from fork. 2) Adjust spherical nut so that the play is within the specified value at the fork end (center of spherical nut).

NOTE:

Take care not to twist the cable during adjustment.

.00 not wash clutch disc with any cleaning fluid.

Play 2 - 3 mm 10.08 - 0.12 inl

Full stroke 17 - 18 mm 10.67 - 0.71 in)

nut

l--*-.:.;Fork Iclutch reI....1
All·013

Fig. 6·2 Adjusting clutch play

' - ' ' ' ' 10..'"

N·m '",·m••,""1

T: 14.2·17.2 11.46 ·1.76.10.6 ·12.7)

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2) Check
1) Upon completion of adjustment, securely lock spherical nut with lock nut. 2) Install return spring on fork.

1 2 3 4 5 6 7 8 9 10 11

Flywheel complete Starter ring gear Clutch disc Clutch cover Ball bearing Spring washer Bolt Clutch release bearing Release bearing. holder Release bearing holder spring Clutch release fork

12 13 14 15 16 17 18 19 20 21

Clutch release fork sealing Release fork spring Clutch release fork (For hill holder) Clutch release bearing Clutch release fork sealing Release folk spring
Clip

NOTE:

Hook the 10Rg spring side of the release spring with the fork. (1600)
3) Depress clutch pedal to assure there is no abnonnality in the clutch system.

Clutch release fork RetUnerspring Release bearing holder
A12·436

NOTE:

Fig. 6·1

Standard dimensions of clutch control system are as follows:

6-1

Release bearing holder springs 2. Do not disassemble either clutch cover CP or clutch disc CPo Be careful not to deform clutch fork & holder clip and clutch fork retaining spring.0.3mm (0. Removal 1) Clutch cover CP and clutch disc CPo NOTE: NOTE: a.12 in) Release fork stroke Play at release fork center 4) Apply grease sufficiently to the release fork portion.08 .0.MANUAL TRANSMISSION AND DIFFERENTIAL Service item Full stroke of clutch pedal Pad surface position of clutch pedal Standard 129 137 mm (5. readjust so that the bend of clutch outer cable becomes flatter. 1. Two clips from fork Release bearing holder Retainer spring from pivot Clutch release fork and sealing 3.67 . Clutch release fork and sealing 3) Precautions When reinstallation. 2) Excessive tighteness or looseness of clutch cable have a bad influence upon the cable durability.08 . 6-8 . If clutch chattering occurs. 4. 2) Release bearing holder and clutch release fork. 3. I.39 in) Above brake pedal level by 15 mm (0.59 in) 17 18 mm (0. Release bearing holder 3.5. Take care not to allow oil on the clutch disc facing. b. S) Position clutch cable through the center of toeboard hole and route it smoothly. 1) Check the routing of clutch cable for smoothness. 6) Make sure not to make clutch chattering at starting forward or rearward.71 in) 2 . pay attention to the following items. Adjustment is done by moving the outer cable. 2. 3) Apply grease sufficiently to the connecting portion of clutch pedal.

21 in) . 1800 (3) Oil soakage on facing (4) Deflection offacing 4WD Dial gauge \ A11·003 /. Replace.4 mm (0. Limit for deflection 0.055 in) 0. transmission case mating surface.012 in) (I) Wear offacing I I I NOTE: Do not wash clutch disc with any cleaning fluid. repair or replace.3 mm (0.. If deflection exceeds the specified value at the outer circumference of facing. and repair or replace if necessary. Replace clutch disc and inspect transmission front oil seal. Replace if facings are worn locally or worn down to less than the specified value. . Parts Clutch disc CP.MANUAL TRANSMISSION AND 01 FFERENTIAL 4. 6-3 Measuring clutch disc deflection (5) Worn spline. engine rear oil seal and other points for oil leakage.14 in) . loose rivets and torsion spring failure. Fig. (2) Hardened facing Correct by using emery paper or replace. Inspection Inspect all the disassembled parts for wear or damage.1 mm (0. No." 1600 and non4WD of 1800 R= 101mm(4.028 in) at R= 95 mm (3. Depth of rivet head Standard value Limit of sinking 1. Inspection Corrective action Measure the depth of rivet head from the surface of facing..

Iine or any solVlnt when _rvic· i. and is of a non-lubrication type. do not wash with . @. (2) Wear and damage of holder surface contacting with fork Repair or replace.. I) Loose thrust rivet CD.. I Replacing of clutch release bearing I 1) Remove bearing out of holder... 64 3 Clutch release bearing.. I Press (899754112) 2 Sealing (Clutch release) 3 Holder (Release bealing) Fig. Repair or replace. 5) Worn diaphragm sliding surface Corrective action Repair or replace. 6·5 Installing clutch reI_ bfJsring 4 Clutch release fork. 2) Damaged or worn bearing contact area at center of diaphragm spring @.. Check fork pivot portion and the point of contact with holder for wear.... 3) Damaged or worn disc contact surface of pressure plate @. 2) Press bearing.... NOTE: Do not depress outer race.. Repair or replace. A12-437 Fig.. 6-10 . 4) Loose strap plate setting bolt @..MANUAL TRANSMISSION AND DIFFERENTIAL No. 2 Parts Clutch cover CP Inspection Visually check for the following items without disassembling. the dutch. NO'rE: Since this bearing is g. (1) Smoothness of rotation Rotate bearing applying pressure in thrust direction.

.~ Flush surfaces - !:! Crankshaft side" .m Brown 0.... 5 Parts FlywheelCP Inspection ( I) Damage of facing (2) Smoothness of rotation Rotate ball bearing applying pressure in thrust direction...39 in) II 6-11 .MANUAL TRANSMISSION AND DIFFERENTIAL No..... NOTE: Do not pntSl inner race. is as follows: Parts No.39 in) 12x32. ----I-..2:. b. Clutch pilot bearilll spec.. Replace.! "0 .:...of dutch cover side.26x Black 0../ - . 6-6 Pressing beering NOTE: .47xl..r .Sx10 1600 806212030 (0. Size Color 12x32x10mm 1800 806212020 (0. Corrective action NOTE: Since dais bearina is ar. do not wash wida gasoline or any sol"nt I Pressing of ball bearing I Press bearing into flywheel until bearing end surface is flush with flywheel.ed and is of a non-lubrication type..:5 II) ~ a e e 2 ___ ~ A12·438 Discrimination groove Fig. ....47x1.. Repair or replace.. 1800 cc flywheel has discriMination groove on its surface ..

Transmission main shaft spline. A5·354 Fig. NOTE: Confirm that retainer spring is securely fitted by seeing through the main case hole. Contact surface of fork and pivot c. Note the front and rear of the clutch disc when installing. b.) 2) Insert Guide (499747000) into clutch disc CP and install them on flywheel by inserting the end of Guide into pilot bearing. NOTE: Before or during assembling.08 to 0.1. 11800 1 a. 6-8 Installing of clutch release fork and relative parts NOTE: Hook up the long spring side of the release spring with the fork.75 kg·m.45 . d. Install holder and fasten it with two clips. Install retainer spring into fork. 6-9 Installing clutch cover Clutch side NOTE: a. b.7 ft·lb) I Holder 2 Fork Torque Fig. Inner groove of release bearing holder. While pushing fork to pivot and twisting it to both sides. c. d.12 in).) b. c. Contact surface of fork and holder. and then retain with two release bearing holder springs. 11600 1 a. lubricate the following points with a light coat of grease. fit retainer spring onto the constricted portion of pivot.2N·m (l. make adjustment with the nut at the fork end so that the clutch release fork end play is 2 to 3 mm (0. 10. (1600) 6-12 . When installing the clutch cover on the flywheel.2-17. Install clutch release fork sealing. Install clutch release fork and release bearing holder CP.12. ("0" marks indicate the directions of residual unbalance. a. Install clutch cover CP on flywheel and tighten bolts to the specified torque. Installation 1) Install clutch release fork and release bearing holder. Transmission A11·35 NOTE: Take care not to twist the cable during adjustment 4) Install release fork return spring. 6-7 Installing holder and fork b. (Use grease containing molyb· denum disulphide.MANUAL TRANSMISSION ANO 01 FFERENTIAL s. 0 3) After remounting engine and transmission on body. Tighten clutch cover installing bolts gradually.5 . Each bolt should be tightened in a crisscross fashion to the specified torque. 14. Fig. Install clutch release fork sealing. position the clutch cover so that there is a gap of 120 or more between "0" marks on the flywheel and clutch cover.

6-10 6-13 . Cross Sectional View • 1800 5-Speed A12-471 Fig.MANUAL TRANSMISSION AND DIFFERENTIAL 6-3. Manual Transmission and Differential 1.

6-11 6-14 .MANUAL TRANSMISSION AND DIFFERENTIAL • 1800 4WD Dual-range A12-472 Fig.

30·35) 18 19 20 21 22 23 24 25 26 27 28 29 30 Bolt (8 x 130 x 22 mm) Bolt (8 x 168 x 18 mm) Bolt (8 x 110 x 18 mm) Bolt (10 x 168 x 18 mm) Bolt (10 x 198 x 18 mm) Bolt (8 x 152x 18 mm) Washer Washer Nut Nut Stud Bolt (8 x 119 x 18 mm) Transmission main case assembly (Dual-range) 31 Oxygen sensor harness clip 32 Back-up light clip 34 Clutch cable bracket 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Oil seal holder lock plate Release spring bracket Bolt Outch housing cover Bolt (8 x 62 x 18 mm) Bolt (8 x 110 x 18 mm) Bolt (8 x 130 x 22 mm) Bolt(8x 119x 18mm) Bolt (10 x 152 x 18 mm) Bolt (10 x 168x 18mm) Bolt (8 x 152 x 18 mm) Bolt(8x 168x 18mm) Washer Washer Nut Oxygen sensor harness clip A12-441 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 (Dual-ra..3·2.2 ·2. 6-12 6-15 .8.2 ·2.7 ·4.30 ·35) Transmission main case assem bIy Pivot Stud Straight pin Outch cable bracket Nut Oil gauge Oil seal Speedometer shaft Snap ring Washer Back-up light clip Speedometer driven gear Snap ring Gasket Drain plug Bolt Transmission main case assembly Pivot Outch cable bracket Straight pin Oil gauge complete Oil seal Speedometer shaft Snap ring Washer Speedometer driven gear Snap ring Gasket Oil drain plug Bolt Lock plate Bolt Bolt (8 x 62 x 18 mm) Tightening torque N·m (kg."" 27 . Component Parts 1) Transmission Main Case 1 1600 I @@@ ~--I@@@ @@@ @@@ 36 ...MANUAL TRANSMISSION AND DIFFERENTIAL 2.20 ft·lb) Tightening torque N-m (kg.31 ft-lb) 23 .42 N-m (3.2 ·4.16·20) T2: 41·47 (4.8.8.2 -4.7 kg-m."" ft·lb) T1: 22 ·27 (2.nge) 35 Clutch hou_ cover (4WD) A12-442 Fig. 17 .26 N·m (2.3 kg.20) T2: 41·47 (4."" ft·lb) T1: 22·27 (2.8. 16 .

ft-Ib) T1: T2: T3: T4: 9 .37 (3.20) 16 .12 . 6.3.0.0) 31 .27) 23 .20 (1.17 .5 .3 .8.1.2612.1.8.7. 23 .MANUAL TRANSMISSION AND DIFFERENTIAL 2) Rear Case I Tightening torque I I N'm (kg-m.2.2 .2.14) *Selective parts BOLT LOCATION 1 2 3 Transmission rear case 4 Filler 5 Aluminum gasket 6 Shifter fork rail spring 7 Shifter fork rail spring 8 Ball 9 Ball 10 Plug (22 x 8 mm) *11 Aluminum gasket o 00 o 0 Fig.11 10.6 .9 . 6-13 12 Reverse accent (*S-speed only) 13 Reverse return spring I 14 Bolt (8 x 55 x 18 mm) 15 Bolt (8 x 93 x 18 mm) 16 Spring washer 17 Washer 18 Oil seal 19 Bolt (8)( 38 x 18 mm) 20 Bolt (8 x 119)( 18 mm) Shaft'~ ~ !l 1 24 25 26 27 28 30 31 "29 Back-up light switch Gasket Baek-up light eord elip Transmission main ease rear gasket (1800 ce) Shifter arm (1800 ec) Transmission rear case (1800 ee) Shifter fork rail spring Shifter fork rail spring Back-up light cord elip Bolt (8 x 65 )( 20 mm) Reverse aecent shaft (1800 ee) (·5-speed only) A12-443 6-16 .

2.2.27 (2.5-8.27) T6: 22 . 6.1.2 .2 .20) I 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Aluminum gasket Filler Aluminum gasket Reverse accent spring 7.0) T5: 30 -3613.8.2 -3.0.350 ball Interlock rail O-ring (10 x 2) Transfer shifter rail Nut Transfer ball joint assembly High-low shifter rail Knock pin Oil seal (13 x 22 x 6) Snap ring (Inner-45) 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Needle bearing Bolt (8 x 38 x 18) Washer Bolt (8 x 65 x 20) Rod arm Back lamp switch Gasket Transfer case unit Shifter arm complete Main case rear gasket 7.56 x 10.MANUAL TRANSMISSION AND DIFFERENTIAL 3) Transfer Case 4WD Dual-range I I @ Tightening torque N'm Ikg-m.12 -141 T4: 9-11 (0.8.144 ball Transmission gasket Shifter arm CP Transfer case Washer Spring washer Bolt Bolt Snap ring Needle bearing 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Bolt Spring washer Transfer case cover Transfer cover gasket Transfer shifter rail Oil seal Straight pin Transfer shifter fork Plug (22 x 8 mm) Gasket Reverse accent shaft Reverse return spring Ball Shifter fork rail spring Back-up light switch assembly 1 2 3 4 5 6 7 8 9 10 11 Fig.8. ft·lb) Tl : 18 -2211.2-3. 13 -16) T2: 31 -37 13.0.13-161 T2: 31 .5 .271 T3: 16-20 (1.12-14) T4: 9 .6-2.2.8.1 -3.37 13.1 .8-2. 6-14 12 13 14 15 16 17 18 19 A12-444 20 Bolt Spring washer Transfer case cover Transfer cover gasket Clip 5.23 .9 . ft-Ib) Tightening torque N·m Ikg-m.8.2712.7.6 .11 10.2.9-1.27) T3: 16·20 (1.16-20) ! I T1: 18·22(1.1 plunger High-low shifter arm Straight pin (5 x 22) Transfer shifter fork Spring 6.23 .0) T5: 22 .16 .1438 ball Reverse aeeen t spring Gasket Filler Shifter fork spring Reverse return spring Reverse accent shaft Gasket Plug A12-445 O-ring 6-11 .6.22 .8 -2.2.1.

25 .6.40 13.1.R. ft·lb) T1: 73·84 (7. 6-15 A12-446 6-18 .13 Extension CP 14 Ch81'l.5·4.54·62) T2: 34 .4·8.MANUAL TRANSMISSION AND DI FFERENTIAL 4) Extension ® 1 2 3 4 S R.P rod busbiD( IS BU&biD& 16 Oil seal 17 Extension dust cover 18 Oil seal Tightening torque N·m Ikg-m.30) 19 20 21 22 Bolt SPrina wuher Washer Transfer rear patet Fig.ear drive spaeer 11 Snaprina 12 Ball beariDg .ear drive shaft Lock nut-18 Lock washer-I 8 Ball bearing 4th driven par thrust plate 6 Transfer driven gear 7 Bushins 8 Synchronizer sleeve 9 SyncluoDizer hub 10 .

144 ball 5 Shifter fork spring 6 7 8 9 10 11 12 13 14 *15 *16 Shifter fork spring Shifter fork spring Aluminum gasket Plug 5.56 x 10.1 plunger Reverse shifter urn Strailht pin Reverse lever CP Ist-lnd shifter fork 3rd4th shifter fork (1. 29 30 31 32 *33 34 35 36 37 38 *39 *40 *41 Fig.1· 21..1 plunger 3 x 11.MANUAL TRANSMISSION AND DIFFERENTIAL 5) Shifter Fork and Shifter Rail * Selective parts Tightening torque N·m (kg·m.9 plunger Straight pjp It.61 41P1ed tran.4· 15.15... ft-Ibl T: 18.. MX~*i! ~'-:: ~ 21 22 ~ *25 26 27 "- 28 """""- .misai~ 1 Reverse shifter rail 2 3rd4th shifter rail 3 ht-2nd shifter rail 4 7..1 (1.556 ball Revene shifter urn spring 5. 6-16 6-19 .85· 2. 13. Reverse lever CP Shifter fork set screw Reverse shifter urn 3rd4th shifter fork Reverse shifter rail 3rd4th shifter rail 1st-2nd shifter rail Shifter fork spring Shifter fork spring Shifter fork spring 1st·2nd shifter fork Spring pin 5th shifter fork Snap ring Reverse shifter rail 3rd4th shifter rail 1st-lnd shifter rail Shifter fork spring Shifter fork spring Shifter fork s ring 3rd4th shifte fork 5.56 x 10.I \'" @ ".800 00) A12·447 5-tpHd transmisaion I ~ ~ .

020 in) • I Install springs on both sides so that relative 0 positions of cut ends are 120 apart each other. .5 mm (0. .54-62) @ ) 1 Transmission main shaft 2 Woodruff key 3 Needle bearing (22 x 42 x 20 mm) 4 on seal (20 x 40 x 10 mm) *5 Main shaft rear plate 6 Snap ring (outer) 7 Ball bearing (22 x 58 x 25 mm) 84th drive gear thrust plate 9 Synchronizer ring 10 4th drive gear bushing 11 Synchronizer sleeve 12 Synchronizer hub spring 13 Synchtonizet hub 14 Synchronizer hub insert 15 16 17 *18 19 20 21 22 3rd drive gear bushing 4th-3rd gear set Needle bearing Main shaft rear plate Lock nut-18 Lock washer-18 5th gear set Reverse idler gear CP 23 24 25 26 27 28 Reverse idler gear bushing Reverse idler gear shaft Knock pin Washer (* 5-speed only) 3rd-4th drive gear bushing Transmission main shaft (4WD) Fig.MANUAL TRANSMISSION AND DIFFERENTIAL 6) Transmission Main Shaft * Selective parts • Clearance between ring and gear Standard: 1.6.4-8.5 mm (0. 6-17 A12-448 6-20 . ft-Ib) T: 73 .8417. Tightening torque N'm Ikg-m.059 in) Limit: 0.

ft-Ib) T1: 73-8417.64 .3.32 12.32 (2.7 .ning torque N·m (kg-m.6.3.81-931 T2: 73·84 17.8 mm) lst·2nd needle bearing race Reverse driven gear lst-2nd synchronizer spring lst-2nd synchronizer hub lst-2nd synchronizer insert lst driven gear 15t driven gear thrust plate Roller bearing (37.8 mm) 11 1st-2nd needle bearing race 12 Reverse driven gear 13 lst-2nd synchronizer spring 14 I 5t·2nd synchronizer hub 15 lst·2nd synchronizer insert A12-449 A12·450 16 I st driven gear 11 1st driven gear thrust plate 18 Roller bearing (37.8 mm) 29 5th needle bearing race 30 5th driven gear tluust plate Fig.2·12.8.3. 20 ..MANUAL TRANSMISSION AND DIFFERENTIAL 7) Drive Pinion !4'lIPlled.3. 6·18 6-21 . Selective parts 1 2 3 4 5 *6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Lock nut·22 Lock washer-22 Ball bearing (25 x 70 x 30 mm) Bolt (8 x 28 x 23 mm) Spring washer Drive pinion shim 4 th·3rd gear set 2nd driven gear lst· 2nd synchronizer ring Needle bearing (37 x 42 x 23. / Tlght.nlng torque N·m Ikg-m..4 .4WD ! * Selective parts .621 T3: 26 . 20 • 241 1 Lock nut·22 :2 Lock washer·22 3 Ball bearing (25 x 70 x 30 mm) 4 Bolt (8 x 28 x 23 mm) 5 Spring washer *6 Drive pinion shim 7 4 th·3rd gear set 8 2nd driven gear 9 lst·2nd synchronizer ring 10 Needle bearing (37 x 42 x 23..8. ft-Ib) T1: 110-126111.IIHP88d I .6.241 .7 .64·621 T2: 26 .5 x 67 x 22 mm) Key Lock nut-22 Lock washer·22 Transfer drive gear Transfer needle bearing race Drive pinion collar Washer Tlght.4-8.5 x 67 x 22 mm) 19 Key 20 Insert stopper plate 21 Insert guide 22 Synchronizer sleeve 23 Synchronizer hub spring 24 SYnchronizer hub 25 Synchronizer hub insert 26 Synchronizer ring 27 5th gear set 28 Needle bearing (29 )( 33 x 23.

22 . 13.039 in) Limit: 0.020 in) @ 31 32 33 34 35 36 37 38 39 40 41 42 *43 A12-319 Counter gear shaft O-ring Counter gear washer Counter gear Needle bearing Counter gear collar Knock: pin Clip Input shaft holder l() Bolt 1 2 3 4 5 6 7 8 9 11 12 13 14 15 *16 17 *18 Input shaft shbn (0 .MANUAL TRANSMISSION AND DIFFERENTIAL 8) Auxiliary Transmission and High-low Shift Linkage * Selective parts I / Tightening torque N'm (kg-m.7.1 .85 .3.5 mm (0.15.6) T2: 30 .2 sheets) O-ring Oil guide Snap ring (Outer) Input shaft retainer Input shaft cotter Ball bearing (22 x 56 x 16) Snap ring (Inner-56) 19 Input shaft 20 Needle bearing 21 22 23 24 25 26 27 28 29 30 High-low synchronizer rilll High-low synchronizer sleeve SprillB High-low synchronizer hub High-low synchronizer insert Input low gear Input low gear collar Needle bearing Input low gear spacer High-low shifter fork Piece High-low shifter lever CP ROd ball joint assembly Nut Rod adjustilll screw Nut (Left-hand threaded) High-low shifter rod SprillB pin Nut Spring washer 3. ft-Ib) T1: 18.4 -15.2.36 (3.27) Clearance between ring and gear Standard: 1. 6-19 8-22 .0 mm (0.1.21.1 11.9688 ball Oil sea1(22 x 40 x 10) Snap ring (Outer-22) A12-461 Fig.

I I I I ...67 (5. 6-20 6-23 ..) Axle shaft oil seal holder Axle drive shaft Roller bearing Boh 6 Crown lear loclc washer (1600 cc only) I 1'.MANUAL TRANSMISSION AND DIFFERENTIAL 9) Differential • Selective parts ''I I ...491 1 2 3 4 5 Oil seal (LJi....B.. ~ I 15 Pinion & crown gear set (4WD) / 16 on seal (a. 7 DUferentiUpm~nshaft 8 DUferential case 9 Straight pin 10 Differential pinion 11 Differential side gear ·12 Snapring ·13 Washer 14 PInion & crown gear set (4-speed and 5-speed) ' . I "-l .. I I I Tightening torque N·m {lcg-m. I .. I. ft·lbl T: 57 . 42 ..H. ....) 17 O-ring A12·462 Fig. .B· 6.

.4 ft-Ib). 11) While holding ball joint ASSY. A12·396 Fig.39. 5) Shift select lever into '4WD LO' range..:. Fig. 4) Shorten the linkage length by turning rod adjusting screw (turn.===~'~~. Readjust it according to the following.MANUAL TRANSMISSION AND DIFFERENTIAL 3./ \ \.. '4WD HI' or '4WD LO' position.0 N'm (0.----"F' NOTE: 1 2 3 4 Rod ball joint assembly Nut Rod adjusting screw Nut (Left-hand threaded) 5 High.2 kg-m. buckle) clockwise one or two turns. confirm that clutch operates properly_ I) Remove starter. NOTE: Pull selact lever to its full stroke. ¥ilP~ A12·394 ~~~~ " . there is a possibility that high· low shift linkage is not adjusted properly. NOTE: Since rear nut is left-hand threaded. 6-21 Disconnecting harness 1 Bracket (499167001) 2 Holder (499167002) 3 Bolt Fig.28 in). [Rod adjust screw tightening torque is 2. 6-26 Fitting holder 3) Loosen front nut of rod adjusting screw first that connects high-low shifter rod with rod ball joint ASSY.) and then turn it back 90 clockwise at the point where ball joint movement becomes tight. 1. and then loosen rear nut. 7' A12·398 Fig.] r ~I@¥\i CV (1)-' ~~ ''''''''''''-'O/!Y 7) Fit Bracket (499167001) included in Stopper ASSY (499167001) on main case.~! LL!-=!!!. 6·23 Turning rod adjusting screw 9) Fit Holder (499167002) included in Stopper ASSY (499167000) with two bolts to Bracket. ~ -.LU~-. 6) Loosen main case attaching bolt and nut that connects the above clip together until the clearance between bolt and case surface becomes 7 mm (0.:.low shifter rod Before fitting Bracket. T~rn back 90° u~}=~. pay attention to the rotation direction. On-car Service ADJUSTMENT OF HIGH·LOW SHIFT LINKAGE (WITH TRANSMISSION MOUNTED ON THE BODY) In case of power not transmitting to axle shaft when select lever is shifted into 'FWD'. A12·392 1 Clip 2 Harness A12·397 Fig. turn rod adjusting screw counterclock· wise (This lengthens the linkage 0 length.. 2) Disconnect harness for back·up light switch and '4WD LO' switch from rear clip on transmission case. 6-25 Tightening bolt and nut Fig. bend clip a little in order not to interfere with Brecket 8) Tighten bolt and nut after the rear end surface of Bracket hits on the main case flange.... 6·24 LooSlJning bolt and nut 10) Confirm that select lever does not move. Rod adjust \ NOTE: Before adjustment.~"'<:'\'''"---"" A12. 6·27 Turning adjusting tlCftlW 6-24 . @J' }/ \ J})-sW. T[.. 6-22 Loosening nut Fig.::.

b. 8) Remove starter with battery cable. 6) Disconnect speedometer cable. . Set the drive selector lever at "4WD" pOSition. b. Ground cable (on the car body). and install harness. f. Unfasten clip which retains outer cable. 4) Remove spare wheel supporter.7 kg-m. NOTE: Do not tighten the nut more than 10 mm (0. c. loosen the lower nuts.MANUAL TRANSMISSION AND DIFFERENTIAL 12) Tighten rear nut (left-hand threaded) at first. g. 3) Disconnect battery cable from negative ( -) terminal. Torque A4·113 Fig.up pOint in front of side sill. b. Disconnect hot air intake hose. 2) Remove spare wheel. 16) Confirm that there is no abnormality in shift mechanism by operating select lever. Back-up light switch connector. c. and pull up gearshift lever with boot.1 . a. Dismountina 1) Open engine hood and hold it securely by a stay. 13) Raise the front end of car by placing a jack on the jack. and then hand brake cover. 10) Loosen nut [by approximately 10 mm (0. 6-29 Removing upper bolts and loosening lower nuts NOTE: Do not put the spare wheel or a hand on the air cleaner case to prevent damage of air cleaner case. 6-30 NOTE: Do not disconnect the battery cable from the starter. 6-25 e. 15) Install starter. A19-096 Fig. Remove clutch cable return spring. Remove both lock nut and adjusting nut from clutch cable. Slightly tilt engine backward in order to facilitate removal of transmission. Remove two nuts to separate rod B and drive selector lever from plate. Torque 14) Restore clip to the original state. d.3 . and unfasten clip on speedometer cable. Loosen nuts which secure exhaust pipe ASSY to the exhaust port of engine. Fig. Remove boot installing screws.36 N'm (3. c. 12) Disconnect O 2 sensor harness and unclamp it. 23 26 N'm (2. a. and tighten nut by an equal amount on the engine side. d. 6-31 4. 5) Disengage clutch cable as follows. 22 27 ft-Ib) b. Fig. Detach rubber boot. Starter harness.7 kg-m. 7) Disconnect wiring connections.39 in)] which retains pitching stopper to the transmission side. 9) Remove the upper bolts which secure engine to transmission. separate both the 4WD selector system and gearshift system from transmission as follows.39 in). Remove hand brake tray cover. Remove rod cover. and put it on bulkhead.6-28 Tighten nut 13) Remove Stopper ASSY and tighten main case attaching bolt and nut.3. and then tighten front nut while holding rod ball joint ASSY. 14) Remove front exhaust pipe ASSY as follows: a. Remove nut connecting gearshift lever with lever. 30 . 17 20 ft-Ib) 11) On 4WD. Remove nut connecting rod B with rod A. a.2.

Interlock rail by turning 90°. NOTE: Discard and do not re-use the spring pins. 5. 14WDI l. Loosen front nut of rod adjusting scr-:. 7. b. 24) Remove crossmember. Remove bolts which secure front exhaust pipe to bracket on car body. 23) Securely support transmission by placing a jack under it. Transfer drive gear. Separate high·low shifter rod from rod arm with Remover II (39879· 1600). When pulling out interlock rail. 25) Remove two nuts which secure engine to transmission. s. Lower jack and dismount transmission. 21) Unfasten clamp on the left side of hand brake cable. and move transmission away from engine just enough so that transmission main shaft does not interfere with engine. 2) Extension and transfer case. Remove bolts which secure front exhaust pipe to rear exhaust pipe. Straight pin with Remover II (398791600). When pulling it out. NOTE: a. 4. NOTE: a. Supporting front exhaust pipe ASSY. d. e. 3. Exhaust pipe ASSY can now be removed.MANUAL TRANSMISSION AND 01 FFERENTIAL c. Fig. Transfer shifter rail. 16) Remove bolts (at two places) which secure the gearshift system to free it from transmission. Fig. separate axle shaft from drive shaft.low shifter rail. NOTE: Be careful not to drop &. Fig.350 ball and shifter fork rail spring. transfer shifter fork. be careful that &. NOTE: a.5& x 10. Transfer case and main shaft rear plate by tapping it with a plastic hammer.350 ball. 15) On 4WD remove bolts which secure propeller shaft to rear differential gear. exercising care not to strike it against any adjacent parts. (except 4WD) 17) Remove stabilizer. and detach propeller shaft. 2. be sure to release the staked pan of nut. set both high-low shifter arm and transfer shifter fork in '4WD· HI' position in order to prevent double meshing. 2. Extension ASSY by tapping it with a plastic hammer. 6-32 links. remove nuts from the exhaust port of engine. When disconnecting the propeller shaft. b. 9. Before turning lock nut. NOTE: a. b. Transfer case cover. be careful of spring and &. When pulling out transfer shifter rail. plug the open end of the drive shaft with a cap to prevent the oil from running out of the drive shaft. 5. 19) Drive both left and right spring pins out of axle shaft. Shift the gear to the "1 st" position to prevent the shaft from turning. I 4WD Dual·range I I.350 ball. Transfer case cover. 6-33 6-26 . in order to facilitate the removal of center crossmember. be careful of &. Transfer shifter fork while turning it in order not to interfere with high. Be careful not to damage O-ring on rail. 6·34 A12·321 3. 6. and lower transverse NOTE: When pulling out transfer shifter rail. 20) Pushing wheels toward the outer side. b. Pin and clip on interlock rail with pliers or the like. 8.350 ball does not fly out from transfer case.350 ball. spring and 5. after shifting transfer shifter rail into '4WD· LO' position.~" ~nd then loosen rear nut. 18) Remove bolts which secure left and right transverse links to front crossmember. Transfer shifter rail. Lock nut with Socket Wrench (499987003) while fixing transmis· sion main shaft with Stopper (498787000). Clip on transfer shifter rail by using screwdriver or the like. 6.1 plunger in transfer shifter fork. Extension ASSY. 22) Remove nuts which secure left and right transmission mount rubber cushions. 4. 7. Removal NOTE: Be careful not to strike the oxygen sensor against any adjacent parts during removal. 6. 1) Install Stand Set (399295120). Be careful not to damage the oil seal located at the end of the propeller shaft.

When pulling out high-low shifter rail. NOTE: 2 High-low shifter rod 3 Rod adjust screw 4 Rod ball joint assembly 5 High-low shifter lever CP 6 Nut a. Fig. be careful of spring and 6. 6-35 a. Be careful not to drop 5.MANUAL TRANSMISSION AND 01 FFERENTIAL NOTE: 14. 6-37 12. pay attention to the rotation direction. Disconnect high-low shifter rod from rod arm by turning rod adjust screw clockwise. Transfer case unit and main shaft rear plate by tapping it with a plastic hammer. Before turning lock nut. Perform job with nut side facing upward. 4) Ball bearing attaching bolts at the drive pinion rear portion. 6-27 . 10 mm (0. High-low shifter rail and high-low shifter arm with Remover II (398791600). and then wrap vinyl tape around the spline portions.350 ball.56 x 10. 15. 6-41 11. 6) Clean spline portion of axle drive shaft on both right and left sides with white gasoline. and disconnect rod ball joint ASSY from high-low shifter lever CPo A12·331 ---. 6-38 13. be sure to release 1I1e staked part of the nut b. 6-36 Fig. Remover II 7) Separate transmission main case into the right half and left half. Other than 4WD & 4WD Dual· range Transmission rear case and main shaft rear plate. Cover sufftcient area from the root of oil seal to the shaft end. 5) i 4WD Dual-range I Input shaft holder attaching bolts.1 plunger in high-low shifter arm. 6-40 10. Shift the gear to "1st" position to prevent the shaft from turning. A12-328 1 High-low shifter rod 2 Nut (Left-hand threaded) 3 Rod adjusting screw 4 Nut 5 Rod ball joint assembly NOTE: A12·333 Fig. Rod arm with (398791600). NOTE: NOTE: Fig. b. A12-330 Fig.39 in) by tapping it with a plastic hammer. Transfer drive gear after pulling out transfer case by approx. 6-39 Turn high-low shifter rail so as to strike out spring pin. Lock nut-22 with Socket Wrench (499987003) while ftxing transmission main shaft with Stopper (498787000).\JIIlll1l~ L1{'ft \\' Fly. Fig. Since rear nut has a left-hand thread. 3) I 1 Remover II (398791600) 2 High·low shifter rail 3 High-low shifter arm Fig.

4WD Dual-range High.H. NOTE: Make sure that the ball housed in arm does not pop out when taking out the reverse shifter rail arm. c. 6-45 A12·018 NOTE: a. Take care not to mix up R. Fig. Take care not to damage the axle shaft oil seal.MANUAL TRANSMISSION AND DIFFERENTIAL 8) I 4WD Dual-range I High-low shifter lever Remover II (398791700). NOTE: Pay attention to the springs and balls in the plug. NOTE: Knock speedometer shaft outside case by tapping lightly.). 23) I 4WD Dual'range Counter gear shaft from main case.1 plunger will move into the notched groove of other rails to prevent double engagement. When a rail is shifted.). keep other rails placed in neutral position. speedometer driven gear.speed I Reverse shifter rail arm and reverse shifter rail. b. 13) IS. I NOTE: Be careful not to drop input shaft and main shaft as they are separable. 17) ! Other than S. NOTE: a. 6. arm spring and 5.26 mm] . 21) 14WD Dual-range I Pull out counter gear shaft forwards until it hits on transmission main case (R. 6-46 NOTE: Job will be facilitated if the shank of a hammer is used. counter gear and two washers. NOTE: a. Oil seel will come out together.H. 18) !S. 19) Axle shaft oil seal holders with Wrench (399780111). reverse shifter rail. 6-28 . Fig. 1 Hammer 2 Drive pinion 3 'fain shaft A12-013 I Fig. reverse shifter rail arm. b. b.H. reverse idler gear and shifter lever. I Fig. 14) Shifter rail spring plugs from case. 6-44 A12·020 NOTE: Be careful not to drop two high·low shifter pieces. shaft and washer. and L.H.speed I 5th shifter fork with Remover II (398791700). 16) Knock pin. reverse idler gear shaft. 10) Drive pinion. and remove knock pin from counter gear shaft. The cross section of the interlock· ing device is as shown in the figure. Pull the rail for 3rd-4th by turning 90° in order not to drop plunger. 5.556 ball.speed ! Outer snap ring. Be careful not to drop knock pin at the front. A12·337 1 Remover II (398791700) 2 High-low shifter lever CPo Fig.1 plunger. 6-43 11) Transmission main shaft ASSY. and remove clip with screw· driver or the like.66 x 10. ( 14WD Dual-range! ) 12) Differential. CP with NOTE: Pay special attention to oil seal in transmission main case (L. 22) 4WD Dual·range ! Slide counter gear washer at the rear. When pulling out a rail. sides of roller bearing [37 x 72 x 18. Transmission main case 20) Snap ring. Be careful not to damage O-ring.56 x 10. 15) Shifter forks and shifter rails for 3rd4th and lst-2nd. 6-42 15th shifter fork 2 Remover n (398791700) A12-420 9) .low shifter fork by turning 90°.

cut a groove with grinder and drive it with chisel or the like. 8) I4WD Dual-range I Snap ring (Outer-22) from main shaft with Expander (899474100). II some ball bearings are installed Dn the drive piniDn without press-fit tightn811. and then pull out oil seal and needle bearing. remove it with press using Remover (899864100) and Retainer II (8998586(0). 6-48 Fig. 1 Socket Wrench 2 Holder A 1 (899984103) Fig. I 5) 5-speed 5th drive gear with Retainer (899714110) and then woodruff key. • Ball bearing • 4th drive gear thrust plate • 4th drive gear • 4th drive gear bushing • Synchronizer hub • 3rd drive gear I I 9) 4WD Dual-range I Remove the following parts by hand. The gear should be supported after removing the lock nut. NOTE: Be careful not to drop neadle bearing in input shaft. I Holder (R98938600) A12·145 2 Socket wrench (899988608) 1 Snap ring 2 Expander (899474100) A12·344 6. 2) lather than 4WD Dual-range Wrap vinyl tape around the main shaft spline portions. 1) NOTE: A12·027 1 Remover (899864100) 2 Retainer (899714110) Fig. Holder (899884100) and bench vise. 6-49 a. When bushing moves a little.).9688) • Needle bearing (25 x 42 x 20) I 2} Drive Pinion Assembly Other than 4WD & 4WD Dualrange Lock nut-22 with Socket Wrench (899984103). 6-51 (899884100) 6-29 . 6-47 4) 5-speed Raise the lock nut staking portions. 3) lather than 5-speed I Snap ring with Expander (899474100). DI •••••mbly Fig.MANUAL TRANSMISSION AND DIFFERENTIAL 24) 14wD Dual-range I Counter gear from main case (R. But if replacement is required. 6-50 1} Transmission Main Shaft Assembly 1) 14wD Dual-range I Separate main shaft ASSY from input shaft CP. b.H. ' NOTE: Be careful that two neadle bearings and counter gear collar in counter gear do not drop. if there is no problem. • High-low synchronizer hub • High-low synchronizer ring • Input low gear • Input low gear collar • Needle bearing (22 x 28 x 23) • Input low gear spacer • Ball (3. and remove high-low synchronizer ring at this time. Fig. 6) Remove the following parts with Remover (899864100) and Retainer (899714110). Raise the lock nut stlking portions before removing lock nut. I I 7) 3rd drive gear bushing may be left fitted. and then remove lock nut with Socket Wrench (899988608) and Holder (898938600).

Fig.H. 6-55 Fig. and L. 6·56 Retainer (899714110) 2 Remover (899864100) A12·222 Fig.rq~ ' / v ~ A 12'()36 Fig. and axle drive shafts. I 8) Remove the following parts with Retainer II (899858600) for 1600 or Replacer (498517000) for 1800.H. differential pinions.MANUAL TRANSMISSION AND DIFFERENTIAL 2) l4-speed 1 Remove the following parts with Remover (899864100) and Retainer (899714110). 6-57 Fig.H. • 1st driven gear • 1st-2nd needle bearing race • 1st-2nd synchronizer hub Take care not to interchange R. 11800 1 10 bolts and crown gear. • Insert stopper plate • Insert guide • Synchronizer hub • 5th driven gear • Needle bearing 4) 1 5-speed 1 Remove the following parts with Remover (899864100) and Retainer (899714110).H. I NOTE: Take out key before removing needle bearing race. 6-30 . snap rings. • 5 th needle bearing race • 5th driven gear thrust plate • Ball bearing • 3rd-4th driven gear 1 Remover (899864100) 2 Race 3 Collar 4 Washer 5 Ball bearing (25 )( 70 )( 30) 6 Retainer (899714110) 3) Differential Assembly 1) R. 8 bolts and crown gear. 1 Remover (899864100) 2 Retainer (899714110) Remover (899904100) A12'()30 A12·202 ~~ (\ y. • Ball bearing • 3rd4th driven gear • • • • • Transfer needle bearing race Drive pinion collar Washer Ball bearing 3rd-4th driven gear A12·031 Retainer II (899858600) 2 Race Fig. 2. 6-52 3) I 5-speed I Remove the following parts. differential side gears and washers. 2) Crown gear 11600 L Straighten crown gear lock washer. and L. 6-53 5) 1 4WD & 4WD Dual-range Remove the following parts with Remover (899864100) and Retainer (899714110). 7) Remove the following parts with Retainer (899714110). • 1st-2nd needle bearing race • 1st driven gear thrust plate 4) Differential pinion shaft. 6·54 NOTE: 6) 2nd driven gear and needle bearing by hand. axle drive shafts. 3) Drive out straight pin toward crown gear with Remover (899904100).

gaskets. 3) Snap ring (IN-56) with Pliers (398663600). gasket. gasket. while holding input shaft holder. like. reverse accent shaft and reverse return spring. 3) Back-up light switch. 2) Punch out rear drive shaft with a hammer and an aluminum rod. Plug. A12·227 Fig. 6-58 a. 6) Back-up light switch. 6-60 4) Remove the following parts with Remover (899864100) and Retainer (899714110). 6-61 Fig. There is no spring and ball in the lower filler hole for 4-speed. Fig. 4) Snap ring with screwdriver or the Fig. reverse accent shaft and spring. • • • • • • • Ball bearing Thrust plate Transfer driven gear Bushing Sleeve and hub Spacer Ball bearing 1 Input shaft bolder 2 Input shaft 5) Transfer Case Assembly (14WD & 4WD Dual-range 1) 2) and 3) I) Shifter arm. Fig. A 12'()38 3) Lock nut-18 with Holder (899884100) and Socket Wrench (899988608). Filler. 6-59 2) Wind vinyl tape on the spline of input shaft. 6) Ball bearing with Remover II (899858600). Aluminum rod 7) Input Shaft Complete (!4WD Dual-range I) 1) Oil guide and input shaft holder shim. 5) Strike out needle bearing with an aluminum rod. 2) Plug. b. springs and balls. Raise the staked portion before rotating the lock nut. input shaft retainer and input shaft cotter. 6) Extension Assembly (14WD & 4WD Dual-range I) 1 Remover (899864100) 2 Retainer (899714110) A12·228 1) Snap ring (inner 72) from extension with screwdriver or the like. 6-64 A12-351 6-31 . NOTE: Fig. 4) Transmission Rear Case Assembly Other than 4WD & ) ( 4WD Dual-range 1) Fillers. reverse accent spring ball. gasket. 6-63 5) Snap ring (Outer). 6-62 A12·348 // NOTE: 4) Take out input shaft by tapping the shaft end with plastic luunmer.MANUAL TRANSMISSION AND DIFFERENTIAL 5) Roller bearing with Puller ASSY included in Puller Set (899524100). and Seat (399520105). ~Iier 13986636001 Fig. Shift sleeve into drive position. NOTE: The quantity of selective shim is 0 to 2 sheets.

Correct or replace. (2) Excessively worn bearing at any part. No. (3) Lubricate bearings with gear oil and rotate. damaged or rusted ball. I Bearing Parts Inspection (I) Broken. 1800: 21 x 10 x 35) should be checked to see if it rotates smoothly before disassembling drive pinion. Inspection Disassembled parts should be thoroughly washed and carefully checked. damage or excessive wear on tooth surface. NOTE: aall blaring for drive pinion rlar Replace..1--. (2) Rough or damaged cone that mates with synchronizer ring.069 in) Replace. Rotation is not smooth or unusual noise develops. AJ Fig. 3 Synchronizer ring (I) The contacting surface (three grooves) with synchronizer hub insert is worn into steps or unusually worn. outer race or cage.Stenderd gep 1.r- A12·254 6-32 . 2 Replace.6 mm (0.020 in) _ I-. 6·65 . Correct or replace. (1600: 25 x 10 x 30. Replace. Corrective action Replace. (3) Damaged inner or end surface of gear. Gear (I) Break.5 mm (0.MANUAL TRANSMISSION AND 01 FFERENTIAL 7. Synchronizer ring Limit: 0. Replace. Since preload is applied to this bearing. Replace. (4) Any other problems. (2) The clearance shown in the figure is extremely small when ring is forced against the gear cone. its rotation may be felt to be a little heavier than other bearings.

(I) Damage. ! (3) Any other problems. Correct or replace. Replace. (5) Excessively worn or damaged axle drive shaft journals contacting the differential case. Replace. (3) Damaged. I i I L (4) Cracked. Correct or replace. i (2) 7 O-ring Any other problems. Replace. side gear. Replace. damage or excessive wear on seal surface. excessively worn or seized tooth surfaces of crown gear and drive pinion. worn or seized differen· tial pinion. Replace. i Correct or replace. Replace. differential pinion shaft and straight pin. (I) Deformation. (1) Damaged. Replace. Replace. excessive wear or bend. hardening.1 x 45 x t). (4) Unusual wear or uneven wear on ring inner surface. Corrective action 4 Synchronizer hub and insert (1) Excessive wear into steps on hub spline or excessive wear on hub end face. (2) S Gear shift mechanism Any other problems. washer (35. Replace. Parts Inspection (3) Damaged inner surface or tooth surface. Replace. 5 Bushing and race (1) Damage or unusual wear on slid· ing part. (2) Deformed or excessive worn hub inserts. Replace. (2) Excessively worn or damaged roller bearing contact surface of drive pinion. hardening and excessive wear on the lip. 6-33 . worn or damaged differential case. Replace. Correct or replace. Replace.MANUAL TRANSMISSION AND DIFFERENTIAL I No. (2) 9 Differential gear Any other problems. (2) 6 Oil seal Unusual wear on the inner face. (I) Damage. Correct or replace.

. b.. Before assembling main shaft.Installer (899874100) .020 (1. 10 Parts Rear extension bushing Excessive scratches.er) 4 Spring (Synchronizer hub) Fig. 3 Hub (Synchroni7..3780 mm (in) Used reamer size (for reference) mm (in) 35. Pay attention to the assembling direction of bushing.Remover (899714110) NOTE: a. 6-34 . Chamferi"O- Fig.MANUAL TRANSMISSION AND DIFFERENTIAL No. ball bearing and bushings suffi· ciently. with the synchronizer ring groove.~. 6-68 Synchronizer hub side I Retainer (8997141 10) 2 Installer (899580100) 3 Bushing NOTE: Install springs on both sides so that relative positions of cut ends are 1200 apart 3) Install 3rd drive gear and synchronizer rings and hub which were subassembled in 2). If the hub cannot be inl8l1ed by hand. cut it with a hacksaw blade and pull it out from the front to the rear. Corrective action NOTE: a. Inspection wear or considerable Replace.Installer (899580100) . 4-speed . b. ro"l~ A12-473 Fig. Afterthe bushing has been replaced.009 .000 bushing hole (1. 6-66 2) Install three synchronizer inserts. finish the inner surface of bushing with a reamer to conform with the outside diameter of the end yoke of propeller shaft if necessary. Sleeve (Synchronizer) 2 Insert (Synchronizer) o-c . Take care so that the insert is in lin. Inner dia. UI8 a press to install.1. of fmished 35.35. c.Installer (899580 I 00) . Assembly NOTE: Gaskets should be replaced with new ones. synchronizer sleeve and two synchronizer springs on synchronizer hub in advance. .3795) 35. When pulling out the bushing. 6-67 Sy. When press·fitting a new bushing into extension. NOTE: a.Remover (899714110) 5·speed .3787) 8.039 1. apply transmission oil to needle bearing. 1) Transmission Main Shaft Assembly 1) Install 3rd drive gear bushing with the following special tools.3783 . the groove on exten· sion and the oil hole of the bushing should be aligned correctly.

5) Install 4th drive gear and 4th drive gear thrust plate. Be sure to use 4111 drive gear having discrimination groove on its to01ll surface. Part No.MANUAL TRANSMISSION AND DIFFERENTIAL b.1047) 2.0988) 2.. 6-75 Chamfering Chamfering A 12·260 Fig.54 (0. 7) Other than 5-speed Assemble snap ring with Press ASSY (899754110).0953) 2.51 (0.69 (0. 6-74 6-35 . b. Select a suitable snap ring from 1IIe following table so 1IIat 1IIe play in 1IIe axial direction is 0 to 0. A12·474 b.0020 in). Fig. 6-72 2 Synchronizer hub (899714110) Fig. 6-70 4) Install 4th drive gear bushing with Retainer (899714110) and Installer (899874100).85 (0.57 (0.42 (0. 1600 • Remover (899714110) • Press ASSY (899754110) 1800 • Remover (89971411 0) • Installer(899874100) Fig.48 (0.63 (0.66 (0.0941) 1 Installer 3 Retainer (899874100) 2 Bushing (899714110) 1 Press Assembly 3 Retainer (8997S4110) A 12'()53 (899714110) 805022019 805022030 805022031 2 Bearing Fig.60 (0. 6-69 NOTE: .1122) 2. always replace it with a new one. I I A12'()51 1 Main shaft 3 Retainer Fig. Be sure to use 3rd drive gear having discrimination groove on its to01ll surface. 6-71 Fig..45 (0. 6-73 NOTE: .1024) 2.1012) 2.39 (0.1059) 2.06 mm (0 to 0. 6) Install ball bearing with the following special tools.1035) 2. When reassembling a snap ring.0965) 2. A12·054 1 Press 2 Snap rinj\ 3 Guide NOTi: Pay attention to 1IIe assembling direc- tion of bushing. Pay attention to 1IIe assembling direction.1000) 2. 805022010 805022011 805022012 805022013 805022014 805022015 805022016 805022017 805022018 Thickness mm (in) 2.0976) 2.

6·77 NOTE: After tightening the lock nut. Part No. 1 Needle bearing (25 x 42 x 20) 2 Ball (3.9688) 3 Input low gear spacer 4 Needle bearing (22 x 28 x 23) 5 Input low gear collar 6 Input low gear 7 High-low synchronizer ring 8 High-low synchronizer hub subassembled in 10). I I NOTE: 12) 14WD Dual·range I Install snap ring (Outer. 805022010 Thickness mm (in) 2. Fig.0941) Spring A 12·475 1 Retainer (899714110) 2 Press (899754110) Hub Fig.1012) 2. stake it.0024 to 0. _ _--L . 6-80 ..100 mm (0.69 (0. I c.51 (0.. and make sure to rotate lightly by means of proper side clearance. align the ring groove and insen.. 6·76 ~ Front side Rear _--1. When installing high-low synchronizer ring.0953) 2. 6-36 1 Guide (499257000) 2 Press (899754112) 3 Snap ring (Outer-22) Fig. Pay attention to the assembling direction of hub.L_ - 805022011 805022012 805022013 805022014 805022015 805022016 805022017 805022018 805022019 805022030 805022031 side NOTE: A12·476 When assembling key.66 (0.1035) 2..ll. 10) 4WD Dual-range Install three high·low synchronizer inserts.60 (0.0976) 2. Be careful not to hit needle bearing A12·353 Fig. b. I Holder (R98938600) 2 Socket wrench (899988608) A12·145 Fig. b.060 to 0. always replace it with a new one. 6-78 Torque 73 (7. When assembling a snap rino.0039 in). tap the gear end surface forward with a plastic hammer.. 6·79 NOTE: a. on the stepped ponion of main shaft. 62ft-Ib) 11) 14WD Dual-range Install the following parts onto transmission main shaft. 9) 15.22) onto main shaft with Guide (499257000) and Press (899754112) included in Press ASSY (899754110).48 (0.4 54 84N·m 8. pay attention to the groove.1122) 2.45 (0..39 (0.0988) 2. b..42 (0.1059) 2.1024) 2.6 kg·m.57 (0.. If input low gear rotates heavily. Install springs so that the relative positions of cut ends are 1200 apan. sleeve and two springs on synchronizer hub.85 (0.1000) 2.1 047) 2. Select a suitable snap ring from the following table so that the play in the axial direction is 0. a. NOTE: a.54 (0.63 (0.MANUAL TRANSMISSION AND 01 FFERENTIAL 8) Assemble woodruff key and then 5th drive gear with Retainer (899714110) and Press (899754110).speed I Tighten lock nut·18 with Socket Wrench (899988608) and Holder (898938600).0965) 2.

use a press to install. 6-85 A12-059 Fig. 6·87 1 Installer (899580100) 2 Installer (499277000) 31st-2nd needle bearing race a. A12-454 7) Install 3rd-4th driven gear with Installer (899580100). NOTE: Fig. 6-81 6) Install needle bearing. 6-82 A12·062 3) Install three Ist·2nd synchronizer inserts. c. 1st gear side 11IU--r=~lll 2nd gear side Be sure to use 2nd driven gear having discrimination groove on its hollowed surface. Fig. 2) Install 1st-2nd needle bearing race with Installer (499277000) and Installer (899580100). 6-83 A12-455 NOTE: Installer (899580100) 2 Installer (499277000) 3 1st driven gear thrust plate I A12-463 a. Install the springs so that the relative positions of cut ends are 120 apart. b.MANUAL TRANSMISSION AND DIFFERENTIAL 2) Drive Pinion Assembly 1) Fit roller bearing in drive pinion. p0 0 ! f @ @ A12-066 1 lst-2nd'synchronizer hub 2 Reverse driven gear 31st-2nd synchronizer insert 4 I8t 2nd synchronizer spring Fig. 6-88 6-37 . 2nd driven gear and inner key into the groove on drive pinion. reverse driven gear and two springs on 1st-2nd synchronizer hub. ht-2nd synchronizer hub II . Be sure to use 1st driven gear having discrimination groove on its hoi· lowed surface. NOTE: NOTE: Installer (899874100) and Installer (899278600) are available instead of Installer (499277000). b. Pay attention to the 1st·2nd syn· chronizer hub assembling direction. 1 Installer (899580100) 24th 3rd driven gear Fig. 1st-2nd synchronizer rings and 1st·2nd synchronizer hub subassembled in 3). If 1st·2nd synchronizer hub cannot be installed by hand. Install 1st driven gear thrust plate with Installer (499277000) and Installer (899580100). 0 1 Installer (899580100) 2 Installer (499277000) 31st-2nd needle bearing race Fig. Take care so that 1st-2nd synchro· nizer ring groove is in line with the insert. 6-86 Reverse driven gear Fig. 6-84 4) Install needle bearing. Low High A12-067 Fig. 1st driven gear. 5) Install 1st-2nd needle bearing race with Installer (499277000) and In· staller (899580100).

6-38 . 6-94 5th gear side 1 Holder (4th/3rd driven gear) (899884100) 2 Socket wrench (899984103) A12-028 14) !4WD & 4WD Dual-range! Tighten lock nut-22 with lock washer22 temporarily. .62 ft·lb) NOTE: Stake the lock nut at 2 points. Installing order A12·140 NOTE: Stake the lock nut at two portions to prevent it from getting loose.8. A12·048 NOTE: Be sure not to stake the nut at this Fig. -{JI$ 7 I 6 I 5 'f 4 ' 3 I~ 2 i. A12·063 A12-477 Fig. 4-speed • Installer (899580 I 00) 5-speed • Installer (899580100) • Installer (899874100) 10) IS-speed I Install 5th driven gear thrust plate and then. synchronizer hub. insert stopper plate. 54 . Torque 78 N·m (8 kg-m.6 kg-m. and tighten lock nut with Socket Wrench (899984103) and Holder (899884100).84 N'm (7. 6-91 11) IS-speed I Install needle bearing. drive pinion collar. insert guide.. 12) I 5·speed I Tighten lock nut-22 with Socket Wrench (899984103) and Holder (899884100) . 6-90 Fig. Fig. 6-93 time. \ ~·lnst8I1er Torque (899874100) 73 . 6-92 A12·238 NOTE: Pay attention to the synchronizer hub assembling direction. transfer needle bearing race and transfer drive gear to drive pinion with Installer (899580100). 9) 14-speed I Install lock washer-22. 6-89 1 Installer (899874100) 25th needle bearing race NOTE: Some ball bearings may be installed in the drive pinion without press tightness. install 5th needle bearing race with Installer (899874100). 13) 14WD & 4WD Dual-range I Install washer. I Installer (899580100) 2 Race 3 Collar 4 Washer Fig.MANUAL TRANSMISSION AND DIFFERENTIAL 8) Install ball bearing with the following special tools. lock washer-22 and lock nut-22.4 . Fig. but it causes no problem in practical operation. 58 ft-Ib) ~@)eQ~~ei~: 9 8 I . 5th driven gear.

1 x 45 x t mm) Part No. 6·98 Installer (399790110) Seat (399520105) A12·067 803135012 803135013 803135014 5) Install crown gear on case. NOTE: Notice that the cups of roller bearings are provided as a set.925 . 803135011 Thickness mm (in) 0.15 (0.975 (0.0.0059) a.0404) 1.49 ft·lb) Fig.6.0404 0.0. Finally drive pin until it falls in about 1 mm (0.000 1.0394 .950 .0. Stake the hole portion after driving it into the differential case. Washers (35.0413) I 2 Fig. I NOTE: NOTE: Unit: mm (in) 1600 Standard backlash 1800\ 0. 6-39 6) Install axle drive shafts and lock it with snap rings.8 kg·m.6.8 kg-m.05 . b. Bend lock washers to prevent bolts from working loose after tightening bolts.0384 . 42 .0051 - 0.0.000 (0. If the backlash is inappropriate. 6·99 A12-263 \1800 \ Install crown gear. 6·97 Torque A 12·262 Fig. 6·96 4) Install bearing cone on differential case with Installer (399790110) and Seat (399520105). Select proper snap ring so that the clearance between differential pinion shaft and tip of axle drive shaft is within the specified range.025 (0.8 . and then insert differential pinion shaft.050 (0.950 (0.1. 11600 I Install crown gear with lock washers.1 x 45 x t mm) on differ· ential case. 57 -67N·m (5. Replaca lock washers with new ones. 6·95 Torque 2) Measure backlash between gear and pinion with Magnet Base (49824· 7001) and Dial Gauge (498247100). 3) Align the differential pinion shaft hole with the holes on differential case and drive straight pin (4 x 44 mm) by tapping lightly with hammer from the crown gear side.025 . i (0.0374) 0.49 ft·lb) Pinion shaft A12-261 803135015 Fig.0374 . .0.13 .0.975 .8 .18 0. 42 . make adjustment by using proper washers.0020 0.MANUAL TRANSMISSION AND DIFFERENTIAL 3) Differential Assembly 1) Install differential side gears and differential pinions together with washers (35.0384) 0. 57-67N·m (5.0.(071) Lock washer A12·035 Dial Gauge (4982471001 \ Straight pin Fig.1.0364 0.0394) 1.04 in) with Remover (899904100).

0.1.2 .0 ft-Ib) 2) Fit reverse return spring and reverse accent shaft and then tighten plug with aluminum adjusting gasket.0. 23 . and fit snap ring with your fingers. (0 . 6-101 Fig.1.5 .25 (0.27 ft-lb) NOTE: When installing the needle bearing.37 N'm (3. 6-104 2 Spring 3 Gasket 4 Filler A 12-251 3) • • • • Install the following parts. Outer snap ring Torque 9 .8 kg-m. There is no spring and ball in the lower filler hole for 4-speed. 6-103 Fig.8.144 balls and reverse accent springs and then tighten fillers with gaskets. put a jig on the side with the stamped marking.1 kg-m.0492) NOTE: 031526000 a.11 N'm (0.0 kg-m.9 .3_8 kg-m.2 . 1 Ball Fig. Torque 31-37N·m (3.0453 .0.20N·m (1. Make certain that the upper spring is yellow and lower one is red.27 ft-Ib) Torque Part No. 6-102 Torque 9 . 6.9 . 6-40 2 Transfer case Fig.11 N'm (0. b. Reverse return spring Reverse accent shaft Aluminum gasket Plug 31 .00 . 6·100 3) Fit 7. 1 Transfer case 2 Reverse return spring 3 Reverse accent shaft A 12-478 4) Transmission Rear Case Assembly Other than 4WD & ) ( 4WD Dual-range 1) Install back-up light switch with aluminum gasket and tighten it.1.8. 6.0394 .MANUAL TRANSMISSION AND DIFFERENTIAL Standard clearance 0.1. 5) Transfer Case Assembly (14WD & 4WD Dual-range I) 1) Install needle bearing into transfer case with Press ASSY (899754110). 6-105 A12-479 .5 .008 in) P#:~~ needle bearing Front ~ 1 Spring 2 Reverse accent shaft 3 Gasket 4 Plug A12-253 Level A12-422 Fig.1 kg-m. 12 .15 .0.144 ball Reverse accent spring Aluminum gasket Filler Torque 16 .6 . 805026010 Thickness mm (in) 1.2mm .2.14 ft-Ib) Fig. 23 .0 ft-Ib) 2) • • • • Install the following parts.10 (0.3.0433) 1. 7.

6-111 CD A12·480 2) Hammer rear drive shaft into extension with a plastic hammer. 16 .6 .8. 6-108 Fig. 7) Install ball bearing onto rear drive shaft with Press ASSY (899754110) and Stand (398405200). Press Assembly NOTE: Fig. 6-112 A12·481 Fig. 12 .20N'm (1. (899754110) 2 Ball bearing 3 Stand (398405200) A12·210 Transfer case Fig. 6-107 A12·229 8) Shift sleeve to the drive position and tighten lock nut-18 with Holder (899884100) and Socket Wrench (899988608).0 kg-m.2. 6-109 Be sure that oil seal does not protrude from the case end surface.6 kg-m.4 . 3) Fit snap ring to the groove inside of extension. I) Install ball bearing onto rear drive shaft with Installer (899580100) and Retainer (899714110). 73-84N·m (7.62 ft·lb) Fig. 6-41 .MANUAL TRANSMISSION AND DIFFERENTIAL 4) Install back-up light switch with aluminum gasket. Fig. 54 . 6-106 'Extension A12·164 5) Install oil seal on transfer case. 4) Install rear drive spacer. synchronizer hub and sleeve onto rear drive shaft. NOTE: Stake the lock nut at four positions after tightening. 1 Back-up light switch 2 Transfer case 3 Switch for 4WD indicator light 6) Install transfer driven gear and thrust plate onto rear drive shaft.14 ft-Ib) Torque @ 1 Installer (899580 100) 2 Relainer (899714110) A12·163 1 2 3 4 Installer (899874100) Bushing Rear drive shaft Stand (398405200) A12·241 Fig. 6·110 6) Extension Assembly Torque (!4WD & 4WD Dual-range I) 5) Install transfer driven gear bushing onto rear drive shaft with Installer (899874100) and Stand (398405200).

and Proper Values for Shims and Backlash Drive pinion The lower figure is the match number for combining it with crown gear. NOTE: Wind vinyl tape on the spline portion of input shaft. 6·113 2) Install input shaft cotter. Part No. 6·114 6-42 .0988) 2. ment.) 2. Crown gear The first figure indicates a number for combination with drive pinion.0031 in). 447257000 447257001 447257002 Thickness mm (. NOTE: If no upper figure is shown. A12·3SG Fig. the value is zero. input shaft holder. 6·118 9. 6·115 A12-354 1 Installer (899580100) 2 Press (899754112) 4) Install input shaft into holder by tapping it lightly by hand. A12-355 Part No.51 (0.1020) Fig. Plier (3986636001 Dummy Collar (398507703) A12-348 Fig. 6·116 A12-357 and Crown Geer. NOTE: Apply greese onto the lip portion.08 mm (0 to 0.43 (0.83 (0.0752) Fig. 1 O-ring (55. NOTE: Before pressing. 6·117 6) Install O·ring and oil guide onto .91 (0.0957) 2. The upper figure is for shim adjust. insert snap ring (Inner-56) between input shaft gear and ball bearing.0689) 1.75 (0.MANUAL TRANSMISSION AND 01 FFERENTIAL 7) Input Shaft Complete (14WD Dual-range I) 3) Install oil seal into input shaft holder with Dummy Collar (39850· 7703). 1) Install ball bearing onto input shaft with Installer (899580100) and Press (899754112) included in Press ASSY (899754110). 6·119 A12-413 1 Cotter 2 Retainer 3 Snap ring (Outer) 4 Thiclcnesa PUle Fig.08 mm (0 to 0.59 (0. Fig.7 x 2. NOTE: Select a suitable snap ring from the following table so that the play in the axial direction is 0 to 0.0031 in).4) 2 Oil guide Fig. 5) Install snap ring (Inner·56) into holder with Pliers (398663600). 805156020 805156021 805156022 Thickness mm (in) l. The following figure indicates a value of appropriate backlash. input shaft retainer and snap ring (Outer) onto input shaft. Installation 1) Matchmarks on Drive Pinion NOTE: Select a suitable cotter from the following table so that the play in the axial direction is 0 to 0.0720) 1.

0197) Torque 26 . b.15 (0.275 (0.1 = Value on the drive pinion +0. 6-727 0. 6-720 0.H.0118) 0.25 (0.0079) 0.30 (0.0089) 0.3.225 (0.0089) 0.0118) 0.0098) 0.1 = 0.3 kg-m.20 (0.5 correctly when the plate end and the scale end are on the same level.7 .175 (0. 4) Slide the drive pinion gauge scale with finger tip and read the value at the point where it matches with the end face of drive pinion.50 (0.MANUAL TRANSMISSION AND DIFFERENTIAL 2) Adjustment of Drive Pinion Shim 1) Place drive pinion on transmission main case (R.Q108) 0. 5) The thickness of shim shall be determined by adding the value indicated on drive pinion to the value indicated on the gauge.0108) 0.) without shim and tighten drive pinion. 20 .) Select one to three shims from the next table for the value determined as described above and take a shim thickness which is closest to the said value. Tighten two bolts. Example 0.0059) 0. 6-43 .0197) Fig.15 (0. (Add if the figure on drive pinion is prefixed by + and subtract if the figure is prefixed by-. Thickness mm (in) 841968601 Fig.24 ft-lb) A 12-074 441967106 441967107 441967108 2) Inspection and adjustment of Gauge ASSY (1600: 899914100.275 (0.25 (0.50 (0.55 Where 0.0059) 0.0079) 0.45 =Value measured by the scale +0.0069) 0. a.175 (0.32 N'm (2. Thickness mm (in) 441967101 441967102 441967103 441967104 441967105 Fig.30 (0. Loosen the two bolts and adjust so that the scale indicates 0.0098) 0.20 (0. Drive pinion shim 1800 Part No.45 + 0.225 (0. 1800: 499917100).1 Drive pinion shim 1600 A12-073 I Plate 2 Scale Part No. 6-722 A 12-076 841968606 841968602 841968607 841968603 841968608 841968604 841968605 3) Position the gauge by inserting the knock pin of gauge into the knock hole in the transmission case.0069) 0.

50.52 mm (0.0205 in). Fig.1. C: Main shaft ASSY length as shown in the figure.88 and less (1.39 and more (1.35 in) B: Input shaft CP length as shown in the figure. 6-124 2) Install transmission main case (L.H. D mm(in) Number of shim Nothing 4) Installation of Transmission Component Parts I) Install oil seal into axle shaft oil seal holder with Installer (399790 II 0). A = 339 mm (13. Screw axle shaft oil seal holder with· out O·ring into case from the bottom by using Wrench (399780111).9839) 49.MANUAL TRANSMISSION AND DI FFERENTIAL 3) Adjustment of Input Shaft Holder Shim (4WD Dual-range) A12·359 Fig. 6·123 1) Place transmission main shaft ASSY and input shaft CP on transmission main case without shim. 6-44 .9835) 49.9638) 1 Installer (399790110) 2 Holder Fig.0189 to 0. 6·125 A12·0?? 1 2 A12·361 NOTE: The thickness of shim is 0.38 (1.) on Stand (399935100).(B +C) A: Main case length as shown in the figure.48 to 0. 2) The proper number of shim can be determined as follows: D =A . A12·360 50.89 .9642 .

bove tha and lurface of tha c.ft dOli not protruda .). 6·737 Fig. Install speedometer driven gear on shaft and retain with snap ring.ke lure to Instill the holder with 'L' marked oU . 1 Two counter gear washers 2 Two needle bearings 3 Counter gear collar 4 Counter gear S Knock pin 6 Clip NOTE: Make lura that cut-out and lurfaca of counter ge. 6·729 A12·412 .15 Ie 115.MANUAL TRANSMISSION AND DI FFERENTIAL NOTE: •• Stop scrawlng wh.2.15 Ie 10 mm 10.H. and push it perfectly into case. I 8) Install reverse idler gear and reverse idler gear shaft and retain with knock pin. 6-726 b.~'c.4 .r [12. Install reverse shifter ralltnto case and arm with Installer (399411700) and then fit snap ring (outer).'2·082 Fig.1 shown in th ••bove figura.482 Ie 0.. A12·141 ..t~~ ''. 4) Drive in 011 seal with Press (499827000).H..728 Fig.al. 3) After installin.ly amb.lS. 6·134 6-45 . (J. 13. 12·080 1 Arm (reverie shifter rail) 2 In.Wrench (399780111)- 1 2 A12·483 Fig.8S .n tha thrlld il antlr. 7) I S-speed I Put reverse shifter arm spring and ball in reverse shlfter rail arm.J I \~ . I ~~\\7i\. =0 ..h.1 N·m Torque (1.p ring 2 Knock pin (4 )( 6) 'WI.810 Ie 0.ddad bafora the hold. 10) !4WD Dual·range I Install the following parts onto counter gear shaft as installing shaft into main case (R.ft 1 Q·rlna (21. 6) Other than S·speed 1 Install reverse shifter rail arm to the end of reverse shifter lever. inllrt it from thl driven gaer lide. ~..1 . 1 O·ring 2 Knock pin (at front side) I 18.e.. S) !4WD Dual-range Install oil seal in transmission main case (L. Fit reverse shifter rail and tiahten shifter fork set screw... . 6·733 A12-071 Fig.taller (399411700) Fig.~ ~---.). M. outer snap ring and washer onto speedometer shaft.5 )( 1.0 I' \"J~~.6 ft·lb) . fit them into case..12·3e2 Sh.1 S kg·m.21.~'-~ '\ '---. 6.~ Fig.39 Inll Fig. I 9) [4WD Dual·range Install the following parts onto counter gear shaft.5) _Outer In. 6·727 .r sh.r rllches the specified POIition.. 730 NOTE: When instilling tha outer snap ring (806012020) onto the Ipeedometer drivi shaft.

6 .2.063) 1.1. 6-137 0-0.0.0.0.020 in) A 12·142 Fig.0mm (0.8 . 440627101 440627102 Mark I 803015085 13) Adjustment of reverse idler gear position.087 .071 .0.2 -.0.059 .0. Shift reverse shifter rail and select reverse shifter rail arm (4-speed) or reverse shifter lever (5-speed) so that the clearance between reverse idler gear and case wall becomes the specified value.055 .2. Washer (15.5 mm (0 . install ball. 6-138 842004103 Fig.0. 6-139 Gap Fig.118 in) Remarks Further from the case wall Center Closer to the case wall 15) Installation of 5.6 (0. Mark Remarks Approach to the wall of case (L.059 .094) Remarks Further from the case wall Center Closer to the case wall 803015082 No mark 3 803015083 Plug 2 Gasket 3 Spring 4 Ball A12-250 340621703 803015084 Fig. 803015081 Thickness mm (in) 0.039 .0.56 x 10.047) 1.1.059 .118 in) 0.0 . then select the washer (15.1 plunger.024 .5 x 21 x t mm) out of 5 kinds of washer so that the gap between washer and case wall becomes the specified value.) Standard Recede from the wall of case (L.) Washer 115.H.2 (0. spring and gasket into case and tighten plug.0 mm (0.3.H.0 mm (0.4 (0.3. 6-46 .079) 2.8 (0.4 .118 in) 2 Reverse idler gear AI2-084 AI2-484 Fig.5 .3.020 in) IS-speed I Install plugs into the case and reverse shifter rail arm. 1. I Other than 5-speed I Reverse shifter rail arm Part No. 340621701 340621702 Mark I Part No.031) 1.5 .MANUAL TRANSMISSION AND DIFFERENTIAL II) I 4WD Dual-range I Position the cut-out portion of counter gear shaft as shown in the figure. I Other than 5-speed I Install the plunger into the case. shift it to the neutral position.0.5 x 21 x II 842004101 I 842004102 No mark 1. 6-136 Reverse shifter lever (1800) Part No. Oearance: 1.0. x 11. 6-135 A12·364 3 12) For reverse shifter rail.0.5 x 21 x t mm) IS-speed I Reverse shifter lever (1600) Part No.0 (0.0.5 mm (0 .5 .9 plunger No mark 3 440627103 Clearance 14) IS-speed I Adjustment of gap After selecting reverse shifter lever.

6·146 21) 14WD Dual·range Install high·low shifter fork with two pieces into high·low synchronizer sleeve. 6-142 NOTE: a. 6-41 A12-367 Fig. . align the ring groove and insert. and turn it upward by 90° .o88 Fig.. 6·144 19) \4WD Dual·range I Put main shaft ASSY.H. High-low I Fig.H. 1st-2nd shifter rail 18) Other than 4WD D~al..speed Install Sth shifter fork on reverse shifter rail and secure with spring pin. A12.range I I After installing needle bearing and oil seal on transmission main shaft.56 x 10. A12-48!i Fig_ 6·141 A12·366 17) Install differential. Make sure that oil guide is positioned in the groove of main case (L. NOTE: Before installation.. b.MANUAL TRANSMISSION AND DIFFERENTIAL NOTE: Be sure to insert the correct plunger. place the open end of moving flange on the ball bearing as shown in the figure. NOTE: ring a. and L. I Fig. install main shaft ASSY into transmission case. Wind vinyl tape around the clutch spline. b. A12·266 I 20) 14WD Dual·range Install transmission main shaft ASSY prepared in 19) into main case. 6·145 16) IS. rang Reverse shifter rail 5. When inltlliing high"ow synchronizer ri . 6·140 Fig. 6·147 . 1 2 3 4 A12·365 . high-low synchronizer ring and input shaft CP together. needle b~aring. Ensure that the knock pin of the case is fitted into the hole in the needle bearing outer race.H. Co In order to prevent the flange of bearing from damage.ol!i Fig. b. 6·143 NOTE: a. axle drive shafts. Co Apply gear oil on the needle bearing race surface.556 ball R shIfter rail arm everse ' High·low synchronizer ring Input shaft CP Fig.1 plunger A12 -277 Main shaft assembly Needle bearing 5. A12. wind vinyl tape around the splines of R. Be careful not to separate input shaft CP from main shaft ASSY.). Be sure to install the input shaft holder shims (0 to 2 sheets) selected before.

15. UII the following math ad.1 N·m (1. 25) Fit 5.). To faeilitlte tha oparation. springs and gaskets into the case. 6·154 6-48 .6 ft·lb) Fig. b. Ihift tha othar raill into nautral pOlition.21.4 . When inmiling rail. 18. 6·152 Fig.1 N·m Torque (US .4 . and tiahten plugs. 26) Install 1st-2nd shifter fork and 1st-2nd shifter rail. L NOTE: Enlure that tha knock pin of tha casa il fitted into the hole in tha baaring outer nca. and tiahten set screw. 6·749 24) Install drive pinion with shims selected before into transmission case. 6-748 (j) Turn outer raca 10 that tha mark 23) Ins~all 3rd-4th shifter fork and 3rd-4th shifter rail with 3 x 11. Torque i Fig. shift tha anothar rail (raverll shifter rail) Into nautral pOlition. Torque 18.21. 6·750 NOTE: When inltliling ran. Whan uling mora than two shims for adjustmant. than lIightly move outar raea right and laft and front and raar until knock pin II fitted into tha knock hola.2.1 . turn 3rd-4th shifter rail by aoo 10 that tha plungar dOli not drop.15 ks-m.1 . 18.1 N·m (1.lb) comn to tha edge of OIIa whila lIightly lifting up tha drive pinion.21. Al:Z·0a3 27) For 3rd·4th shifter rail and 1st· 2nd shifter rail.H.range I Install blah-low shifter lever CP into hiah·low shifter fork throuah main case (L.2.2. and do not place shim cut Ind on the lama lida in order to facilitlte tha job. 1 No slit 2 Slit A12·091 Fig.4-IS.85 . Fig.15 kg-m.MANUAL TRANSMISSION AND 01 FFERENTIAL 22) 14WD Dual.6 ft-Ib) Knock pin hole A12·368 A I :z.56 x 10.85 .1 . Fig. and then strike in spring pin. 6·151 b. 6·153 L NOTE: Whan Inltliling ran. install balls.m.oa:z 1 H!ah-Iow shifter lever CPo 2 Hlth-low shifter fork 3 Sprilll pin (5 x 22) Fig. 13. placa thlnnar on8 to flanga lida.6ft.15 kg. CD POliti on the knock hole to tha adga of ctll and put a mark on the top of outlr raca.9 plunger and tishten set screw.1 plunger into the case.15. 13. 13.

4 mm (0.008 in) Approach to 3rd gear by 0.f I 1 I st-2nd shifter fork i ~J ")~~'f ftf"c~ I ~'I\: 'J 'Ji:.008 in) 2 or no mark 3 4 5 3rd-4th shifter fork 842014125 11 mm (0. 442017001 442017002 442017003 442017004 442017005 Identification Mark 1 2 No mark 4 5 Remarks Approach to 4th gear by 0.374 in) 4th drive gear b. i [ A 12·096 I: Part No.016 in) Approach to 4th sear by 0.5 mm (0. rl-.4 mm (0.43 in) 3rd drive gear \ ( 0r 1 9.016 in) Approach to 4th gear by 0.016 In) Standard Approach to Ist gear by 0.008 In) Approach to Ist gear by 0.008 in) Standard Approach to 3rd gear by 0. t.2 mm (0.I 1st-2nd shifter fork Reverse driven gear 1st driven gear 2nd driven gear 842024123 842024124 842024125 r Lr:3~~"' 1 A 1 2·097 3rd·4th shifter fork Part No.4 mm (0. \1600 I 3rd4th shifter fork Identification Mark 1 Part No.{ .2 mm (0..008 in) .016 In) Standard Approach to 3rd gear by 0.. ~ L t-7~7Jmf ~/l~u.MANUAL TRANSMISSION AND DIFFERENTIAL 28) Selecting 3rd-4th shifter fork and lst-2nd shifter fork.008 In) Approach to 3rd sear by 0.2 mm (0.4 mm (0..o .km""!I") . 842024121 842024122 Identification Mark 1 2 or no mark 3 4 5 Remarks Approach to 2nd gear by 0.016 in) Fig.:.016 in) Approach to 2nd gear by 0.2 mm (0.2 mm (0.2 mm (0. Select 3rd-4th shifter fork and 1st-2nd shifter fork so that synchronizer sleeve and reverse driven gear are positioned as shown below when transmission main shaft and drive pinion are placed in normal position (both the main shaft and drive pinion are forced against the forward side without any clearance).' .~ ::r':t·~/I(LI/lu:l. 842014121 842014122 842014123 842014124 Remarks Approach to 4th sear by 0.4 mm (0. 6·155 6-49 .4 mm (0.

008 in) Approach to lst gear by 0.4 mm (0.2 mm (0. ----- Fig. 342031711 342031712 342031713 342031714 Identification Mark 1 2 3 or no mark 4 Remarks Become closer to gear side by 0.2 mm (0. 442027001 442027002 442027003 442027004 442027005 Iden tification Mark 1 2 No mark 4 5 Remarks Approach to 2nd gear by 0.016 in) Become closer to gear side by 0.4 mm (0. 5th shifter fork Part No.4 mm (0.2 mm (0.016 in) Approach to 2nd gear by 0.016 in) 342031715 5 A'2·203 11800 1 5th shifter fork Part No. 6-756 442037015 5 I 6-50 .008 in) Become distant from gear side by 0.2 mm (0.008 in) Center Become distant from gear side by 0.008 in) Center Become distant from gear side by 0.2 mm (0.016 in) -.008 in) Standard Approach to 1st gear by 0.016 in) 29) 1 5-speed 1 Selecting 5th shifter fork.4 mm (0.2 mm (0. Select 5th shifter fork so that synchronizer sleeve is positioned as shown below.4 mm (0.4 mm (0.016 in) Become closer to gear side by 0.008 in) Become distant from gear side by 0.MANUAL TRANSMISSION AND DIFFERENTIAL lst-2nd shifter fork Part No. 442037011 442037012 442037013 442037014 Identification Mark 1 2 3 or no mark 4 Remarks Become closer to gear side by 0.

2.083) Fig.H. be careful not to let oil seal tilt.. Apply liquid gasket (Fuii Bond "c" or equivalent) with no break in the middle. 6-161 Fig. 4pcs . Remove the outer race of upper roller bearing. fork and set screw so that specified value is obtained. in the follOWing sequence..7 kg-m. 15 pcs 10 mm bolt .). d.063) 1. clip.3 kg-m. 13 pcs 10mm bolt . Unit: mm (in) ~ 1600 Non4WD A B 0. oil and dust on the mating surfaces of transmission cases with white gasoline. When joining case (R. A 12·099 Fig.1.7 . 6-159 33) Tighten bolts with bracket. A12·104 Fig...1 (0. replace rail.3 .1 21.012 .. 8 mm bolt 10mm bolt 1600 8 mm bolt .H. 6-162 36) Install upper bearing cup.1. and then put case (R.3 kg-m.42N'm (3. 26 -32N·m (2.3 . and apply liquid gasket (Fuji Bond "C" or equivalent).2. b. 6·160 Fig.6 (0. 17 .20 ft-Ib) 36 . Torque 23 . Put cases togetller so that drive pinion shim and input shaft holder shim are not caught up in between.3 . a. b.6 ft-Ib) Torque A12-425 Fig.) and (L.8 3.122) 1800 0...071 0. Co Confirm tIIat counter gear and speedometer gear are meshed. 18.) together. 6-163 6-51 .0.H. 20 .A12·336 1800 Fig.2.4 15.MANUAL TRANSMISSION AND DIFFERENTIAL 30) Check the clearances 'A' and 'B' at the end of each rail. When positioning oil seal. 6-158 32) Wipe off grease.. 27 .31 ft-Ib) 35) 14WD Dual-range I Tighten three input shaft holder attaching bolts. fit the oil seal end surface to the case end surface A.26 N'm (2.4.24 ft·lb) Torque 4WD 1800 0. 34) Tighten ball bearing attaching bolts at the drive pinion rear.85 ..1 N'm (1.6 (0.012 0. If dimensions 'A' and 'B' are not within specification. 6-157 31) Position oil seal.063) NOTE: a.15 kg·m.7 3.. etc.012 0.. 2 pes 8 mm bolt . NOTE: Insert bolts from the bottom and tighten nuts at the top..3 ..1 (0.H. 13.) to case (L. and high-low shifter lever shaft is inserted perfectly.

To reduce backlash.0. Remove weitht and screw in holder without Q. crown IIIr and drive pinion is h. .70011 G.H. Backlash is insufficient. Tooth contact is correct. Loosen the holder on the lower alde by 1\& notches of lock plate and tum in the holder on the upper alde by the same amount in order to obtain the backluh.0.) from the bottom with Wrench (399780111).1. Screw axle shaft 011 seal holder into case (L. Fit Handle (499927000) on the transmission main shaft. side) by the same amount.107 F/f. a. f. make the following correction. 6-166 d. Move the crown gear back and forth by turning the transmission main shaft until a definite contact pattern is developed on crown gear. Tum in the holder on the upper side additionally by to 1 notch in order to apply preload on taper roller bearing. If it is incorrect. backl'" bttwnn til. Apply a uniform thin coat of red lead on both tooth surfaces of 3 or 4 teeth of the crown gear.0. ~ ~-----FfI.0. Repeat the above sequence several times to ensure the contact point.lde Hel A12·111 8-&2 . loosen holder on the lower side (case L. 6·168 Fig. This is the contact point of crown aear and drive pinion. * 38) Checking tooth contact of crown gear. Shift gear into 4th or 5th and tum the shaft several times.0071 in) 0. Fit lock plate. ttl. Tighten temp ora rOy both the upper and lower lock plates and mark both holder and lock plate for later readjustment. a. side) and turn in the holder on the lower side (case L.rina on the upper side and stop at the point where siight resistance is felt. Set Dial Gauge (498247100) and Magnet Base (498247001). g. 1600 0. Al:2.0051 .H. b.H. NOTE: At ttlia point. side) by the same amount.H.13 .18 mm (0. 1<4882. Oriw. 6·'64 c.0071 in) b. e. 6·161 I . 6·166 FfI. No'rE: The notch of the lock plate moves by % notch if ttle plata is turned upside down. To increase backlash.H. Backlash is excessive. loosen holder on the upper side (case R. Place the transmission with case (L. Toe Ori\/!! side Coast side A12·114 Fig. side) and tum in the holder on the upper side (case R. NOTE: Gear should be shifted into 4th geaf.MANUAL TRANSMISSION AND 01 FFERENTIAL 37) Backlash adjustment of hypoid par and preload adjustment of roller bearing. Insert the needle through transmission oil drain plug hole so that the needle comes In contact with the tooth surface at a right angle and check the backlash.H.18mm (0. and judge whether face contact is correct. .004 .utI <_2471001 8 •• A12. Turn transmission main shaft dozens of turns while tapping around axle shaft bearing holder lightly with plastic hammer. nro. 6·169 Backlash 1800 c.) faclna downward and put Weight (399780104) on bearing cup. Screw in the holder while turning Handle untU a sHaht resistance is felt on Wrench. Fig.

Dimension A mm(in) 3.. lock washer and transfer drive aear from drive pinion. 43) Other than 4WD " 4WD Dual· range Install shifter arm in transmission rear case and install them to main case with aasket and plate.3 .0.7 q·m.1720 .3. NOTE: Clrry out this Job on both upper Ind lower holde.8 qin. Increase its thickness.1772) Part Number 441347001 441347002 Thickness mm (in) 5.197) 5.20 ft·lb) 8-&3 NOTE: For IIIler fitting of fUr CUI.1823) 4.4.13 (0. Ihlft 1st·2nd shifter rail to 2nd position Ind put the shifter Irm In the groove of 1st-2nd Ihlfter rail.4.1327 . Tiahten lock plate.2.1378 . 6·111 .1772 . Uslna Depth Gauae (498147000). 42) Selectina of proper plate.50 (0. 17 .1429) 3.50 .2.2020) Discrimination stamp T71·2 T71·3 FIg. Fig.0 (0.0.63 (0.lb) Torque NOTE: aefore mellUrlng.3.'1·270 F". tip the end of mlln shift by the platlc hlmmer lightly In order to meke the clurance zero between the mlln CUI IUrflce Ind the moving fllnge of buring.50 .26N·m (2. Fit O·rina into the groove and tighten holder into the position where holder has been tiaht.0.6-173 e.1378) Part Number 441342112 441342113 Thickness mm (in) 5. 40) 4WD" 4WD Dual. ened in. I Torque . 22 .ur oil on it. 41) 14wD" 4WD Dual·ranae I Install shifter arm into transfer case. Reduce its thickness.0..37 . 6·112 Dimension A mm(in) 4.0 (0.63 (0.197) 5.2 . The drive pinion shim selected before is too thick.37 .13 (0. A NOTE: Apply .ranpl Remove lock nut.20 ft.27 N·m (2.d. measure the amount (A) of ball bearing protrusion from transmission main case surface and select the proper plate in the following table.50 (0. 16 .2020) Discrimination stamp T81·1 T81·2 39) After checking the tooth contact of crown aears. Then loosen axle shaft holder until the O·ring groove appears. remove the lock plate. The drive pinion shim selected before is too thin. 23 .

48) 14WD Dual-range I Fit shifter fork rail spring and ball in transfer case. Apply gear oil to shifter arm and make sure that oil seal fits in with shifter ann. 6-176 Fig. 6-179 Fig.27 N·m (2. confirm that shifter ann can be shifted smoothly to any select direction.8 kg-m. a. While installing. 16 .20 ft-Ib) 46) I 4WD Dual-range I Install O-ring in the inside of high-low shifter rail bushing. 6-180 47) 14WD Dual-range Fit 5. b. 81 .1 plunger into high-low shifter arm. When tightening.4.2. I NOTE: Apply grease to plunger so that it will not drop off.12.126 N'm (11.2 .56 x 10. Before tightening bolts. the gean (transfer drive and driven) should engage each other. 6-181 6-54 . 25 . Fig.1 Plunger 45) I 4WD & 4WD Dual-range I Install lock washer and lock nut on drive pinion. b.1 kg-m. 10 mm (0. A12·333 50) 14WD & 4WD Dual-range I Install extension ASSY with transfer rear gasket and tighten bolts. 6-178 Torque 110 .30 ft-1b) NOTE: Fig. 6-175 5.56 x 10. and h~gh­ low shifter laver should be shifted to 'HI' or 'LO' position. NOTE: Apply gear oil to rail. 22 . and tighten lock nut while fixing main shaft with Stopper (498787000).MANUAL TRANSMISSION AND 01 FFERENTIAL 44) 14WD & 4WD Dual-range I Install transfer case ASSY to main case with gasket and plate. A12-372 Torque 34-40N·m (3. e.8 kg-m. Torque NOTE: Transfer drive gear should be installed when the clearance between main case and transfer case becomes approx.39 in). A12-373 1 High-low shifter rail 2 High-low shifter ann A12-370 1 Shifter ann CP 2 Oil seal (16 x 26 x S) Fig.5 .93 ft-1b) NOTE: a. 49) 14WD Dual-range I Strike straight pin into high-low shifter rail. Fig. 6-177 A12·371 Fig. After tightening lock nut. stake it to prevent it from turning.2 . gear should be shifted to '1st' position. and install high-low shifter rail with high-low shifter ann.

. c. t:Ht:N IIAL 51) \4WD Install the following parts in transfer I case.. b. b. 6. 6·183 53) 14wD Dual. When installing rail.56 x 10. 57) 14WD Dual·range Fit shifter fork rail spring and 6.. rail A12-377 NOTE: a. I NOTE: Insert knock pin smoothly by aligning the holes of case and rail. 6·185 Fig. Fig. Apply grease to plunger and ball so that they will not drop off. Install fork diagonally so that it does not interfere with high·low shifter rail. d...MANUAL I HAN~MI~~IUN ANU UI . 22 .36 N·m (3.3. A12-378 Fig. a. 6-186 1 Knockpin 2 Oip 56) ~D Dual·range Install transfer ball joint ASSY to transfer shifter rail to the specified length and tighten nut. When installing the ball. Shifter fork rail spring I 55) 14WD Dual. 6.56 x 10. 6·182 1 2 3 4 Fork 5.range Strike in clip onto interlock rail groove.1 plunger b. Co Install rail while pressing the ball downward with proper rod. Apply gear oil to rail.7 mmNut (7. I NOTE: After the straight pin has been struck in. 52) 14WD Strike in straight pin. 5.1 Plunger Spring . align the rail and the hole of high·low shifter arm.028 inl A12-424 Fig. e.1 .01 ±O. Perform this job at the position of '4WD HI' so that the interlock mechanism does not operate. NOTE: a. move transfer shifter rail and check the accent. I --------------~ !1 = 178 ±O. 6-187 I NOTE: a. a. And then rotate the rail by 1800 to i15 proper position.range Install the following parts into transfer shifter fork. Push ball in transfer shifter fork by applying the tapered end. 6-55 Fig. and install transfer shifter rail. 6·184 l 54) !4WD Dual'range Fit a·ring onto interlock rail and insert rail into transfer case. Apply grease to rail. A12-376 I Fig.350 ball And then install it onto synchronizer sleeve. Apply grease to the ball to prevent it from moving.350 ball Torque 30. b. Transfer ball joint assembl Y Transfer Shifter rail Fig.350 ball in transfer case. d. press it down by using the end of transfer shifter rail while forcing the rail into the case with the round side down. Transfer shifter fork Shifter fork rail spring Ball Transfer shifter rail c. Apply grease to ball. b.27 ft·lb) NOTE: a. b. and insert knock pin into the interlock rail hole.7 kg·m. 6-188 1 Sprinl 2 Ball A12·380 3 Transfer shifter rail CP .

ran. and then strike in stralaht pin. (Rod adjust· ing screw tlahtening torque is 2 N·m (0..21. 1 Hiah-low ullner rod 5 Rod ban jointASSY j . I. CD Hlah·low shifter rod (f) Nut (Left.hand threaded) (J) Rod ball joint ASSY NOTE: Confirm the high-low shift opel1t1on by moving high-low shifter rod blCk end forth..e 1 59) 14WD Dual·ranse . 4WD HI . 6-'93 .2 ka-m.6 ft·lb) 64) 14wD Dual. I NOTE: When finding no groove.hand threaded) (I) Rod adjusting screw ® Nut (Riaht. confirm the ICCtnt in .2.1 .85 .rm or fork. b. IIld strike in strataht pin.12·383 I 1 Strallht pin (5 x 22) 2 Rod arm 61) I4WD Dual·ranse I Connect rod ball jOint ASSY with blah·low shifter lever and dahten nut.6·194 .6-'91 63) !4WD Dual-ranse Shift hlah·low shifter lever into 'LO' position and lengthen linkage length by turning rod adjusting screw (turn buckle) counter-clockwise wblle hold· Ing hlah·low shifter rod. 1. Alian the holes of rod arm and blah· low shifter rod..4 ..12·382 62) I 4WD Dual... After fitting clip.6·189 (1...MANUAL TRANSMISSION AND DIFFERENTIAL 58) !4WD Dual·range Fit clip onto the transfer shifter rail groove. (4WD LO . 13. move . FWD) FI..1 N·m Torque FI.--=1 t L'.12·387 FI.4 ft-Ib)..6-'96 8-H .12·3•• 18.ranae I FI". 6·192 Ilur'. and then turn it back 90° clockwise at the point where ball joint movement becomes tlaht. FIg.6·1go 60) 14WD Dual.range I Shift transfer shifter rall into '4WD LO' position and fix hiah-Iow shifter raU by insertlns Stopper Pin (49926· 7000) into its hole. .12-311 Insert rod ann Into the rear portion of blah-low shifter rod.ell Ihlft pOliti on.6·196 Fig. FI.'.15. Assemble the following parts and shorten lInkale length by turninl the rod adjusting screw (turn buckle) clockwise. . tum rod adjusting screw counterclock' wise.15 kg-m. StopptrPln (499287000) 'LO' pOlitlon 2 Nut (Left·hand threaded) 3 Rod adjuatiq ... FI"..crew 4 Nut (RlIht-hand threaded) 65) 14WD Dual·ranae I WhUe holding rod ball joint ASSY.

6 ft-Ib) I Torque Detail '8' (11 The .3.tete of pushing ball Detail '8' 121 stardard Detail '9' (31 The state of larger clearance .016 in).0. 13. Turn shifter shaft to the reverse side lightly and contact reverse accent shaft to the ball as shown in the figure. The case that shifter shaft is shifted to the 5th position after the second resistance (ball climbing resistance on the shaft) is felt.05 to 0. 6-197 67) 14WD & 4WD Dual-range Install transfer case cover with gasket and tighten bolts. 6-202 6-57 .2.1 N·m (1. I I NOTE: a. the resistance will be felt. (1) Shift shifter shaft to the 5 th·gear position after installing transmission rear case on transmission main case. 18.12-281 Fig.85 . Measure it at the point that reverse accent shaft contects to the ball. so replace the proper reverse accent shaft in order to increase the contact clearance.4 . 6·799 NOTE: When shifter shaft is turned hard until it stops.1 . 22 . .4 mm (0. 201 (2) Select reverse accent shaft so that the contact clearance is within 0. In this case the contact clearance is .MANUAL TRANSMISSION AND DIFFERENTIAL 66) 4WD Dual-range Tighten rear nut (left-hand thread) at first.0.1 . when in the S·speed position.0. I zero. b. Confirm the accent in each shift position by shifting transfer shifter rail. Then perform the above measurement described in a.12-389 Fig. b. and then tighten front nut while holding rod ball joint ASSY.0.12-279 Magnet Base (498247001) Dial gauge Fig.15 kg-m. The case of smooth shifting. Pull out Stopper Pin (499267000) after tightening the nuts. Remove plug and set dial gauge and Magnet Base (498247001) as shown in the figure with the tip of dial gauge stem resting on the top of reverse accent shaft. 6-200 Fig.7 kg-m. c .0020 to 0. 30-36N·m (3. a.27 ft-Ib) Torque 68) IS-speed 5th-gear position adjustment. 6-798 Fig.12-390 IdentifiQtion number A12·213 Fig.21.15. where the ball climbs on reverse accent shaft. Measure the contact clearance.

Part Number Dimension C mm (in) 16.13.535) 13.0 (0.0.4 (0.2 (0.709) 18.0 .0.488) 12.6 (0.12. No. (4) To adjust.2 14.0.0.6 .512 .16.0.646) 16.677) 17.18. (2) Shifter arm turns lightly toward the lst/2nd gear side but heavily toward the reverse gear side because of the function of the return spring.8 (0.4 .2 16.504) 13.14.717 0.480 .559 .567) Contact clearance 1 442747101 become smaller 2 442747102 - 442747103 4 442747104 5 442747105 6 442747106 become larger 6-58 .669 . 6·203 I No.6 (0.661) 17. until arm contacts the stopper .8 (0.693) 17.701 .0.520) 13. shift gear into 3 rd gear position.4 (0.0 (0.6 .8 .654 .543 .685 .0 .18.0.12.4 17.2 .MANUAL TRANSMISSION AND 01 FFERENTIAL 69) Neutral position adjustment.4 (0.2 (0.8 .17.0.2 .528 .496 0. (1) After completing the 5th-gear position adjustment <I5-spee~. remove the plug on rear case and change the thickness of aluminum gasket.0.4 (0.724) Contact clearance 1 • 442747001 become smaller 2 442747002 - 442747003 4 442747004 5 442747005 Plug GasJc:et 6 442747006 become larger Fig.638 .13.551) 14.0. (3) Make adjustment so that the heavy stroke ( reverse side) is a little more than the light stroke (1st/2nd side). Part Number Dimension C mm (in) 12.

• Tightening torque for cable clamp: NOTE: Fill the internal groove of the holder withgr. Release bearing holder 3..7 .5 (0. Co Contact surface of fork and holder.95 kg-m.079) 20. NOTE: Always install a new spring pin. and drive spring pin into the holes. 3.5 (0.8 kg-m. 2. lubricate the following points with a light coat ofgr. Be careful not to allow transmission to strike any adjacent parts while raising jack. 14 . Align left and right rubber cushion guides for transmission mounts with guides on crossmember. 25 35 ft-Ib) 6) Align the spring pin holes on axle shaft and drive shaft. NOTE: Before or during assembling. 2) Carefully raise jack until transmission is aligned with engine.0 . b. Tighten rubber cushion retaining nuts.3 N·m (0.. 803922022 Neutral position approaches lst/2nd gear side 803922023 Neutral position approaches lst/2nd gear side 70) Install bearing holder and release fork. 6·205 Installing axle shah 6-59 .0 (0. a. d.0 (0.9 ft·lb) NOTE: NOTE: Continn that retainer spring is securely fitted by seeing through the main case hole. Install holder and fasten it with two clips.. Li§i] I.19 ft-Ib) 037022000 Standard NOTE: Always use new self-locking nuts.) Torque A15-015 Fig. b.MANUAL TRANSMISSION AND DI FFERENTIAL Thickness Part Number mm c.65 . (Use grease containing molybdenum disu'phide. Tighten crossmember by using selflocking nuts. Install clutch release fork sealing.. Install retainer spring into fork. 4.4. i Torque 6. a. Apply a coat of grease to the splines of the transmission mainshaft in advance.0. support transmission on jack just behind engine. from transmission ASSY. 71) Remove Stand Set (399295120). Remounting I) With car body and engine in the same position as when they were removed. 5) Clamp parking brake cable to body. b. Contact surface of fork and pivot.2. If the main shaft is hard to align with the engine.. and secure it to engine.4 . 4. 1. A4-133 ! 1600 I Install the following parts.6. 34-47N·m (3.059) 2..5 . 3) Install center crossmember on car body as follows: a. Clutch release fork 2.25 N·m (2.020) 1.039) 1. 6-204 Installing crossmember 10. and temporarily retain crossmember to car body. Inner groove of release bearing holder.6 kg-m. Input shaft spline.9. Release bearing holder springs 4. Clutch release fork sealing Fig. 4) Remove jack from transmission. simultaneously turn the left and right transmission drive shafts until the main shaft splines engage with the engine. While pushing fork to pivot and twisting it to both sides. Remarks Torque Neutral position approaches reverse gear side -~~~-~ (in) 803922021 0. fit retainer spring onto the constricted portion of pivot.

25 ft·lb) *Non-4WD (10 .6 3. Also install starter. 19 . properly align the bolt holes on both left and right transverse links with crossmember.18 N·m (1. Install a new gasket to the exhaust port of engine. Position exhaust pipe on bracket on car body.54 N·m (4.lb) Fig.40 ft-lb) A4·123 Torque Fig. Torque 18 .0 kg-m. 46 . and then securely tighten differential gear flange using bolts and nuts. 6·208 Connecting gearshift system 10) On 4WD. b. 10 .0 kg·m. Tighten nuts securely.5. install propeller shaft.2 kg·m.13 ft-lb) Torque A4-14!5 \ ~ A4-128 Fig. 59 .5 kg·m. 13) Connect hot air intake hose.5 I ft.0 1.4 .22 N·m (1. d.3.5 kg·m.8 kg-m. c.29N·m (2.5 kg·m.7.5 . A4·140 NOTE: Be careful not to strike the oXYlJ8n sensor against any adjacent parts durinll installation.18 ft-Ib) Torque A40093 Fig. Torque Front exhaust pipe to engine: 25 . Tillhten the nuts to the specified torque after finishing all work and lowering the car to the floor. 15) Tighten bolts and nuts which retain engine to transmission to the specified torque.22 ft·lb) Front exhaust pipe to rear ex· haust pipe: 42 52 N·m (4.3 .69 N'm (6.25 N·m (1. Temporarily tighten front and rear exhaust pipes with new ga&ket in place.8 2. 13 .16 ft·lb) I Torque NOTE: a. 18 . 18 .0 .5. 13-16ft. 34 .38 ft·lb) Front exhaust pipe to bracket: *4WD 25 34 N·m (2.lb) NOTE: Always use new self-locking nuts. 31 . 6·210 A4-t25 12) Securely connect O 2 sensor har· ness to O2 sensor and clamp it. Always use new nuts. b. and insert bolts into the holes from the front side. remove drive shaft cap. 43 . and temporarily tighten exhaust pipe retaining nuts. After making sure that exhaust pipe ASSY is properly pOSitioned. and secure it with bolts. 7 .7 .2 kg·m.8 2.2. retighten bolts and nuts securely. Be sure to position two center bush· ings with their slits facing the rear side of car and two outer bushings with their slits facing the inside. 11) Install front exhaust pipe ASSY as follows: a. 6·206 Installing transverse link 8) Install stabilizer. 6·209 Installing propeller shaft 6-60 .22N·m (1. 14) Lower car body to the floor. (except 4WD) 14.6·207 Installing stabilizer Fig. 9) Install the gearshift system on transmission.3 kg·m.MANUAL TRANSMISSION AND DIFFERENTIAL 7) Using a screwdriver.

A4·117 Fig. 19) Make all necessary wiring connections. c. using pliers. and then hand brake tray cover. f.0 . retighten cable by approximately 30°. 18) Route speedometer cable underneath pitching stopper with battery cable.) A4·113 Fig. 23) Check the transmission oil level and. Install rod cover. 6-213 Connecting spe8CIometer Specified clearance 0.8 .2 kg-m. Install hand brake cover. 27) After all work has been completed.1.13 ft-lb) Be sure to connect the ground cable. Connect rod A with rod B by tightening nut while holding rod A with a wrench.5. 20) Connect clutch cable and adjust the free play of cable. (Use new self-locking nuts.MANUAL TRANSMISSION AND DIFFERENTIAL 17) Connect speedometer cable to transmission. (Use new self-locking nut. and clamp it on pitching stopper. and tighten it hard with your fingers. 6-212 Adjusting pitching stopper Torque (Selflocking nut) 14 . Loosen nut until pitching stopper on bracket (on the engine side) is free to move. Insert rod A into boot. and fix boot to body.16 ft-Ib) A4-116 d. 35 .4 . 48 -49 N·m (4. 25) Check the operation of clutch for smooth engagement and disengagement. 6-214 NOTE: 10.22 N'm (1. Check exhaust pipe connections to ensure there is no gas leakage.2. connect both the 4WD selector system and gearshift system with transmission as follows: a. 6-61 . 26) Check the operation of shift lever or select lever for smooth gearshifting.36 ft-lb) A4-096 Fig.047 in) c. 6-211 Tightening bolts and nuts Torque (Nut) 16) Adjust pitching stopper as follows: a. add oil.2.9 .18N·m Torque (1.2 mm (0. if necessary.2 kg-m. A19-l07 Fig.031 .0. Tighten rear nut until the rubber cushion-to·washer clearance is with· in specified value.0 kg-m.8 kg-m. 21) On 4WD.) A4-105 Torque (Selflocking nut) 14 . 7 .1. and connect gearshift lever with lever. Attach a wrench to rear nut. Then.4 . 24) Start engine. install spare tire. 22) Connect battery ground cable. and tighten front nut securely. b. 10 .22N·m (1. Insert gearshift lever into dust seal. NOTE: Insert the dun sell upper end into the groove of galnhift leVlr firmly_ b. Install rod B and drive selector lever to plate.16 ft-Ib) e. 10 .

Tightening torque N'm (kg-m..25 .4 10.. 6·215 6-62 ..:::~~: J.0.3. ft-Ibl T1: 12· 18 11. 1.29 (20 .4.221 Lever Knob Boot Boot Plate Bushing (Resin) Bushing (Rubber) Spacer Rod Spacer Joint Spring pin Neutral set spring Dust seal Plate Bushing Cushion Cushion rubber Stay Spacer Bushing (Rubber) Flange tapping screw Nut Bolt Bolt Nut Flange bolt Flange nut Flange nut Bolt Nut Spring washer Lockwire A19-129 Fig. 9 .2.. 0.5· 5.1.131 T2: 2. Component Parts IExcept 4WO I It----@ '""r--@ .:..3.01 T3: 13·23 (1.8.9 .171 T4: 20 . 14 .2 .8 . Transmission Control System 1.3 .MANUAL TRANSMISSION AND DIFFERENTIAL 6-4.. @ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 IS 16 17 18 19 20 21 22 23 24 2S 26 27 28 29 30 31 32 33 .55.

7.6· 6. 0. 6-216 6-63 ..3.2 .6.49 14. pin Neutral set spring Bracket Self-locking nut Washer Bushi. 3.0 .5 .3 .5.1611.:nl~y~)_ _ _1 2S Washer 26 SeIC-Iocking nut 27 Cotter pin 28 Bushins (Rubber) Spring washer Self-lockin& nut 29 Plate 30 RodA . ft-Ib) • T1: 12. r Tightening torque N'm (kg-m . 29 .Qg (Rubber) S Dust seal 6 Clip 7 Spacer 8 Bushi.Qg (Resin) 20 Wave washer 21 RodA 22 Rod B 23 Drive selector lever 24 Plate (DUal-rang~e~o:.5' 37 BushA 38 39 40 41 42 Washer Self-locking nut Bracket Neutral set spring Cotter pin A19-151 Fig.0.9.17 27) (Dual-range only) - 31 32 33 34 Switch Bracket 3S Bush B 36 Washer rT5: ~ T4: 39 . 9-12) : n· 23·36 (2.MANUAL TRANSMISSION AND DiffERENTIAL ~ (Dual-range only) ~G 1 Knob 2 Nut 3 Gear shift lever 4 Bushi.Qg (Resin) 10 Boot 11 Plate 12 Self-locking nut 13 14 IS 16 17 18 19 Lever Spri.361 5· 9 10.1.Qg (Rubber) 9 Bushi.

Spacer. Lever from stay d. Bush S Washer 6 Washer 7 Sclf-locking nut A19-153 Fig. 6) Boot and neutral set spring. 14) Remove the following parts from rod A as shown in the illustration. 7) Separate rod A from transfer rail of transmission. a.1 . Rod (from joint) d. a. remove switch from plate. NOTE: Be clreful not to lose bushing. Cushion. 2) Front exhaust pipe. bushing (rubber) and bushing (resin) from rod c. Cushion rubber 4) Disassembly of gearshift lever ASSY. 11) Disassembly of gearshift lever. 6-218 6-64 . 13) Remove the parts shown in figure from drive selector lever. Spacer. Bushing (resin) c. (except DUII-rlnge) 1 RodB 2 Wave washer 3 Bushins . R. a. 6-217 14WDI 1) Exhaust system. 10) Dust seal. parking brake cover and tray. 9) Lever from shifter arm by taking out cotter pin and driving out spring pin. bushing and cushion rubber from stay rodA.MANUAL TRANSMISSION AND DIFFERENTIAL 2. Spacer b. Rod from lever b.mov. 4) Nut which connects rod B with IExcept 4WD I 1) Gearshift lever knob. 2) Rod cover. 3) Removal of gearshift lever ASSY. Neutral set spring b. plate and dust seal from lever e. 5) Plate from body.nd DI •••••mbly 3) Gearshift lever knob.. Stay (from engine rear mounting bracket) c. 8) Gearshift lever from lever. For dual-range. Bushing (rubber) 12) Separate plate from drive selector lever.. Washer S Self-Iockins nut 6 Bushins (resin) 7 Bushing (rubber) 8 Spacer A 1111-100 Fig. bushing. 1 RodA 2 Bracket 3 Bush .

. 3) Assemble plate· and dust seal. IExcept 4WO I (Oual . Inspection Inspect the following parts by comparing with new ones for deformation. 14 . Correct or replace if defective. 6-221 6-65 ). Bushing Face its smaller flange inward. rod... lever and atay 6 Plate 7 3 Rod 4 Lever Fig. NOTE: Torque (Flange nut) 20 29 N·m (2. 1 Cushion rubber M9-0la 2 Bushina 3 Spacer b. and twist the ends of wire so as to tighten them.0 kg-m. Spacer A19-0t9 Fig.. wire round dust seal to fix it. 6-220 Fig.0 . 6-219 4. c.22 ft-lb) Flee the ends of wire toward the lonuer periphery side of pllte. Assembly IExcept 4WD I 1) Clean all parts before assembly. damage and wear.-. a. .3. Cushion rubber Be sure to fit the locating pin of cushion rubber into the stay hole... 2) Assemble following parts to stay. ) A19-130 1 Bumina 1 Spacer $ DUIl_ Bracket A19-1114 1 Buahina 2 Cushion 3 Spacer 4 5 OUlt seal Joint. Wind 1 mm dia.MANUAL TRANSMISSION AND DIFFERENTIAL 3..

Apply sealant to the plate mating surface of stay around the recess on stay but inside four thread holes.5 ".8 kg-m. 6-225 Torque (Flange bolt) 2.] b. yawing torque 2. 6-224 Fig. Dust seal b.6. ·Sealant: Butyle rubber (string) [1. One end with wider width of rod is for the transmission side and the other end is for lever side. 14WDI I) Clean all parts before assembly.059 in) dia.lb) :1 Wave washer 3 Bulllina 4 Washer S SeJf-lockina nut 6 Bulllina (resin) 7 Bulllina (rubber) 8 Spacer A19·100 Fig. 6-226 A18-071 8) Make sure that each portion has no looseness and moves smoothly. b.55 kg·m. apply grease to the inside and side surfaces of bushing. (Be sure to apply grease to the sliding part of bushing. 1.25 .Assemble following parts to lever.18 N'm (1.) Torque 12 . 6) Assemble bushing (rubber). 2.0 ft·lb) 1 RodB c.0.28 kg-m. <D Fig.222 l' ! a. A1N82 3) Assemble the parts shown in figure to drive selector lever.MANUAL TRANSMISSION AND DIFFERENTIAL 4) . 6-228 6-66 . c.8 .28 kg-m. check lever for smooth movement. Assemble chromium plated spacer to the lever side of rod and zinced spacer to the transmission side respectively.4.0 ft. 2) Assemble bushings and a spacer to gearshift lever. bush· ing (resin) and spacer to rod. D 1 Dust aea1 :1 Bushing 3 Culllion AlI·Q87 o • Q---g a 6 a e 0 At9·063 . Cushion 5) Assemble the lever assembled in 4) to stay. 9 13 ft-lb) rr 11! a I 2 3 4 Spacer Bushing (rubber) Bushing (resin) Bushing (rubber) A 19-098 A18-o70 Fig.5.0 ft-Ib) Fig. 6·223 Fig. c. Maximum yawing torque 2.5 mm (0.7N·m (0.2 1. Fij. When assembling spacer.7N·m (0.4 N'm (0. 2. Install plate to stay so that the ends of dust seal fixing wire come to the left side (lst/2nd gear side). ~ Max. Bushing Apply grease to inside of bushing. 6-227 a. After assembling. a. 7) Connect lever with rod.

c. 2 . 9 .MANUAL TRANSMISSION AND DI FFERENTIAL a. 6-229 14WD I a.3 kg-m. 6-231 s. Be sure to apply grease to the slid· ing part of bushing. 10 . ~ Dual range 1 Bushing 2 Rod A A 19-1152 3) Connect body. Minimum torque (Nut) 4N·m (0. Use new self-locking nut.2 kg-m.17 ft-Ib) 6-67 .2 . Then tighten lock nut. 9 . 4) Install neutral set spring.13 ft-Ib) S) Assemble the following parts onto rod A as shown in the illustration.13 ft-Ib) Fig.0 ft-Ib) 2) Connect stay with engine rear mounting bracket. Torque (Self-locking nut) Maximum yawing torque (Lever to plate) 14 .8 kg-m.2. 0. b.1 kg-m.2. b.4 . Use new self-locking nut.18 N·m Torque (1. S) Install lock nut and knob.12 ft-lb) Torque (Flange nut) 13 23 N·m S Cotter pin (1. Fig.22 N·m (1.18 N·m 1.4 kg-m. b.7N·m (0. 7) Attach front exhaust pipe. Torque (1. install switch onto plate. Switch (Dual·range onlvl A19·1315 Installation 6) Check lever for smooth movement.1. cushion rubber with 3 Washer 4 Self-locking nut Torque (Self-locking nut) 12-16N·m (1.8 kg-m.6 kg-m. 2. Be sure to apply grease to the slidinfpart of bushing.3 2. 6-230 NOTE: Use new self-locking nut A 11-0151 Fig. Screw in knob to the extent that it can not be screwed in lightly. I Except 4WD I 1) Connect rod with joint after inserting bolt from the right hand. 12 . 9 . 6-232 9 . Fig.4 .9 ft-Ib) Torque (Self-locking nut) Maximum yawing torque (Lever to rod B) 14 . 10 16 ft-Ib) 2.1.7 ft-lb) 1 Rod A 2 Bracket 3 Bush 4 Bush S Washer 6 Washer 7 Self-locking nut A19·153 4) Assemble drive selector lever assembled in 3) to plate.16 ft·lb) 1 N·m (0. For dualrange. a. 12 .22 N·m (1.2 kg-m.2 I) Install following parts to transfer rail. 2. Screw in knob further (less than one rotation) so that the shift pattern (on the head of knob) matches the movement of lever.28 kg-m.

Drive thetpring pin in securely.3 . (Set knob so that the shift pattern matches with the movement of lever. 411·1011 Fig. 6·239 411-108 Fig.6 ft·lb) Fig.2.2 kg-m. Before installation. Align the hole of plate and notch on drive selector lever. NOTE: Before instailition. 4WD is engaged).6 6. b. set the transfer rlil It the frontmost position (i.5 .31 in) dia.0 .9 kg-m. 6·237 c.0.5. pin to fix them. and insert 8 mm (0. Be sure to bend cotter pin ends. 2. Confirm that transfer rail is set at the frontmost position. 6-235 5) Install neutral set spring.6-233 Installing dust seal Fig.4 . and then insert rod A into boot.MANUAL TRANSMISSION AND DIFFERENTIAL a. Then tighten lock nut.9 . b.e. 7) Install plate to body so as to fix boot to body. 6-236 a. 8) Install lock nut and knob to gearshift lever. 6-234 6-68 .36 N'm (2. Insert rod A from the right side of transfer rail.49 N'm (4. 44-142 9) Connect rod A with rod B by tightening nut while holding rod A with a wrench. 10) Install plate to body as follows.22N·m (1. 2) Apply grease to transmission bushing. 4) Install gearshift lever. 411·103 411·107 Fig. Torque (Nut) 39 . Install dust seal to transmission and fix it with clip. set the shifter rod in the 3rd1l8lr position. Use new self-locking nut. 3.2 3.9N'm (0. NOTE: I.) I 411·1115 I Torque (Nut) 2.7 kg-m. Fig.5 ft-Ib) 23 .27 ft-Ib) NOTE: 4WD ! dual-range Insert the dust seal upper end into the groove of lever firmly. b.9 N'm (0. 17 .50 kg-ro. c. to .0 kg·m.0. 6) Install boot and plate to gearshift lever. (Use new self-locking nut.4. 29 36 ft-Ib) Fig.16 ft-Ib) I 4WD 5 . 6-238 3) Install lever to shifter rod. Be sure to bend cotter pin ends.30 .) Torque (Self-locking I nut) 14.3.

0 kg-m. 12) Install rod cover etc. Pull out 8 mm (0. 13) Install exhaust system. readjust plate position.] in case of need. II) Make sure that gearshift lever and drive selector lever can be operated smoothly in their full stroke.57 in).3. confirm that the distance between grip lower surface of drive selector lever and rod cover upper surface is approx.0 . 40 mm (1. 6-240 d. If without specification. [Readjust plate position without the pin [8 mm (0. Install plate to body.31 in) dia. pin.22 ft-Ib) For dual-range. NOTE: Torque \ 20 29 N'm (2.] Fig. 6-69 . 14 .MANUAL TRANSMISSION AND DIFFERENTIAL c.31 in) dia.

Readjust. Clutch drags As a symptom of this trouble. the clutch is slipping if the car does not start off and the engine does not stall. Replace. Correct or replace. (f) (g) (h) 2. • Method of testing: Refer to diagnostic diagram on page after. a harsh scratching noise develops and control becomes quite difficult when shifting gears. because much trouble of this sort is due to defective synchronization mechanism. The symptom becomes more apparent when shifting into the first gear. (f) (g) (h) I l Replace. Disengage the clutch and shift the transmission gear into the first. Gradually allow the clutch to engage while gradually in· creasing the engine speed. Replace. Replace. Correct or replace. However. -~- (a) (b) (c) (d) (e) Excessive clutch pedal play Excessive clutch release fork play Worn or rusty clutch disc hub spline Excessive deflection of clutch disc facing Seized crankshaft pilot needle bearing Malfunction of pedal and cable system Cracked clutch disc facing Sticked clutch disc (smeared by oil or water) Readjust. Power falls. Readjust. Clutch Condition I. Troubleshooting 1. (a) (b) (c) (d) (e) No clutch pedal play No release fork end play Clutch facing smeared by oil Worn clutch facing Deteriorated diaphragm spring Distorted pressure plate or flywheel Defective release bearing holder Defective pedal and cable system Readjust. Correct or replace. Replace clutch disc. (a) (b) Engine revs up when shifting. particularly when ascending a slope. However. Correct or replace. (c) • Method of testing: Put the car in stationary condition with parking brake fully applied. High speed driving is impossible. . Replace. Clutch slippage Possible cause and testing Corrective action It is hard to perceive clutch slippage in the early stage. carry out the test as described after. especially rapid acceleration impossible and vehicle speed does not increase in proportion to an increase in engine speed. Correct or replace. and there is a smell of burning of the clutch facing. The clutch function is satisfactory if the engine stalls. but pay attention to the following symptoms. Replace. It may be judged as insufficient disengagement of clutch if any noise occurs during this test.MANUAL TRANSMISSION AND DIFFERENTIAL 6·5.

aU!iC al1U lCl)UIII. Noisy clutch Examine whether the noise is generated when the clutch is disengaged. 5. Repalce. Replace clutch disc. worn or unlubricated release bearing Insufficient lubrication of pilot bearing Loose clutch disc hub Loose torsion spring retainer Deteriorated or broken torsion spring Replace release bearing. Replace clutch disc. I Correct. Correct or replace. or partially engaged.'-UIIUILIUII CU~lUIC \..UVC a\. (I) (g) (h) 4. Replace clutch disc. Replace clutch disc. Replace clutch disc.UUlI 3. Retighten or replace mounting. Adjustment. Clutch grabs When starting the vehicle with the clutch partially engaged. engaged. Clutch chatters ! Clutch chattering is an unpleasant vibration to the whole body when the vehicle is just started with clutch partially engaged. (a) (b) (c) (d) (e) Broken. '-UIIC\. (a) (b) (c) (d) (e) Improper clutch cable routing Adhesion of oil on the facing Weak or broken torsion spring Defective faCing contact or excessive disc deflection Warped pressure plate or flywheel Loose disc rivets Loose engine mounting Improper adjustment of pitching stopper Replace clutch disc. Replace clutch disc. Take off rust. Apply grease. apply grease or replace clutch disc or mainshaft. the clutch engages suddenly and the car jumps instead of making a smooth start. Replace clutch disc. Replace clutch disc. (a) (b) (c) (d) (e) Grease or oil on facing Deteriorated cushioning spring Worn or rusted spline of clutch disc or main shaft Deteriorated or broken torsion spring Loose engine mounting Deteriorated diaphragm spring Replace clutch disc. Retighten or replace mounting. (I) 6-71 .

. I Test (2) I Shift to reverse after O.MANUAL TRANSMISSION AND DIFFERENTIAL Diagnostic Diagram of Clutch Drags Test (I) I Disengage the clutch and shift quickly from neutral to reverse in idling condition I I Gear noise Yes :I-__ N0-l Sufficient disengagement of clutch . Defective pilot bearing Excessive disc deflection Defective transmission Defective clutch disc hub spline 2.. Defective transmission or excessive clutch drag torque [Cause] 1. Clutch disc smeared by oil 2. 2.. Clutcti disc smeared by rust 3. S... 4.S to 1.. Yes Test (3) Shift the gear N :.-------~ 11-----+ Sticked clutch disc [Cause] I 1. I I Gear noise JI-__ N0-t . 3. Clutch drags I Cracked clutch disc facing Damaged or worn clutch cover Malfunction of clutch release system Insufficient clutch release amount Excessive clutch pedal play 6-72 .0 sec of clutch disengagement. 4. 3..:! R several times during disengaging clutch as test (2) I Gear noise I No. Defective clutch disc hub spline Yes I [Cause] 1.

but if any part is broken. Lubricate or replace with specified oil. (e) Excessive clearance between splines of synchronizer hub and synchronizer sleeve. Gear slips out. Corrective action Gears are difficult to intermesh. Manual Transmission and Differential Condition and possible cause I. (h) Worn 2nd driven gear. defective clutch disengagement may also be responsible. needle bearing and race. rhythmical knocking sound will be heard even at low speeds. (k) Worn reverse idler gear and bushing. However. The cause for difficulty in shifting gears can be classified into two kinds: one is malfunction of the gear shift system and the other is malfunction of the transmission. (a) Defective pitching stopper adjustment. (g) Worn 1st driven gear. (d) Incorrect contact between synchronizer ring and gear cone or wear. Replace. damaged or burred chamfer of spline of gears. (c) Worn fork shifter. 3. before checking the gear shift system and transmission. merely a high roaring noise will occur at high speeds. broken shifter fork rail spring. Replace. (c) Worn or scratched bushings. (f) Worn tooth step of synchronizer hub (responsible for slip-out of 3rd gear). Replace. (b) Worn or damaged gears and bearings. Replace. (0 Worn 3rd drive gear and bushing. (j) Worn 4th drive gear and bushing. Replace. 6-73 . (1) Gear slips out when coasting on rough road. Replace. (NOTE) If the trouble is only wear of the tooth surfaces. Correct or replace. Replace.MANUAL TRANSMISSION ANO 01 FFERENTIAL 2. 2. Adjust. if the operation is heavy and engagement of the gears is difficult. Unusual noise from transmission. Check whether the clutch is correctly functioning. needle bearing and race. (d) Worn or damaged ball bearing. damaged or burred chamfer of internal spline of sleeve and reverse driven gear. Replace. (b) Loose engine mounting bolts. Replace. Replace. (a) Worn. (a) Insufficient or improper lubrication. Replace. Tighten or replace. it may be considered that the noise comes from the transmission. If an unusual noise is heard when the car is parked with its engine idling and if the noise ceases when the clutch is disengaged. (2) Gear slips out during acceleration. (b) Worn. Replace. Replace.

Therefore noise is the first indication of the trouble. (c) Improper adjustment of taper roller bearing. (b) Use of vehicle under severe conditions such as excessive load and improper use of clutch. (a) Insufficient oil (b) Improper adjustment of crown gear and drive pinion. (I) Worn washer (35. (4) Noise which mainly occurs when turning: Unusual noise from differential side gear. Add recommended oil to specified level. (2) Gear noise when coasting: Damaged gears due to maladjusted bearings and incorrect shim adjustment.1 x 45 x t mm) or differential pinion. broken or damaged bearings. Readjust bearing preload. etc. (I) Gear noise when driving: If noise increases as vehicle speed increases it may be due to insufficient gear oil. Differential and hypoid gear noises. 6-74 . Readjust bearing preload and backlash and face contact of gears. Do not use vehicle under severe operating conditions. damaged gears. (3) Bearing noise when driving or when coasting: Cracked. (d) Loose roller bearing (35 x 72 x 18. Replace. (e) Excessive backlash due to worn differential side gear. (a) Insufficient or improper oil. Check tooth contact. washer (35. There are following four kinds of noises. However noises from the engine. Readjust crown gear to drive pinion backlash and check tooth contact. Disassemble differential and replace broken components and at the same time check other components for any trouble. bearing. Replace. and replace if necessary. etc. incorrect gear engagement. tire. I (I) Loose crown gear clamping bolts. body. (d) Improper adjustment of drive pinion and crown gear. exhaust gas. Replace in a set. 5. are easily mistaken for the differential noise. Troubles of the differential and hypoid gear always appear as noise problems. bearing. Pay special attention to the hypoid gear noise because it is easily confused with other gear noises. gear. (c) Worn teeth of crown gear and drive pinion. Corrective action Broken differential (case.1 x 45 x t) and differential pinion shaft. differential pinion. etc.MANUAL TRANSMISSION AND 01 FFERENTIAL Condition and possible cause 4. differential pinion shaft. etc. (e) Distorted crown gear or differential case.25) Lubricate. muffler.) Abnormal noise will develop and finally it will become impossible to continue to run due to broken pieces obstructing the gear revolution.

Special Tools 1. 6-242 Preu A11-o26 6-75 . 6-24' A'1·014 iFig.MANUAL TRANSMISSION AND 01 FFERENTIAL 6·6. Clutch 499747000 899754112 Guide Clutch disc Press Clutch release bearing holder ~ Fig.

6-248 ~ ~ Q Fig. Drive pinion Rear drive shaft 899904100 Remover Straight pin (Differential) 899874100 Installer Transmission main shaft. 6·256 A12-182 899474100 Expander Snap ring (Transmission main shaft) 899984103 Socket Wrench Drive pinion lock nut (4-speed. Drive pinion 899884100 Holder Drive pinion. Rear drive shaft Extension assembly 899580100 Installer Transmission main shaft. Transfer drive gear bushing Transmission main case Fig. 6-257 A12-177 899864100 Remover Transmission main shaft. Drive pinion 899524100 Puller Set Roller bearing (Differential) 899754110 Press Assembly Transmission main shaft Needle bearing (transfer case). 6-258 i VI ST-156 .MANUAL TRANSMISSION AND DIFFERENTIAL 2. Hypoid gear backlash Fig. 6-254 A12-179 Fig. 6-250 A12-186 Fig. Rear drive shaft Axle shaft oil seal holder [ ~ J Fig. 6-244 A12-168 Fig. Manual Transmission and Differential 399295120 Stand Set 899714110 Retainer Transmission main shaft. 6-253 Fig.5-speed) 399520105 Seat Roller bearing (Differential) 899278600 Installer Drive pinion /1 Fig. 6-246 ~ / A12-184 Fig. 6-252 8A5-142 Guide o i- Press A12-183 Fig. 6-255 A12-185 399780111 Wrench 899858600 Retainer II Transmission main shaft. 6-245 A12-178 g A12-190 0) A12-171 Fig. 6-249 Fig. Drive pinion. Ball bearing (Rear drive shaft) 498247001 Magnet Base Backlash between side gear and pinion. 6-251 A12-187 q Fig. 6-243 ~ A12-169 ~ Fig. Dri ve pinion. 6-247 ~ A12-181 ~ Fig.

:} I Fig. Hypoid gear backlash 399780104 Weight Preload on roller bearing 499277000 Installer Drive pinion 398405200 Stand Rear drive shaft Fig. 6-262 ST-147 ~~ I (f) Fig. 6-266 A12-176 Fig. 6-274 1 Bracket (499167001) 2 Holder (499167002) A12-402 6-77 . 6-265 A12-191 Fig. 6-264 Fig. 6-269 I w A12-174 Fig. 6·263 ~ ~ A12-172 ~ '- ~-=-==- ~--- Fig. 6-260 lO) - ~~ I. 6-268 Fig. 6-261 . 6·267 A12-296 Fig.. 6-270 A12-174 Fig. 6·273 A 12-401 499827000 Press Oil seal (Speedometer) 898938600 Holder Transmission main shaft 398791700 Remover II Spring pin (5-speed) 499167000 Stopper Assembly High·low shifter rod and main case ® Fig. Rear drive shaft (4WD) 398791600 Remover II Straight pin (Transfer shifter fork) 499267000 Stopper Pin High-low shifter rail [. (Differential) Axle shaft oil seal 498147000 Depth Gauge Main shaft axial end play adjustment 399411700 Installer Reverse shifter rail arm 499927000 Handle Transmission main shaft input shaft -Fig. 6-271 ST·144 399790110 Installer Roller bearing.MANUAL TRANSMISSION AND DIFFERENTIAL 498247100 Dial Gauge Backlash between side gear and pinion. ~-(%) 2 Scale A12-188 1 Plate ~ Fig. 6·272 A12-189 899914100 Gauge Assembly Drive pinion shim 899988608 Socket Wrench Transmission main shaft. ~ ST-146 ~ A12·170 A12-175 Fig. 6-259 ~ " \ ST·157 Fig.

MANUAL TRANSMISSION AND DIFFERENTIAL 498787000 Stopper Transmission main shaft 499257000 Guide Main shaft snap ring Fig. 6·276 Fig.J ~ I ': . 6·281 498517000 Replacer Drive pinion thrust plate and needle bearing race ~ Fig. 6·279 A 12-400 499987003 Socket Wrench Drive pinion (4WD) 398507703 Dummy Collar Oil seal of input shaft holder ( A 12·191 0 A14~82 Fig. \-(1) 1 Plate 2 Scale A12·188 Fig. 6-275 f ~ 0 A12·173 Fig. 6·277 A13·205 Fig. 6·278 ST·151 6-78 . 6·280 398663600 Pliers Input shaft snap ring 499917100 Gauge Ass'y2 Drive pinion shim ~ [.

........................ Dismounting.. Component Parts ..... ........ Removal ........ 7-75 3.............. 7. Special Tools for Differential .. 7........... 7-4.....4 AUTOMATIC TRANSMISSION AND DIFFERENTIAL 7-1... 7-77 1...... ......... 7-73 SPECIAL TOOLS ...................... 7-41 Disassembly............ ... 7-20 4..... ... . ..... 7-28 5...................................................... 7-68 TRANSMISSION CONTROL SYSTEM ............. 7....... .............. Remounting .. Service Data .......9 1..... Assembly ...... . 7-11 3....9 2...... 7-73 5........................... Component Parts .................. ...... 7-73 Installation .................... ......... 7-42 7....... 7-3...... 7-2...2 1..... Inspection and Assembly .... ... 4.............-! ... 6. ........ Construction and Operation ........ 7-80 SUBARU .. ..... .......... . Special Tools for Transmission ....................... ... 7. ... 7-77 2.......... .......... 7... ............ ...... ................. .. ...... . ....... 7-72 1...... Disassembly . .. 7-72 2.. Cross Sectional View ..........2 2.......... ...................................... Troubleshooting and On·car Service 6...... ....CHAPTER 71 Page SPECIFICATIONS AND SERVICE DATA ....... .. .... AUTOMATIC TRANSMISSION AND DIFFERENTIAL . Specifications . 7-73 Inspection .... ..... ........................... ...

and engine start possible.'-"'<>II""-'-~~-~''''-'--------- __''''_--_______... Specifications and Service Data 1... 0 7-2 "'.. output shaft immovable.. 2-phase torque converter coupling 0 ~ E-< 0 8" 3-forward..AUTOMATIC TRANSMISSION AND DIFFERENTIAL 7 -I.""'v.... multiple planetary gear transmission Multi-disc clutch Multi-disc brake 2 sets 1 set 1 set 1 set 2.. 3-element. .- Q...600 1.100 . '" Reverse Reverse sun gear Forward sun gear Tooth number of planetary gear Short pinion Long pinion Output gear P (park) R (reverse) Selector position N (neutral) D (drive) 2 (second) 1 (first) Control method . e -< Transmission in neutral..... E-< § . Type Number Drive system . .~ cu . Hydraulic remote control Internal involute gear pump 1 unit Engine drive ~ 2nd ~ 3rd (Forward) ~ e Q. Deceleration from 2nd to lst (lst gear locked). Specifications Non-4WD I 2: 1 236 mm (9.. e_"""'---______________- .9 '" .. "~"'-. Automatic gear change lst 2nd gear locked. Transmission in reverse for backing.""-"""".2.~ 0 ... I-reverse. single stage.. ~ u <U ~ .~ ~ .505 1...167 36 30 20 21 78 Control element Band brake One-way clutch 1st 2nd Reduction gear ratio 3rd ~ ~ .300 rpm Sprag type one-way clutch 4WD . ......000 2. Q) Type Stall torque ratio Nominal diameter Stall speed One-way clutch Type Symmetric.. cu ~ 0 ..29 in) 2. Transmission in neutral. and engine start possible.

8 US qt...0£ (5. Fluid :..) 0 (.AUTOMATIC TRANSMISSION AND DIFFERENTIAL Non-4WD Type 4WD Automatic shift control over 3 forward speeds based on intake-manifold vacuum and output shaft speed Automatic transmission fluid (ATF) Texamatic Fluid 6673 Dexron TEXACO Texamatic Fluid 6673 Dexron CALTEX CASTROL: Castrol TQ Dexron BP Autran Dexron BP MOBIL Mobil ATF 220 5. . 75W-80 3..5..~ '" -g. c:: 0 . .026 (39/38) 3..- ~~ ::s .948 (37/39) Hydraulic multi-disc clutch Hydraulic remote control The same Automatic transmission fluid used in Automatic transmission 1....5..6. 0 c:: Lubrication system Oil Cooling system Forced feed lubrication with oil pump Automatic transmission fluid (above-mentioned) Liquid-cooled oil cooler incorporated in radiator - CooIing 0 c:: Transfer gear ratio Transfer clutch Control method Lubricant lst reduction gear ratio 0..700 (37/10) 3.) - :.6 Imp qt) (Including transfer section) --::s '1:1 II) .. E!:: 0.3 US qt.4£ (6.. 0.090 (12/11) .8 US qt..181 (35/11) API. 5 c:: 0 '0 .5 1..7 Imp qt) 7-3 -~ . (. 4.272 (36/11) "- ..S:! 'fa f-o .3 US qt.) '-' c:: "3 .900 (39/10) 1.9 .: £ ~ ..0 .8£ (0.) . ::s Speedometer gear ratio Lubricating oil Front drive Oil capacity Rear drive 3. 5.6...6.3 .6 .. (.3 Imp qt) 6..) '1:1 cu -.974 (38/39) '" -5 cu 0 ~ 'E 2nd reduction gear ratio Governor gear ratio Front drive Rear drive e c:: +:I (. 1.. +:I ~ § .2£ (1. (.1 Imp qt) - 0.6. .9 .3 .~ .0 .. '" . ::c Fluid capacity . GL-5.

AUTOMATIC TRANSMISSION AND DIFFERENTIAL 2. Clearance between cresent and tooth tip of outer gear Radial clearance between outer gear and oil pump carrier Clearance between seal ring and groove Q.05 .0.0 .1.039 .031 in) 0.047 in) 1...8 mm (0.0..9 kg-m.0059 .0079 in) 0.4 .20 mm (0.5 .6 mm (0. 6.04 .9 mm (0.0020 .063 in) 4 (Forward clutch) Brake band adjusting screw Axial clearance between governor cover and governor body .60 mm (0.5 ft-Ib) 0.0..8 mm (0.0.071 in) (Reverse clutch) 2.008 .1.0083 in) 0.0.071 in) 4 0.2 .::s Q.0.0.2 mm (0.0016 in) 0.1.0055 .0.0 mm (0.2.0.c: u .02 .071 in) 2.0.100 .0008 .020 .0.0..5 mm (0.300 rpm Turning screw back two turns after tightening it to the torque of9 N'm (0.8 mm (0.8 mm (0.071 in) 1.059 in) (Reverse clutch) 1.21 mm (0.3 mm (0. Service Data 1) Service Standard Value Measuring location Idling speed (N or P position) Stall speed Standard value 800 ± 100 rpm 2.0.079 in) 4 (Forward clutch) 1.031 in) Thickness Facing Number 3 Thickness Steel plate Forward/Reverse clutch Number 3 Thickness Dish plate Warping Forward clutch Clutch clearance Reverse clutch Thickness Facing Low and reverse brake clutch Steel plate Number Clutch clearance Thickness Facing Number Transfer clutch Steel plate Number Clutch clearance Clearance between inner/outer gear and transmission cover 2 0.18 mm (0.0.0063 in) 0.0.063 .6 .04 mm (0.::s U 0 E .0.114 in) Number Wave height Thickness 1. .0.047 in) 2.091 in) 4 0..0016 .0236 in) Thickness 3 1. Clearance between planetary carrier and planetary pinion washer 7-4 .8 mm (0.15 .16 mm (0.0071 in) 1.016 .14 .2 mm (0.8 mm (0.

.012 in or less) 0...08 mm or less (0.25 ..87.. 240) '. 80) 278 (2.....0. . .811 53..871 t ~ 13..7 (500 19.3 mm (0 .Ol Full throttle : i 28..-. 828(8..14.3 .!~_---'-----Full..ronle / 20 30 I 1 I l kiling 66.0315 in) 0.5 ..772 . Mln_- 1 J 0 .'OJ (11.3 in-Ib) 19.379 ! (14. "C I:: >.751 :! t.L 02 Kic~ownr.50 .23 ..0098 -. - I 2_ _ "i_m. I. Ii ~ I 40.0.. Total axial end play Reverse clutch drum end play W Run-out at the tip of reduction drive gear shaft Starting friction torque of drive pinion Distance from the final reduction case face to the end face of the reduction drive gear Run-out of converter drive plate surface 2) Automatic Shift Characteristics (Non-4WD) I -. (200.1.3 mm or less (0.~02 0/ 0.oe.0197 . 10.. 200) I i I 1.--jR .3 (400.50 mm (0.AUTOMATIC TRANSMISSION AND DIFFERENTIAL Measuring location Clearance between manual plate and spacer Clearance between rear shaft and intermediate case Standard value 0.44. 3.0. 10 (81 I I V "'I " . 7-2 Line pressure characteristics A13-220 7-5 . ~ 7..012 in) 0.~ (100..0197 in) 0.1181 40 (251 80 80 1121 1191 (311 (371 70 (431 80 (801 80 (661 100 (821 Fig.2 HoI! ".941 r-. 03 y lY' I I / 03 > (300.81..9 . -----.83..854 118. '20) Ml2 (5.6 ... 15.7 I 02~ ' V.0.0.80 mm (0. 1801 .0..0031 in or less) 1.. 0..020 in or less) '" 0.62 N·m (12. --- fU\l"'~-..0 I I I 11.25. ~02 0'±~2 __ 02 +t03 02-J.5 mm or less (0. 7-1 Automatic shift characteristics Vohielo opood km/h (MPHI A13-254 3) Line Pressure 1) Line pressure characteristics kPo (kg/em'.0.r---.. ~.5 kg-cm.780 in) 0.19. 40) O~--~----~---'----------r----T----- o (10) '8 32 48 (20) (30) 94 (40) 80 (80) 98 (80) km/h (MPH) Fig. Pli) 1.8 rom (0.16.

0.0 .93) 60.520 (4.64 .81) 44.-50 mmHg.7 (380.75) 57.9 .5 MPH)] and "after cut-down" implies the vehicle speed of more than 35.3.441 (3.6. 11.157 (10.AUTOMATIC TRANSMISSION AND DIFFERENTIAL 2) Line pressure in each range Unit: kPa (kg/cm 2 . I' I 7-6 I III tl>1 t M "W' . D ranges) Intake manifold vacuum: -kPa (-mmHg.4.85) 481 .142) 1. 43 .677 (5. 121 . -16.75) 412 .16.2 . fl.97 inHg)] before cut-down 834 .373 .363 (3.11. 14.93 .8.-450 mmHg.5 .18 .3.2 .47) a.1.11.0 kPa (-430 .7 kPa (-30 .5.0.7. 12.559 (4.168) after cut-down 294 . 84 . -1.3 (400.98) Range D 2 R 1. 145 .71) 363 .4 km/h (22.559 (4.0 (450.637 (5.3 . 84 .0.81) NOTE: 3) Change of line pressure with intake manifold vacuum (N.60 .1.7.5.5.57) 1.0 (300.7.0.6.9.569 (14. 53 .490 (4.392 (3.-60.392 (3.98) Minimum-throttle [-57. b. psi) 510. The line pressure during idling of the engine corresponds to the oil pressure before cut-down operation with the minimum throttle.2. 48 .3.7 .6.3 (430.412 (3. 78 .9 .3 (280.92) 579 .4.-1.78) 50.67 .5.99) 46.4.0 .0.0.81) 441 .72) Line pressure: kPa (kg/cm 2 .t" 1 I r .4.677 (5.4 .3 km/h (9.000 . -inHg) 37.1. 13.16.72 inHg)] before cut-down 294 .46 .70 .0 .0 MPH).2 .53) 314 .981 (8.2 .2 .-17.3.157 (10.5 .5. 145 .17.324 (3.96) 53.-6. 74 .7 (350.9.60) 314 .57) 579 .5. 199 .02) 40.168) after cut-down 539 . psi) Throttle Full-throttle [-4.5 .000 .64) 333 . Line pressures in each of 0.2 . 46 .6. 2 and R ranges will change in steps at certain points (where pressure modifier valve functions) and these points are called "Cut-down point". "Before cut-down" stated in the above table implies slow driving condition [less than 15.11.8.10.9 . f r 11 t.15.0 (330.0 .7 .588 (5. 43 .228) 461 .

2 Outer gear 434710100 .106.1.291.0. 0.0.039.0.0.2.5.15.6287) 0.4 Adjustinaline pressure Adjusti.0.2.2 (0.0.7.775 (0.9. end play of rear drive shaft Adjusting clearance of transfer clulch II Front pressure plate 7-7 .228.625.008.9.071.0.339. Part Name Retaining plate 2 Part Number Dimension mm (in) Application I 444267001-8 803021048 803021049 803021040 803021044 .047.5.3839.275.031.6 Inner gear 5 Oil pump gear 434610100 .6299 .4.0.6.0.0.283..307.055) Adjusting clearance of low and reverse brake Washer (21 dl.0.8.0.2.185.268 ) 1.0.0059.7 7.9 (0.220.1.6.5 (0. 1.067) 16.378.6295-0.024.0.075. 0.0.7.7.315.0.8.15.0.0.8 9 10 VICUurn diaphr. I) 2 Washer(21 .0.220.9.0.15.0.3848) 34.8.5.4.2 Adjusting side clearance of oil pump 6 Shim 2 442182511-8 Adjusting drive pinion height 7 Shim 441967001 .97 (0.8.0.0.205.063.8.6.0.6291) 15.98(0.5.9.25 (0.0079.5.0069.3799.00 .6295) 15.4 803242010 .QI18.6.0.2.9.0.232) Adjusting clearance of reverse clutch Adjusting end play of reverse clutch drum 3 Retaining plate 456712900 .0098) 0.0.0.091.5.0.725.8.225.0.236.99-15.0 (0.1.2 (0. 2.197.0.3 Adjusting preload of drive pinion bearing AdjustinB preload of drive pinion bearing 8 Spacer 446107001 .1.1.35.0197) 0.700.34.2.0.9.175.0.0.083. 0.7.087) 5.30.6.5.6291 .5.059.0.7.0.98 .1. rod Wuher(42 x 51 x I) 493210110 .0.1.0.99 (0.0.36 (1.AUTOMATIC TRANSMISSION AND DIFFERENTIAL 4) Location and Dimension of Adjusting Parts Fig.50 (0.3.0. 2.7 (0.0.20..650.0.35.2 . 7-3 A13-397 No.039) 9.6.675 (0.1.0. I) Adjusting total end play 1.0.020) 4. 0.5.0.2.2.5.0.0.0.6.7.600.5.6 4 Washer 452810100 .417) 0.8 (0.244) 1.299.31.209.0.5.0108.0.0.0. 0.079.0.197. 2.3819.276.3780.5.358.3809) 9.0089.098.213.}.323.750.I 447677000 .3789.0.2. !.6.0.9.398.4 (0.3829.1.

0.0.15 .0071 .0118 .0059 .25 mm (0.0.051.22 mm (0.0.125 mm (0.0.0319 in) 0.AUTOMATIC TRANSMISSION AND DIFFERENTIAL 5) Backlash Forward sun gear to Short pinion Reverse sun gear to Long pinion Planetary gear Short pinion to Long pinion Long pinion to Planetary output gear 1st reduction gears 2nd reduction gears Governor gears Speedometer gears Transfer gears 0.0020 .0.0.0118 .0087 in) 0.0.__ _ 1i' HIF "~--I • .0.0059 .13 .0098 in) 0.12 mm (0.81 mm (0.0.0.0.0087 in) 0.18 .15 .30 .0.0087 in) 7-8 L.30 .0049 in) 0.81 mm (0.15 .0.0.0.0020 .0047 in) 0.05 .0319 in) 0.2imm (0.0.22 mm (0.0071 in) 0.0059 .0.18 mm (0.0051 .

AUTOMATIC TRANSMISSION AND DIFFERENTIAL

7-2. Automatic Transmission and Differential
1. Cross Sectional View

® CD

1 2 3 4 5 6 7 8 9 10
11

12
13

14 15

Stator shaft Impeller Turbine Stator Turbine shaft Torque converter Oil pump drive shaft Converter housing Crown gear Drive pinion Reduction gear Onl>-way clutch Oil pan Control valve Connecting shell

16 17 18 19 20 21 22 23 24 25 26 27 28 29

Transmission cover Oil pump Reverse clutch Brake band Transmission case Forward clutch Center support Low & reverse brake Planetary gear Parking gear Governor drive shaft Governor shaft Onl>-way clutch Final reduction case

A13-398

Fig_ 7-4

7-9

AUTOMATIC TRANSMISSION AND DIFFERENTIAL

redluC1tiOll---¥-Transmission case section-..,.>------ Transfer case section - - - - - - - I case section

1 2 3 4 5 6 7 8 9 10

Stator shaft Impeller Turbine Stator Turbine shaft Torque converter Oil pump drive shaft Converter housing Crown gear Drive pinion 11 Reduction gear 12 Oil seal holder

13 One-way clutch

14 15 16 17 18 19 20 21 22 23 24

Control valve Connecting shell Oil pump Oil pump carrier Reverse clutch Brake band Transmission case Forward clutch Center support Low & reverse brake Planetary gear

25 26 27 28 29 30 31 32 33 34 35

Parking gear Speedometer & governor drive gear Governor shaft Final reduction case Oil pan Transfer drive shaft Transfer gear Intermediate case Transfer clutch Rear drive shaft Extension case
A13-399

Fig. 7-5

7-10
~>''''~"'.~"'''''~"''~"4'''"'_''''''-~J,.,~''''~"",,,",n"'f-""

_''''',.....'' 1"11_ _'

_ _ _- - _ ,...._ _ _.......""''''''''..._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _- ,

AUTOMATIC TRANSMISSION AND DIFFERENTIAL

2. Construction and Operation
1 4WD AT

1.

Construction

1) Overall Construction
The 4WD automatic transmission is basically composed of the conventional SUBARU 1800 automatic transmission, the transfer gear and rear wheel hydraulic driving clutch attached to the rear end of the transmission, and the hypoid pinion and transfer gear are connected by the transfer drive shaft. The transmission route of power is unchanged from that of the SUBARU 1800 4WD model (with manual transmission).

case and transmission case have been changed thoroughly, and an oil seal holder has been newly introduced in the reduction drive gear portion. The hydraulic clutch, planetary gear, control valve and other elementary components of the automatic transmission section are unchanged from those of the current automatic transmission.

3) Rear Drive Portion
1) Transfer The transfer consists of a hydraulic multi-disc clutch, transfer clutch valve and solenoid, and these units are housed in the extension case together with the transfer gear.

Hydraulic multi-disc

Extension case

2) Front Drive Portion
The basic construction is unchanged from the current automatic transmission. Along with the adoption of a 4 wheel drive system, the final reduction

Transfer gear

A13-400

A13-401

Fig. 7-6 Transfer

The current to the solenoid is controlled by the 4WD selector switch located on the selector lever.
4WD selector switch (pushbutton type) Selector lever

CHECKER
UNIT
l

Fuse

Ignition switch

4WD pilot lamp (on instrument panel)

Fusible link

*

Checker unit is tightened together with intermittent wiper unit by one screw at the back of instrument panel.

4WD selector valve (4WD-FWD) Battery

Fig. 7-7 Transfer clutch control system

Al3-402

7-11

AUTOMATIC TRANSMISSION AND DIFFERENTIAL
2) Rear differential The rear differential is unchanged from the SUBARU 1800 4WD (manual type). The difference in gear ratio with the front side differential is adjusted by the transfer gear (gear ratio 37/39 = 0.948) so that the front and rear wheels will rotate at the same speed. 3) Transfer clutch control circuit The transfer clutch circuit and transfer valve have been added to the line pressure circuit between the oil pump discharge side and control valve. Along with this change, the oil supply circuit to the torque converter and the lubricating circuit to the clutch and planetary gear portions have been partially modified.

AT for 83 MY Torque converter Lubrication to rear portion -r.:::::::;;t---I"""rr (c1 utches) Oil pump

AT for 82 MY and before Transfer (4WD) Torque converter Oil pump

r---------,
I
I

I

Oil cooler

Lubrication

X Lubrication to front portion (planetary one-way clutch)

portion (planetary one-way clutch)

Pressure X Drain Restriction regulator

valve1~~~~

'*

A13-403

Fig. 7-8 Comparison of hydraulic circuits

4) Transfer valve The transfer valve is an of-off valve which opens and clbses the line pressure circuit to the transfer clutch, and this valve is operated by the solenoid. In the FWD mode, the solenoid push rod and valve are set at the right side by the spring positioned on the left side, and the line pressure to the clutch is disconnected. If the solenoid is energized by depressing of the 4WD selector switch, the push rod is activated and the valve is pressed to the left against the pressure of the spring. As the valve is moved,

the transfer clutch circuit opens while the drain circuit closes, and the line

pressure is led to the transfer clutch circuit to engage the transfer clutch.

Transfer clutch

Line pressure

A13-404

Fig. 7-9 Transfer valve

7-12
I III 11"
.'''~4

....... -." .....

".-'1' 41-'' ' ' ' ' ' '_ _ 1'''''''''''1t..._____- - -__ ,q_ _ , •...

fJ1"'---_______________

-~

AUTOMATIC TRANSMISSION AND DIFFERENTIAL

2. Operation
1) Front Wheel Drive (FWD)
• The line pre~sure to the transfer clutch is disconnected by the transfer valve, and the clutch is kept in the disconnected state. • All power is transmitted from the transmission to the front wheels through the front hypoid gear. During operation, both the drive member and driven member of the transfer clutch are rotating at the same speed.

Torque converter

r - - - - - - - --,
I

Transfer (4WD)

· . Oil pumpl L ub ncatlOn I to r~ar I
-F.~:t---,t-=;r-portlon

I

I
I

(clutches)

I
LL.;:::=;~ I
Oil cooler

I I

I
I I

x
Lubrication to front portion (planetary one-way clutch)

I I I I I
Closed

I

L _______ J

Transfer valve

I I

Pressure X regulator valve X

Manual valve (line pressure)

X : Drain
..L : Restriction T
A13-405

Fig. 7-10 Hydraulic circuit in FWD mode

Torque converter

Oil pump Transfer clutch

Rear drive shaft

Front differential

Front hypoid pinion

Transfer drive shaft

Extension shaft
A13-406

Fig. 7-11 Transmission of power in FWD mode

7-13

AUTOMATIC TRANSMISSION AND DIFFERENTIAL
2) 4-wheel Drive (4WD)
Torque converter Transfer (4WD) r--------,

If the pushbutton on the selector lever is set to the 4WD position from the FWD position, the transfer valve opens the circuit to the transfer clutch as the solenoid is activated, and, at the same time, the green 4WD pilot lamp illuminates on the meter panel. The line pressure, led through; transfer pipe .... intennediate case .... rear drive shaft, connects the transfer clutch (hydraulic clutch). The power is branched to the front and to the rear on the front hypoid pinion. The power branched to the rear from the shaft end of the pinion is led through; transfer drive shaft .... transfer gear .... transfer clutch .... rear drive shaft .... propeller shaft .... rear differential, and transmitted to the rear wheels.
These characteristics have been established as being necessary to transmit the power from the engine to the rear wheels. If an excessive brake torque is created on the front and rear wheels in a tight cornering operation, the transfer clutch acts as a torque limitter (that is, the clutch slips), and weakens the braking torque, and also protects the driving members. As shown in the characteristic curve in the figure, the torque limiting function is more effective when the line pressure is lower (that is, when the throttle opening is smaller).

Oil pump' Lubrication I of rear I -F=:=::;=+--+f:""""'I1- portion --~~~(clutch)

I ,

I I

,

J~~b'
Oil cooler

I
I

I

x
Lubrication of front portion (planetary one-way clutch)

I
I

I
I
I

I

I
: Transfer valve L ________

J

I

1..:::== -+
X :
Drain : } : Restriction

Manual valve (line pressure)

A13-407

Fig. 7-12 Hydraulic circuit in 4WD mode
Torque converter Oil pump Rear dr i ve shaft

/

Front hypoid pinion

Transfer drive shaft

Extension case

A 13-408

Fig. 7-13 Transmission of power in 4WD mode

3) Characteristics of Transfer Clutch
The line pressure is applied to the transfer clutch, and the clutch capacity varies, like the other hydraulic clutches, with the throttle opening and vehicle speed, as shown in the characteristic curve in the figure.
Throttle full open

A13-409

o

490 (5,71)

981 (10,142)

Line pressure kPa (kg/cm 2 , psi)

Fig. 7-14 Characteristics of the transfer clutch (before o range "cut down")

l __

II"-,,,_~:=::.-=-;},

..

,,~~,"fj"'f

w ' ................ ....ffif • •

TF_.,..._-__. .

7-14
·-1flliii _ _....................... " " , _. ."':_ _ _ _'f _ _ _ _ _ _ _ _ _ _ _ _ _- _ "'i -... : _

AUTOMATIC TRANSMISSION AND DIFFERENTIAL

3. Precautions for 4WD automatic transmission
1) Be sure to use recommended au tomatic transmission fluid (A TF). The use of any other fluid may cause chattering of the transfer clutch. 2) If the driving mode is changed from 4WD to FWD while making a turn, a light shock may be felt in the vehicle body. This shock is caused by the releasing of the tight corner braking feature, and is a normal phenomenon. A similar shock may also be felt when changing from 4WD to FWD after a sudden stop. 3) If the pilot lamp remains off even after operating the 4WD selector switch, the 4WD operating electrical circuit may be faulty; the circuit must be checked and repaired.

4) If the front wheels must be engaged with the front end of the vehicle jacked up, or on a roller, be sure to set the 4WD selector switch to the FWD position, or disconnect the transfer solenoid harness connector in the engine compartment. Remember, if the switch is kept in the 4WD position, the vehicle may be moved as the engine is started. When disconnecting the harness in the engine compartment, use extreme care not to confuse the connectors. 5) The use of different sized tires will cause a shock when releasing the 4WD mode even when driving straight ahead, or will result in deteriorated fuel consumption. Be sure to use tires of the same size on all of four wheels. The tire inflation pressure must be set to the specifications. 6) When attempting to get out of a immobile state by switchback opera-

tion (switchover between "D" and "R"), avoid racing the engine with the lever set in the N position. 7) If the engine or transmission has failed, the vehicle must be towed with the front wheels lifted up. In such an event, the 4WD selector switch must be set in the FWD position.

A13-411

Fig. 7-15 Transfer solenoid harness connector

2 LOCK UP TORQUE CONVERTER
1. Construction
An installation drawing in which the centrifugal lock up clutch is built into the torque converter and a view of the shoe section as seen from the front of the engine are shown below. This lock up clutch transmits torque by the centrifugal force acting on the shoes that slide along the inner circumference of the turbine cover. It has a very simple construction, consisting of five components: shoes and weights with paper facings pasted on their outer surfaces, two leaf springs (main and retractor springs) and pins. Eight shoes are used.
Centrifugal lock-up clutch

Fig. 7-16

A13-413

7-15

AUTOMATIC TRANSMISSION AND DIFFERENTIAL

CD

@ @ @

1 2 3 4 5

Shoe Main spring Retractor spring Weight

Pin

Fig. 7·17

A13-414

• Operation of each component Shoe ... The shoe rotates at the same speed as the torque converter turbine, and slides along the inner circumference of the turbine cover. The shoe sometimes becomes completely engaged with the turbine cover, however, it usually slides in a half-clutch condition. The engine torque is transmitted from the turbine cover through the shoe to the reaction plate and then to the output shaft. Paper is used for the facing. Weight ... Using the centrifugal force produced by the rotation of the weight, the clutch transmits torque. The weight's primary purpose is to increase the transfer torque capacity in the medium- and low-speed ranges. Main spring '" The centrifugal force acting on the weight is transmitted to the shoe through the main spring. In the medium- and low-speed ranges, the load of the spring increases in proportion to the centrifugal force of the weight, so that torque capacity also increases. In the medium- and highspeed ranges, however, the spring load becomes constant regardless of the centrifugal force of the weight, functioning as a torque limiter. Retractor spring '" This spring always functions to pull the shoe inward, which, in the low-speed range where the centrifugal force is small, prevents the shoe from touching the drum. Pin ... The pin fixes the shoe in place so that it will not come off the reaction plate, and also serves as the weight stopper.

2. Operation
1) First range (low-speed, nonoperating range) Because the return force of the retractor spring is greater than the centrifugal force acting on the shoe and weight, the shoe is drawn inward and kept away from the drum. Thus, torque is not transmitted through the shoe. As the revolution increases and when the centrifugal force becomes greater than the return force of the spring, the shoe contacts the drum and begins to transfer torque (lower figure).

greater part of it pushes the shoe through the main spring, working as the power that transmits torque. On the other hand, the centrifugal force acting on the shoe itself becomes the force that pushes the drum regardless of the movements of the weight. Therefore, the press of the shoe necessary to transmit torque in this range becomes: Shoe's centrifugal force + (Weight's centrifugal force - Retractor spring's return force). When the speed of rotation goes still higher, the centrifugal force of the weight increases further, and the main spring deflects more, both ends of the weight butt against the pins (through the retractor spring), so that the weight will not move toward the circumference.

A13·415
"

/

/

/

/

/

/

/

/

Fig. 7-19
A13-416

Fig. 7-18

2) Second range (medium- and lowspeed range, centrifugal clutch range) The centrifugal force of the weight deflects the main spring, and the weight floats up off the concavity at each end of the shoe (portion @ in

Fig. 7-19).
Although a portion of the weight's centrifugal force is transmitted from the retractor spring to the pin, the

3) Third range (medium- and highspeed ranges, torque limiter range) Because the speed of rotation is high, the weight is stopped, completely pressed against the pins at both ends. The centrifugal force acting on the weight at this time is carried directly from the weight to the pins and then to the reaction plate, and therefore it is not transmitted to the shoe. Accordingly, in this range the transfer torque of the clutch is the frictional force produced by the centrifugal force of
.II

,

!

j

11

. _I"

, I , "I,

~

··. ,..

l·,-~··-···~

. . _. - ........... '
~...,.H

!_1-""'!~---

.'_.___,.. _..

7-16

11

'.11_..... ........__________________ , ",... , ,,

II

AUTOMATIC TRANSMISSION AND DIFFERENTIAL
the shoe. The increasing rate of torque due to an increase in the rotational speed is considerably lower than in the second range; consequently, this is what is called a torque limiter condition. Further, the centrifugal force of the main spring is balanced and offset by the force with which the spring is pushed, and there is no change in the force pushing the shoe. 4) Fourth range (high-speed range) The main spring deflects outward due to its own centrifugal force, and separates from the weight. Thus, the upward pressing load with which the weight pushes the spring dies away. In the third range the centrifugal force of the main spring is offset by the pressing load of the weight. In the fourth range, however, because the centrifugal force of the main spring is carried to the shoe as it is, the transfer torque of the clutch greatly increases as does the torque capacity somewhat increases accordingly.

A13-419

Fig. 7-21

A13·418

Fig. 7-20

7-17

AUTOMATIC TRANSMISSION AND DIFFERENTIAL

3 OIL PRESSURE CIRCUIT

Brake

r---------,

Transfer (4WD)

I

I

Transfer

I
I

I
I
I

I

clutch:

I

I
I
I

I

I
I I

(.1 '>

Pressure Regulating Valve

Manual

Valve ',2) p

Note: Marked X are Dra.n _ _ _ _ Line pressure (Governor feed pressure) Governor pressure Torque converter pressure and lubrication Throttle pressure
Governor

Valve

Fig. 7-22

A13·420

7-18
• I I

II

~I~'

"d-""-"~"4<4_'·-""

__ ""I""~'_""

.. ..... '_

'_r~,,

______. . --.. . . ,.,. .,-.. . . . .

t..., -.......tl'".'_ _ _ _ _ _ _ _ _ _ _ _ _"",_,_ _ _ _ _ _ _ _- '"

AUTOMATIC TRANSMISSION AND DIFFERENTIAL

4 FLUID PASSAGES

1 2 3 4 5 6

Oil seal air breather Oil seal air breather circuit Line pressure (Governor feed pressure) Governor pressure Drain Governor pressure (To test plug)
A 13-421

1 2 3 4 5 6 7 8 9 10

Oil pump outlet port Blind hole Forward clutch pressure Reverse clutch pressure Oil pump inlet port Servo connecting pressure Servo release pressure Governor pressure Line pressure (Governor feed pressure) Low & reverse brake pressure
A13-424

Reverse clutch pressure 2 Air breather hole 3 Rear portion lubricating hole 4 Forward clutch pressure
A13·427

Fig. 7-29 Oil pump carrier

Fig. 7-23 Final reduction case

Fig. 7-26 Transmission case bottom side

1 2 3 4 5

Governor pressure Line pressure (Governor feed pressure) Drain To circuit breather To oil seal air breather
A13-422

1 2 3 4 5 6 7 1 2 3 4 5 6 7 Air breather hole To torque converter To transfer clutch Oil pump outlet port Forward clutch pressure Reverse clutch pressure Oil pump inlet port
A13·425

To torque converter Oil pump outlet port Line pressure inspection hole Forward clutch pressure Reverse clutch pressure Oil pump inlet port Reverse clutch pressure inspection hole
A13-428

Fig. 7-24 Transmission case front side

Fig. 7-30 Transmission cover front side

o

0

Fig. 7-27 Intermediate case front side

Transfer clutch pressure

To transfer

valve

1 2 3 4

Oil pump inlet port Reverse clutch pressure Forward clutch pressure Oil pump outlet port
A13-423

A13·426

Fig. 7-25 Transmission case rear side

Fig. 7-28 Intermediate case rear side

7-19

AUTOMATIC TRANSMISSION AND DIFFERENTIAL

3. Component Parts
1) Torque Converter & Housing and Gauge & Piping System

,
('

, , ,

1 ATF oil gauge CP 2 Oil gauge CP
,
1-'

3 4 5 6 7 8

Hose Vacuum pipe CP Vacuum hose Bolt & washer ASSY Oil supply pipe CP O-ring

Tightening torque N·m (kg-m, ft-Ib)

T1: 23-26(2.3-2.7,17-20) T2: 46 - 54 (4.7 - 5.5, 34 - 40)

1 Torque converter ASSY
2 3 4 5 6 7 8 9 Bolt Connector housing CP Oil seal (42 x 60 x 9 mm) Bushing Stud Bolt Stator shaft gasket Stator shaft CP

10 Spring washer 11 Bolt 12 Washer 13 Bolt 14 Washer 15 Spring washer 16 Nut 17 Hanger

A13-429

Fig. 7-31

7-20
, , ~
~ II
Ij ,I

j,·,~ . . ~~~"'-...,~,....,.._+~~ __.-";O-.... ............... , -. . -- f§' · , ,

'.-'''!''T...._,- _ _""'"_ _ _ _ _ _""-' ' 'If... ' '

'e.·.

---"""~,

. .- .r-----------.--.

AUTOMATIC TRANSMISSION AND DIFFERENTIAL
2) Final Reduction Case and Differential Gear

Tightening torque N·m (kg-m, ft-Ib)

T1: 14 -17 (1.4 - 1-7,10-12)
T2: 9-11 (0.9-1.1,6.5-8.0) T3: 4 - 5 (0.4 - 0.5, 2.9 - 3.6) T4: 8 - 11 (0.8 - 1.1, 5.8 - 8.0) T5: 23 - 26 (2.3 - 2.7, 17 - 20) T6: 22 - 27 (2.2 - 2.8, 16 - 20) T7: 57 - 67 (5.8 - 6.8, 42 - 49) 1 2 3 4 5 6 7 8 9 10 Final reduction case Oil seal (22 x 40 x 10 mm) Needle bearing (22 x 28 x 12 mm) Plug Nipple Needle bearing (45 x 55 x 20 mm) Converter housing gasket Bolt Oil seal holder lock plate Oil drain gasket Oil drain plug Snap ring Ball Speedometer driven gear Oil seal (12 x 17.5 x 8 mm) Speedometer shaft Snap ring Washer Washer Parking ball spring Spring retainer Ball Parking actuator support 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Ball retaining plate Bolt Bolt Oxygen sensor harness clip Earth cord Governor cover Governor cover gasket Washer Governor body Governor shaft Governor driven gear Spring pin Bolt Bolt Governor shaft sleeve Governor seal ring Vacuum hose clamp Spring washer Nut Washer Bolt Seal ring 1 2 3 4 5 6 7 8 9 Oil seal (LH) Axle shaft oil seal holder Axle drive s,'\aft Roller bearing Bolt Differential pinion shaft Differential case Straight pin Differential pinion Differential side gear Snap ring Washer Pinion & crown gear set (Non-4WD) Oil seal (RH) O-ring Pinion & crown gear set (4WD AT)

10
*11 *12 13 14 15 16

11
12 13 14 15 16 17 18 19 20 21 22 23

Fig. 7-32

A13-430

7-21
#);1"

---'

AUTOMATIC TRANSMISSION AND DIFFERENTIAL

3) Transmission Case and Control Valve
*Selective parts

Tightening torque N·m (kg-m, ft-Ib) T: 23 - 26 (2.3 - 2.7,17 - 20)

Transmission case CP 3 4 5 6 7 8 *9 10 Stud bolt (8 x 47 x 12 mm) Straight pin (8 x 18 mm) Plug (1/8 in) Parking lever pin Transmission cover gasket (4WD AT) Vacuum diaphragm ASSY Diaphragm rod O-ring (22 mm) Downshift solenoid ASSY Parking pawl shaft Clip Transmission case gasket (4 WD AT) Clip Parking pawl

11
12 13 14 15 16

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Parking pawl return spring Parking shaft support plate Parking rod Nut Manual plate Manual shaft spacer Washer (15.2 x 26 x 0.2 mm) Parking lever O-ring 00 mm) Dust seal Selector arm Washer Spring washer Bolt Bolt

2 3 4 5 6 7 8 9 10 11 12

Control valve ASSY Bolt (6 x 36 x 18 mm) Bolt (6 x 40 x 16 mm) Bolt (6 x 25 x 16 mm) Gasket Oil pan CP Oil drain gasket Oil drain plug Bolt & washer Orifice Servo-apply pipe Servo-release pipe

,~.,

A 13-431

Fig. 7-33

7-22
.,~,

l

l.

1·11

_#.;

1

""'~'.'''''''",''-'''~.J'''''~,,,",-,,,,~-,,,~~,,,,,,,

... q'''t'''Ht''''_'''I0111!_

_

- - _ - -_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _'''''

AUTOMATIC TRANSMISSION AND DIFFERENTIAL

4) Shaft & Reduction Gear
*Selective parts

/1
1
1
I I

1

1 1
I I

)
(

i
I

1 I

1/

/ //

//

/",,/"

1/
1 1

4WDAT

0

1

1 2 3 4 5 *6 7 8 9 * 10 * 11 12

13
14 15 16 17 18 19 20 21

Oil pump drive shaft Turbine output shaft Reduction drive gear unit Ball bearing Snap ring Drive pinion shim 2 Taper roller bearing Thrust bearing retainer Reduction driven gear Drive pinion shim Drive pinion spacer Taper roller bearing Lock washer Lock nut Bolt Snap ring (IN-80) Oil seal O-ring Oil seal holder Washer Spring washer

1 1 1 1 1 1 1 1-/

Tightening torque N'm (kg-m, ft-Ib)

T1: 23 - 26 (2.3 - 2.7, 17 - 20) T2: 108-118 (11-12,80-87)
T3: 92 - 104 (9.4 - 10.6,68 - 77)

Fig. 7-34

A13-432

7-23

AUTOMATIC TRANSMISSION AND DIFFERENTIAL
5) Planetary Gear and Low & Reverse Brake

*Selective parts
Tightening torque -N'm (kg-m, ft-Ib)

T: 14-16(1.4-1.6,10-12)

"'1,

, , ,

Needle bearing Planetary pinion 2 Planetary pinion washer Planetary pinion Planetary pinion spacer Planetary pinion pin Low free wheel Free wheel outer race Planetary bushing 10 Planetary pinion washer 11 Free wheel race lock plate

1 2 3 4 5 6 7 8 9

12 Bolt

13 Thrust bearing 14 Planetary input gear 15 Planetary carrier 16 Thrust bearing 17 Planetary output gear 18 Washer 19 Thrust b~airing 20 Planetary input gear 2 21 Circlip *22 Retaining plate 2

23 Outch driven plate 2 24 Clutch drive plate 2 25 Outer snap ring (55 mm) 26 Low & reverse return spring 27 Thrust spring ring 28 O-ring (56 mm) 29 Lathe cut seal ring (132 mm) 30 Outch piston 2 31 Center support 32 Inner snap ring (144 mm)

Fig. 7-35

A13-37~

7-24
,. j j

1 ij

JI

~,,~j,

-.

,-~,,""I·"-""--~""'i!

- - - ·........ 1'

"""""'t_ _......'1'1"""$,....""'_ _ _ _. .. ,

_ _ _ _ _" " " " - - -_ _ _ _ _ _ _ _ _ _ _ _ _ _- -

• 'fl ,

'''' ,

----~--l

AUTOMATIC TRANSMISSION AND DIFFERENTIAL

6) Forward Clutch & Reverse Clutch

* Selective parts

I

I

1
1

.1
I

~~)

"

1 2 3 4 5 6 7

8
9 10 11 12 13 14 15 16 17

I

I
I I I I I I

I I I I I

~,

,,

18
19 20 21 *22 A13-363 23

Connecting shell Lock washer Thrust bearing Washer Qutch hub Forward clutch assembly Snap ring Retainer plate Driven plate 115 Dished plate Snap ring Spring retainer Spring Qutch piston assembly Drive plate 115 Forward clutch drum Seal ring Lathe cut seal ring Thrust bearing Washer Reverse clutch assembly Retainer plate Reverse clutch drum

",,¥,"

Fig. 7-36

7-25
----'

." _ ..8 (0._~~. ft-Ib) T1: 6 ._______.j .8) T2: 25 ..9. . Tighten lock nut to secure the adjustment.8.28 (2._'''''oji'''I'''''P''''_ _ ' 1""'''"'''''1-----.".F· -I .18 .-----''''.5 .AUTOMATIC TRANSMISSION AND DIFFERENTIAL 7) Band Servo & Oil Pump ·Selective parts ® /1 @ 1 2 3 *4 5 *6 7 8 9 10 11 *12 13 14 15 16 17 18 19 20 21 22 23 24 25 *26 27 28 29 30 31 32 33 34 35 36 37 \ ® @ CD Oil pump ASSY Transmission cover CP Plug Oil pump inner gear O-ring Oil pump outer gear Bolt Needle bearing Oil pump carrier bushing Seal ring Seal ring Washer Snap ring O-ring Servo-piston cover Seal ring Servo-piston CP Seal ring Servo return spring Brake band strut Brake band ASSY Brake band adjust screw O-ring Washer Nut Thrust washer Thrust bearing Oil pump drive shaft 2 Snap ring (Inner) Snap ring (Outer) Servo piston rod O-ring Accumulator piston Accumulator spring Accumulator supporter Band servo clip Intermediate case • Tightening torque N·m (kg·m..5.5 ft-Ib).0. 1-# 41 '" -~ ~ +'o~~...___..21) Adjusting brake band Tighten adjusting screw to a torque of 9 N·m (0..'_--_____.3 ..~.2.9 kg-m.).. j. r".6 . -"~n . 6. then turn it back two turns. 4. Fig. . 7-37 A13-433 7-26 .

20 (1.0.12 -14) A13-434 Fig..2.3 . ft-Ib) T1: 23..5) *7 Pressure plate (F) 8 Driven plate 3 9 Drive plate 3 10 Pressure plate (R) 11 Transfer clutch drum 12 Rear drive shaft 13 Ball bearing 14 Externsion case CP 15 Needle bearing 16 Oil seal 17 Dust cover 18 Transfer clutch solenoid 19 O-ring 20 Gasket 21 Temperature switch ASSY 22 Pipe 23 Bolt 24 Clip 25 Transfer clutch valve ASSY \ \ @ 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Oip Transfer valve body Transfer valve spring Transfer clutch valve Plate Extension gasket Plug Intermediate case CP Coupling Straight pin Transfer drive shaft Clamp Snap ring (OUT 30) Ball bearing Thrust plate Transfer drive gear Bushing Oip Washer Spring washer Bolt Tightening torque N·m (kg-m. 7-38 7-27 .20) T2: 16 .--1 AUTOMATIC TRANSMISSION AND DIFFERENTIAL 8) Extension Case *Selective parts *I Washer 2 Seal ring 3 Ball bearing 4 Washer 5 Transfer driven gear UN 6 Snap ring (IN 98.6 .26 (2.2.17 .7.

.. .______-"4 .. 7) Confirm that the manual linkage adjustment has been completed.""" --________.) 3) Ensure that the vacuum pipe is not disconnected..-...-. n_""''''''. i:l' ii 11 ~j 7-28 ~-----r. If engine is out of adjustment.. perform checks on the items listed in 4.. Necessary Test Gauges 1) Tachometer (It is desirable to be able to read to 50 rpm. (Check the full-opened and fully closed positions... 0 to 356 psi) range]. . Preliminary Inspection 1) Confirm that the engine tune-up has been completed. 2... ... Check the idling speed and idling boost.. carry out the following preliminary inspection...---. Before starting the regular troubleshooting operation..... 5) Check that the kickdown switch functions at the normal pedal position. 4) See that no fluid is leaking from the ATF cooler circulation pipe. NOTE: Chattering of transfer clutch • If considerable chattering is felt in the transfer clutch when making a turn in 4WD mode.. replace two to three liters of transmission oil with the recommended ATF..·-i=-~""f-=~.>l I . ..) 2) Vacuum gauge (It is used for measuring intake manifold vacuum. ... Troubleshooting and On-car Service 1 TROUBLESHOOTING Many troubles of the automatic transmission may be corrected by performing the basic inspection and adjustment procedures.452 kPa (0 to 25 kg/cm 2 .. 2) Check that the linkage between the accelerator pedal and the carburetor is functioning properly.AUTOMATIC TRANSMISSION AND DIFFERENTIAL 4.. 9) See that the ATF level and differential oil level are normal... After completing the above listed operations. . according to the Troubleshooting chart.. transfer solenoid and inhibitor switch are functioning properly.. 8) See that no fluid is leaking out of the transmission. Set above gauges so that the driver can see them.-j .T~-I· ~-ll . . 6) Check that the electrical circuits of the kickdown solenoid. .j.. 'fi"""'---_Sff_ _ _.""' ~ Jr. ·-v . 1.- ..) 3) Oil pressure gauge [0 to 2. · 'q"'·-"§""IT"'_"'·_WR...:1I''. check also the stall speed.

M.J. No shock when shifting 2-3.J K.J L.J k.J j j.M. "2". r. (Above kickdown limit.J L.t m k.r k.m. v m.M. No shock is felt.AUTOMATIC TRANSMISSION AND DIFFERENTIAL 3. Large shock when shifting 1-2.J J L.G L K.k. No shock when shifting 1-2. t e j.J n. or slip occurs.J L. Engine races.N. (Car runs in FWD mode. L.J G.G. Car is braked when shifting 2-3. r • No shift from 1st to 2nd.G.K. Car is braked when shifting 1·2.M. r m. Slip is felt when starting in FWD D range. (Car runs in "R".J K.L.J G. J H.M.J G.G.G.M.m m.J G. Car is braked if lever is set in "R".r k. slip.r m 7-29 . 3-2 shift point or 2-1 shift point is too high.J L.M.J G.r n.r m k.L. Shift occurs from 1 to 3.M.r q.) Car will not run in any range.J L.M. slip. Troubleshooting Trouble Large shock when shifting "N" -+ "D" Car will not run. Low maximum speed. (Car runs in "D".M.G. or engine races when shifted from" 1" to "2". k m.) Engine races when gear is changed from 3rd to 2nd and accelerator pedal is depressed.) Car runs even in "N". r m. (Car runs in "1" range. No shift from 2nd to 3rd. Shift points too high from 1-2 and 2-3.r k. and" 1".X K. t r r m. "2". or poor acceleration. or acceleration is very poor in "D".) Kick down occurs or engine overruns when accelerator pedal is depressed from 3rd. No shift from 3rd to 2nd.h j. (Within kickdown limit speed. or "1".J L.G.M.r r m. No kickdown occurs when accelerator pedal is depressed from 3rd.J K.m.m. Large shock when shifting 2-3.K. or from 3rd to lst. v r.k.G.L. or slip occurs.J L. r Off the car check item G. Large shock is felt when car speed decreases when accelerator pedal released. or acceleration is very poor in "R".) Car will not run.G.J On the car check item G.J K.J K.G.G. No shift from 2nd to 1st. Gear remains in 3rd and is not changed to 2nd even when lever is set to "2".n.) Slip is felt when starting in 4WD mode.

b.L. n. or parking gear remains engaged even when lever is moved from "P".m. Large noise in "2".L H. Automatic transmission fluid is contaminated with differential gear oil. and when it is 1) Checking fluid level a. the level should be above the center of upper and lower marks. Large noise when running in FWD 3rd gear. On the car check item L. Ensure the vehicle is level and set the selector lever in "P" range.H. "1".x l' 4.W N k. Car exhaust emits white smoke while running. Large noise in "P" or "N" . Inspection Items 1) Inspection Items with Automatic Transmission Mounted on Vehicle G Oil pressure check H Stall speed J Control valve K Governor valve L Brake band adjustment M Servo pipe N Inspection of fluid by draining W Vacuum diaphragm X Nylon gear l' m n q r Transfer gear Brake band and band support Low & reverse brake Oil pump Leak from hydraulic circuit Power train one-way clutch v Parking linkage w Hypoid gear x Reduction gear Z Stator shaft and reduction drive gear oil seals and O-rings. [This temperature may be attained by 7-30 . r n. h. r v G. Method of Inspection and Adjustment 1) Fluid Level Check and Fluid Replacement 1) Automatic transmission fluid (ATF) 2) I nspection Item with Automatic Transmission Detached from Vehicle e Transfer valve.j j. or "R". n. 2 ON-CAR SERVICE 1. m. Measure fluid level with the engine idling. m.AUTOMATIC TRANSMISSION AND DIFFERENTIAL Trouble Gear remains in 3rd and is not changed to 2nd even when lever is set to "1". Pay attention to the fluid temperature when checking oil level. If the fluid level is below the lower limit mark. r. When the transmission is hot. transfer pipe. Raise the ATF temperature to 60 to 80°C (140 to 176°F). n q q.j k. add the recommended ATF until the fluid level is found within the specified range (within upper and lower limit marks). 1 Z.J J K. Fluid spouts out while running. Unusual smell from oil supply pipe. t.G. k.G.g w. and governor shaft oil seal running a distance of 5 to 10 km (3 to 6 miles)]. Transmission overheats.J Off the car check item k. Gear shift 2-1 does not occur in "1".K. NOTE: The level of ATF varies with fluid temperature. A change in the ATF level by oil temperature is shown in the following figure. m. r r n. Gear shift 1-2 or 2-3 occurs in "1".J G. Car begins to move even when lever is set to "P". No engine brake is applied in 1st gear. idle the engine for one or two minutes before measurement c. h. g z. Large noise when running in 4WD 3rd gear. rear drive shaft seal ring f Transfer clutch g Drive pinion rear oil seal h Torque converter one-way clutch j Forward clutch k Reverse clutch Planetary gear NOTE: After running. Differential gear oil is contaminated with automatic transmission fluid.

-,
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
cold, the level should be found below the center of these two marks.
Fluid temperature range / " for fluid level check . . mm Upper IImlt marrk

NOTE:

~

(1.5i~

r

)

a. Use care not to exceed the upper limit level shown in item 2) below. b. Check the ATF level when deliver· ing a car to a customer.
2) ATF level a. ATF level varies with temperature as shown in figure. Remember that the addition of fluid to the upper limit mark when the transmission is cold will result in the overfilling of fluid.

30 (1.18 )

8,
~
Qj
::J

E -c

>

M_

co ~

E'-

20 (0.79 )P""

~~

~

~

-

~

~

• up" range
• Idling (Engine rpm: 800 - 850 rpm)

i

3

Lower limit mark

1

IO.3~

)

0

30 (86)

40 (104)

50 (122)

60 (140)

70 (158)

80 (176)

90 (194)

100°C (212WF)

Automatic transmission fluid temperature
A13-435

Fig. 7-39 Automatic transmission fluid level (4WD A T)

b. Fluid temperature rising speed, • By idling the engine / Time for rising temperature to 60°C (140°F) with atmospheric temperature of O°C (32°F): More than 25 minutes (Reference) Time for temperature rise to 30°C (86°F) with atmospheric temperature of O°C (32°F): Approx. 8 minutes • By running the vehicle Time for temperature rise to 60°C (140°F) with atmospheric temperature of O°C (32°F): More than 10 minutes c. Method for checking fluid level upon delivery or at periodic inspection. Check fluid level after a warm-up run of approx. 10 minutes. During this warm·up period, the automatic transmission functions can also be checked. 3) Inspection and replacement intervals

4) Replacement of ATF a. After allowing the engine to cool for 3 to 4 hours, remove the fluid pan drain plug, and drain oil thoroughly.

until the oil level can be found within the specified range.

NOTE:

NOTE:

a. The fluid will be discharged to the front as the drain plug is removed. To avoid the stream of fluid, the worker should stand under the oil pan toward the front of the car performing this procedure. b. The amount of fluid that can be drained is approx. 4Q (4.2 US qt, 3.5 Imp qt) of the total capacity of 6.0 to 6.4 Q (6.3 to 6.8 US qt, 5.3 to 5.6 Imp qt) for 4WD and 5.6 to 6.0 Q (5.9 to 6.3 US qt, 4.9 to 5.3 Imp qt) for non-4WD. Some fluid will remain in the torque converter, oil passage, or in the valve body.
b. Tighten the drain plug. [Tightening torque: 25 N'm (2.5 kg·m, 18 ftlb )].

a. If the drained fluid is black or thick, it indicates that some com· ponents in the transmission are faulty. Disassemble and check the transmission. b. Be sure to use recommended ATF when changing the transmission fluid.
2) Differential gear oil
• Checking oil level 1) Ensure the vehicle is level.

NOTE:

Do not check the oil level nor add oil to the case with the front end of the vehicle jacked up; this will result in an incorrect reading of the oil level.
2) Check whether the oil level is between the upper and lower marks. If it is below the lower limit mark, add oil until the level reaches the upper mark. The difference in level between upper and lower marks corresponds to 0.4Q (0.8 US pt, 0.7 Imp pt). • Oil to be used Recommended gear oil

NOTE:
At delivery, after initial 1,600 km (l,000 miles) and every 24,000 km (lS,OOO miles) or 15 months Every 48,000 km (30,000 miles) or 30 months

Be sure to replace the gasket with a new one.
c. Pour 4Q (4.2 US qt, 3.5 Imp qt) of recommend~d ATF into the case through the oil supply pipe. d. Run the vehicle until the fluid temperature rises to 60 to 80°C (140 to 176°F), and then add fluid

Inspection

API classification
SAE viscosity No.

GL·5
75W·80

Replacement

7-31

AUTOMATIC TRANSMISSION AND DIFFERENTIAL
• Inspection and replacement interval Every 12,000 km (7,500 miles) or 7.5 months Every 48,000 km (30,000 miles) or 30 months • Governor test plug • Air breather 4) Automatic transmission case Idling rpm for automatic transmission cars (N or Prange)

800 ± 100 rpm

Inspection

Replacement

• Replacement of oil Remove the drain plug located on the left side of the final reduction case, and drain the oil completely. Tighten the plug to a torque of 25 N·m (2.5 kg-m, 18 ft-lb), and remove the oil gauge, and pour new oil into the case through the opening until the oil level reaches the upper level mark [total quantity of oil: 1.2Q (1.3 US qt, 1.1 Imp qt»).

• Mating surface of oil pan and transmission case • O-ring on the outer diameter of servo piston cover • Test plug (Servo connecting side and servo release side) • Oil supply pipe connections • ATF pipe connector • Vacuum diaphragm location • Downshift solenoid location • O-ring on the outer diameter of servo adjusting screw • Oil pan drain plug • Governor pressure and line pressure checking blind plugs (steel ball) 5) Intermediate case

4) Checking and Adjusting the Kickdown Switch and Downshift Solenoid
Set the ignition switch to ON, and fully depress the accelerator pedal to see whether the solenoid functions or not. If no kickdown occurs, or if the shift point occurs with the throttle half open, check the kickdown switch, downshift solenoid and associated wires. If kickdown failure occurs infrequently, it may be due to malfunction of the solenoid contaminated with dirt. Wash the inside of solenoid while moving the push rod. After washing, carefully check the operation of the solenoid.

2) Oil Leakage Check Points
It is difficult to accurately determine

the precise position of a oil leak, since the surrounding area also becomes wet with oil. The places where oil seals and gaskets are used are as follows:
1) Jointing portion of the case

• Test plugs (two plugs for line pressure, and plugs on forward clutch, reverse clutch, and transfer clutch) • Blind plug (steel ball)

NOTE:

6) Extension
• Rear drive shaft oil seal • Transfer solenoid location • Thermoswitch location The points listed above should be checked for fluid leak. Checking method is as follows: • Place the vehicle in the pit, and check whether the leaking oil is ATF or not. The ATF is wine red in color, and can be discriminated easily from engine oil and gear oil. • Wipe clean the leaking oil and dust from a suspectable area, using a noninflammable organic solvent such as carbon tetrachloride. • Run the engine to raise the fluid temperature, and set the selector lever to "D" in order to increase the fluid pressure and quickly detect a leaking point.
3) Checking the Engine Idling

Before removing or installing the solenoid, drain approx. 2 Q (2.1 US qt, 1.8 Imp qt) of ATF.

• Transmission case and final reduction case jointing portion • Final reduction case and converter housing jointing portion • Transmission case and transmission. cover (or intermediate case) jointing portion • Intermediate case and extension case jointing portion
2)

5) Checking Negative Intake Pressure Check whether pressure is over -60.0 kPa (-450mmHg, -17.72inHg) at idling speed of engine, and whether pressure decreases in proportion to increase of engine speed when accelerator pedal is depressed.

Converter housing

6) Checking Creeping
Check whether car exhibits a certain amount of creeping when it is brought to a temporary stop with selector lever in "D", "2", "1" or "R" position.

• Engine crankshaft oil seal • Torque converter impeller sleeve oil seal • ATF pipe connector 3) Final reduction case

• Final reduction case and governor cover • Axle shaft oil seal • O-ring on the outside diameter of axle shaft oil seal holder • Differential oil fIller port • Differential oil drain plug • Speedometer cable mounting portion

7) Checking and Adjusting the Manual Linkage Adjustment of the manual linkage, like the inspection of fluid level, is an important operation in the automatic transmission service. Remember that improper adjustment may lead to a damaged transmission.

rpm
Excessively low engine idling rpm will lead to rough engine operation and excessively high idling rpm will lead to a sudden shift shock or creeping when shifting from N to D or R.

7-32

AUTOMATIC TRANSMISSION AND DIFFERENTIAL
R
Push button Selector lever Indicator Slide plate Inhibitor switch

N

0

Operation indicated by solid arrow mark .. must be done while pressing the push button. ¢:J Operation indicated by white arrow mark may be done without pressing the button.

Rod

check the vacuum hose for cracks or check the vacuum hose joint. Excessively large shift shocks and the emission of white exhaust smoke while running may indicate a broken vacuum diaphragm. If such symptoms occur, loosen the two bolts securing the vacuum pipe (at governor cover and at the engine and transmission jointing), and turn the vacuum pipe upward around the bracket of the diaphragm joint until the bracket comes free from the bolts. Pull the vacuum hose and vacuum pipe out toward you and drain approx. 2Q (2.1 US qt, 1.8 Imp qt) of ATF. Remove the vacuum diaphragm by rotating by hand.

Fig. 7-40 Selector system

A13-436

1) Inspection 1) While pressing the release button, move the selector lever from the "P" to "1" range; a click will be heard in each position. This clicking sound is caused by a detent of the manual valve in the transmission, and it indicates the correct selector lever position. Check to see that the indicator needle is aligned to this position, and also see that it is aligned with the groove of the guide plate when the release button and selector lever are released. 2) Confirm that the selector lever cannot be moved into "R" from "N" when pushed lightly, without first pressing the release button. 3) Confirm that the engine can only be started in "P" and "N" ranges. 4) Confirm that the backup lamp will light only when the selector lever is moved to the "R" range. 5) Place the vehicle on a slope, and set the selector lever to "P" and check whether the vehicle is locked properly. 2) Adjustment
If the manual valve detent position is not aligned with the guide plate groove position, perform the adjustment as follows. 1) Set the selector lever to "N". 2) Loosen the adjusting nut of the linkage rod.

3) Set the detent position so the selector arm is aligned with the "N" locating mark of the transmission case [within the range of a 6 mm (0.24 in) dia. boss].

NOTE: a. Be sure to remove the vacuum diaphragm when the transmission is cold. (To avoid a burn.) b. Also take out the diaphragm rod.
9) Checking, Correcting, Disassembling, and Reassembling the Governor Valve
If automatic shifting is not performed normally while running in the D range, or if acceleration is possible only up to 50 to 60 km/h (31 to 37 MPH) in the D range, it is often attributable to malfunctioning of the governor valve. Such malfunctioning may be caused by sticking of the valve due to clogged dirt, burrs or nicks on the valve body, etc.

A13-437

Fig. 7-41 Adjusting rod

4) Adjust the rod so that the "N" mark of the guide plate is aligned correctly with this detent position. 5) If the indicator needle is not aligned with the guide plate marking, remove the console box, loosen the four indicator mounting screws and adjust the position of the indicator ASSY.

A13-438

Fig. 7-42 Component of governor valve

8) Checking the Vacuum Diaphragm and Vacuum

1) Disassembly 1) Remove the three governor cover mounting bolts from the right side of the final reduction case, and remove the governor cover by turning it slightly in order to avoid interference from the vacuum pipe bracket.

Hose
A loose or disconnected vacuum hose will result in rough engine idling and an abrupt shifting shock even with light acceleration. In such a case,

7-33

AUTOMATIC TRANSMISSION AND DIFFERENTIAL
2) Pull the governor valve out while carefully turning clockwise. 3) Remove the E·clip ® snap ring @ then remove the valve @, spring ® and other parts from the body © . 4) Remove two bolts ® securing the shaft CD and body © and disassemble them. 2) Burrs and nicks at the edge of the valve body groove should be removed by using a small standard screwdriver. 3) Clean the repaired parts in clean lamp oil or white gasoline. Fit the governor valve and governor valve 2 into the valve body, and check for smooth sliding of these parts by lightly pressing them to the inside of the valve body while rotating.
Check these areas.

2) Confirm that there is no foreign matter in the oil passage of the governor shaft, and tighten the shaft to the governor body after washing. Tightening torque

9 - 11 N·m (0.9 - 1.1 kg-m, 6.5 - 8.0 ft-lb)

NOTE:

Be sure to perform the steps 3) and 4) after pulling the governor valve out from the final reduction case.
2) Checking Check the governor valve and body visually and by feeling with a finger for burrs and dents, and repair as necessary. If the sliding surface of the body or valve is defective, replace the governor body ASSY with a new one. 3) Correcting 1) To correct the governor valve and governor valve 2, lightly apply a fme grained oil stone to the burred edge as shown in the figure, and rotate the valve one or two turns. Check whether or not the burrs have been removed by feeling with a finger. Repeat this operation until the burrs are no longer felt.

NOTE:

When tightening, fix the flange of the shaft, and be careful not to damage the nylon gear of the shaft.
3) When assembling the governor
valve to the final reduction case, it is unnecessary to dry out the governor valve. However, the governor valve should be assembled after confirming that the seal ring is normal.

A13·440

Fig. 744 Checking the edge of the governor body groove

NOTE:

NOTE:

If the governor valve checks out to operate normally, the seal ring of governor sleeve must be checked.
4)
Reassembling

When assembling, use special care not to damage the seal ring, and the lip of the oil seal installed inside the case.
4) Before assembling the governor cover, replace the gasket (governor cover) and confirm that the washer is included. Tightening torque

14 - 17 N·m
(1.4 - 1.7 kg-m, 1O-12ft-lb)

O@~~D@-.
A13-441

NOTE:

a. Note that the finishing of the end face is not chamferring, but it is light deburring. A sharp edge having no burrs is desirable. b. Replace the valve ASSY if flaws and dents are noted on the sliding surface.

Fig. 745 Reassembling the governor valve

10) Adjusting the Brake Band
If the following abnormal shifting conditions are noted in a road test, the brake band must be adjusted. 1) Shift state and adjustment 1) The 2nd gear state can be achieved but: • the engine rpm increase excessively shifting up from 2 to 3. • a shift delay (over O. 7 sec) accompanies at kickdown from 3 to 2. If any of these problems occurs, it is attributable to excessive clearance between the reverse clutch drum and brake band: Tighten the adjust screw by turning it clockwise. 2) The 2nd gear state can be achieved, but: • the shifting shock is too small at shifting up from 1 to 2. • a braking phenomenon is noted when shifting up from 2 to 3.

1) Reassemble the governor valve components by referring to the figure shown above. Pay attention to the orientation of the weight.

Keep oil stone fixed.

Turn Wi:Jh - -+U---+fingers

'----

....

Correct these areas.
A13-439

Fig. 743 Correcting valve

-1,,---1

•.

,'*

I

~,I,II

tj

I"

,.~

-j",.,,41.~~_-_·.w..""""~<.t;""""""

__""'itl_"''''r.r

t-_-1~'_'-

__"._--___
7-34

"'~I""w

_______- _________-

----------

------------,

AUTOMATIC TRANSMISSION AND DIFFERENTIAL
If any of these phenomena are noted, it is attributable to excessively small brake band clearance: Loosen the adjust screw by turning it counterclockwise. 3) When accelerating, direct shift up from 1st to 3rd occurs: ........ Excessively large clearance. When shifting up from 2nd to 3rd, tire slip occurs: . : ...... Excessively small clearance.

11) Inspection, Removal and Installation of the Transfer Solenoid (4WD Models)
If the 4WD pilot lamp on the instrument panel remains off even when the 4WD pushbutton switch has been depressed, check the transfer solenoid and wiring. If the 4WD mode is not achieved with the lamp illuminated, the solenoid may be malfunctioning. Check the solenoid and transfer valve as follows. • Removal and installation of solenoid (transfer valve) • Removal 1) Open the hood. 2) Disconnect the battery ground cable. 3) Remove the spair tire. 4) Loosen the pitching stopper (to a position just before it comes oft). 5) Disconnect the 4WD selector solenoid harness. (Keep the disconnected harness suspended.)

10) Remove the rear crossmember. (To ensure safety, support the oil pan with a transmission jack.) 11) Remove the side cable from the body clip. (Move it downward as far as possible.) 12) Push the transmission to the left. (Insert a piece of wood between the clearance thus achieved.) 13) Remove the solenoid valve.

A13-444

A13-442

Fig. 7-46 Adjusting the adjusting screw

Fig. 7-48 Removing the solenoid valve

2) Adjustment of the adjusting screw 1) Using a socket wrench, immobilize the end of the 10 mm screw projecting on the left side of the transmission case, and loosen the nut with a double-end wrench. In the case of occurrence of problems 1) and 2) mentioned previously, perform the adjustment by loosening or tightening the nut within a range of 3/4 turn from this state.

• Installation Reverse the sequence of removal procedure.

12) Disassembly, Inspection and Assembly of the Transfer Section (4WD Model)
I) Disassembly 1) Completely drain the AFT. 2) Remove the transfer solenoid. Refer to the Removal and Installation of the Transfer Solenoid for details. 3) Remove the temperature switch harness from the clamp. 4) Remove the eight 8 mm bolts and extract the transfer section and extension ASSY as a unit from the intermediate case.

NOTE: Tool No. Tool name
A13-443

398603610

Socket wrench

Fig, 7-47 Removing the 4WD selector solenoid harness

00 not loosen excessively; otherwise,

the band strut on the servo piston will drop off.
2) In case of the occurrence of problem 3) mentioned previously, perform the adjustment as follows: Adjusting procedure: Tighten adjust screw to 9 N·m (0.9 kg-m, 6.5 ft-Ib) torque, then back off two turns.

NOTE: Do not tighten the adjusting screw with an excessively large torque.
3) With the adjusting screw immobilized, tighten the lock nut to 26±2 N·m (2.7±0.2 kg-m, 20±1.4 ft-Ib) torque.

6) Remove the uppercover. [This is necessary for removing the exhaust pipe (F).] 7) Remove the exhaust pipe (F). 8) Remove the intermediate side cable clamp. . 9) Drain the torque converter oil (one liter). (The oil will not come out of the case when the valve is removed, if one liter of oil has been drained. Measure the drained amount so that the amount to be added after completing the inspection can be easily determined.)

NOTE: a. Be careful not to drop the internal component parts. b. Place a container to collect the remaining oil.

7-35

AUTOMATIC TRANSMISSION AND DIFFERENTIAL

o
A13-445

A13-447

A13-448

Fig. 749 Removing the extension ASSY

Fig. 7-51 Valve component parts
2) Attach the valve body to the intermediate case and tighten with the two 6 mm bolts. Tightening torque 6- 8 N·m (0.6 - 0.8 kg-m, 4.3 - 5.8 ft-lb)

Fig. 7-52 Removing the solenoid, diaphragm, etc.
3) Remove the converter oil pan. Be sure to place a container under the oil pan to collect ATF remaining in the oil pan. 4) Disconnect the servo pipes.

5) Separate the clamp from the pipe at the bent position and disconnect the transfer pipe from the valve body and intermediate case.

NOTE:

a. Do not forget to install the plate. b. Pay attention to the direction of the valve body. c. Do not forget to install the clamp.
3) Insert the transfer pipe into the intermediate case and tighten the clamp by bending.

A13-446

Fig. 7-50 Removing the clip and pipe

A13-449

NOTE:

Fig. 7-53 Removing the servo pipe

6) Remove the two 6 mm bolts securing the valve body. 7) Remove the E-clip and remove the transfer valve from the body_

Always use a new pipe and clamp.
4) To assemble the transfer unit, reverse the order of disassembly. 5) Remove the six 6 mm bolts (shown by the arrow) and detach the control valve ASSY.

NOTE:

NOTE:

NOTE:

Be careful not to lose the coil spring.

Be sure to install the rear drive shaft seal ring.
5) Replenish ATF and check the level.

2)

Inspection

• Visually check all peripheries to ensure they are free from burrs, dirt, metal chips, etc. • Cleaning all parts by washing them and install them in the valve body. Ensure these parts move smoothly without binding_ • If the valve body or the frictional surface of the - valve is faulty, replace with a new one.

a. Be careful not to drop the manual valve. b. Be careful not to damage the oil strainer. c. Be careful not to allow dust or dirt from getting into the valve ASSV.

13) Inspection of the Control Valve Assembly
1) Disassembly

3) Assembly 1) To assemble the transfer valve parts, refer to the following figure.

1) Raise the vehicle with a jack and drainATF. 2) Disconnect the vacuum hose, and remove the downshift solenoid and vacuum diaphragm.

NOTE:

A13-450

Also remove the diaphragm rod together with the vacuum diaphragm.
7-36

Fig. 7-54 Removing the control valve

t,,~

'r1".4·jf,·'t'I'j,,-",,_""~'~'''''''''''"'"'''

__ ''''''''''''''''''''''''... ....t '-~r""" I'i_' t ...

......'r-'·..

f_ _ _ _ _ _ _ _...'"'"...

"_lsr""'_--_______________-

AUTOMATIC TRANSMISSION AND DIFFERENTIAL
2) Inspection For selection of a suitable diaphragm rod, refer to "5. TRANSMISSION CASE SECTION". 6) Install the downshift solenoid and connect the vacuum hose. 4) While forcibly depressing the foot brake pedal, gradually depress the accelerator pedal until the engine operates at full throttle. 5) When the engine speed is stabilized, read that speed quickly and release the accelerator pedal. 6) Shift the select lever to Neutral, and cool down the engine by idling it for more than one minute. 7) Record the stall speed. 8) Perform the stall tests with the select lever in the 2, 1 and R ranges.

Refer to the Control Valve ASSY section. 3) Assembly 1) Install the control valve ASSY.

NOTE: Do not forget to install the "0" ring.
7) Replenish ATF and check the oil level. The amount of ATF to be replenished is approximately 4 liters (4.2 US qt, 3.5 Imp qt).

NOTE: Be sure to tighten the bolts equally one at a time - using a torque wrench. ,
Tightening torque 2)

6 -8 N·m (0.6 - 0.8 kg·m, 4.3 - 5.8 ft-Ib)

2. Various Test Methods 1) Stall Tests and Interpretation of Test Results
The stall test is of extreme importance in diagnosing the condition of the automatic transmission and the engine. It should be conducted to measure the engine stall speeds in all shift ranges except the P and N ranges. 1) Purposes of the stall test 1) To check the operation of the automatic transmission clutch and brake band. 2) To check the operation of the torque converter. 3) To check engine performance. 2) Test methods Prior to the stall tests, check to ensure the carburetor throttle valve opens fully, and that the levels of engine oil, cooling water and ATF are correct. Set the select lever in the P range and idle the engine at 1,200 rpm for several minutes until the ATF reaches approximately 60°C (l40°F). 1) Install an engine tachometer at a location visible from the driver's compartment and mark the stall speed range of 2,100 to 2,300 on the tachometer scale.

Connect the servo pipes.

NOTE: Always install new servo pipes.

A13-451

Fig. 7-55 Installing the servo pipe

3) Align the mating surfaces of the converter oil pan and converter to en· sure no clearance exists at any point. The gasket should not be used at this point. 4) Wipe any oil from the mating surfaces and install the converter oil pan with the gasket in place.

NOTE: a. Do not continue the stall test for MORE THAN FIVE SECONDS at a time (from closed throttle, fully open throttle to stall speed read· ing). Failure to follow this instruction causes the engine oil and ATF to deteriorate and the clutch and brake band to be adversely affected. Be sure to cool down the engine for a, least one minute after each stall test with the select lever set in the P or N range and with the idle speed lower than 1,200 rpm. b. If the stall speed is higher than the specified range, attempt to finish the stall test in as short a time as possible, in order to prevent the automatic transmission from sustaining damage.

NOTE: Always use a new gasket.
Tightening torque Drain plug tightening torque 3.4 - 4.4 N·m (0.35 - 0.45 kg-m, 2.5 - 3.3 ft-Ib) 25N·m (2.5 kg-m, 18 ft-Ib)

I Stall speed I 2,100 -

2,300 rpm

I

5) Using the Diaphragm Rod Gauge Set, check the length of the diaphragm rod is within specifications and, if the length is correct, install the vacuum diaphragm.

2) Place the wheel chocks at the front and rear of all wheels and engage the parking brake. 3) Move the manual linkage to ensure it operates properly, and shift the select lever to the D range.

7-37

AUTOMATIC TRANSMISSION AND DIFFERENTIAL
3) Interpretation of stall test results Stall speed Higher than 2,300 rpm Assessment Slippage of automatic transmission clutch, brake band, etc. (Further stall tests are not necessary. ) Cause • Low line pressure (If stall speed is higher than specified range at any shift position). • One-way clutch slippage. (If stall speed is higher than specified range only in the D range.) * 1: Brake band slippage (If stall speed is higher than specified range only in the 2 range.) *2: Slippage of low & reverse brake or reverse brake (If stall speed is higher than specified range only in the R range.) Remarks * 1: Brake band slippage cannot be judged by stall tests; however, if it slips, engine speed is higher than specified rpm while car is being driven in the 2 range. *2: Slippage of reverse clutch/ low & reverse brake can be judged by road tests. If engine compression can be used as a brake with select lever in the 1 range, reverse clutch is slipping; if it cannot be used, low & reverse brake is slipping.


2,100 - 2,300 rpm

• Control members are in good order in the D, 2, 1 and R ranges. • Engine in good order. • Throttle not fully opened. • Erroneous engine operation or one-way clutch slippage. • Acceleration is not properly made up to 50 km/h (31 MPH). • Car speed does not attain more than 80 km/h (50 MPH). • Operation is not proper at all car speeds. One-way clutch slippage. *3: One-way clutch jamming. Erroneous engine operation.

• One-way clutch can be checked for condition by road tests. **

Lower than 2,100 rpm ** Road test

*3: Abnormal temperature rise occurs.

7-38
!
II
"I,l'l I.·

II!

fl'

FE

P'P

"",Ff

AUTOMATIC TRANSMISSION AND DIFFERENTIAL

2) Road Test
Road tests should be conducted to properly diagnose the condition of the automatic transmission.

Negative pressure -kPa(-mmHg, -inHg)

Shift DI -+ D2

Car speed km/h (MPH) 50 - 59 (31 - 37) 89 - 99 (55 - 62) 82 - 92 (51 - 57) 37 - 47 (23 - 29) 15-22(9-14) 41 - 51 (25 - 32) 13-22(8-14) 10-17(6-11) 41-51(25-32)

I) Speed change characteristics
The standard speed change characteristics are indicated in the following table.

Kickdown 4.0 - 6.7 (30 - 50, l.18 - 1.97)

D2 -+ D3 D3 -+ D2 D2 -+ DI DI -+ D2

Half-throttle 26.7 (200, 7.87)

D2 -+ D3 D3 -+ D2 or D3 -+ D I Dl -+ DI

Full-throttle 4.0 - 6.7 (30 - 50, l.18 - 1.97) Minimum throttle 57.3 - 60.0 (430 - 450,16.93 - 17.72)

*1 2 -+ II *12-+11

41 - 51 (25 - 32)

* 1: Reduce the car speed by shifting to 1st range from D range [while car speed is 50 km/h (31 MPH) or thereabout].

2) Shift characteristics
Pay careful attention to ensure the shift is made smoothly at the proper car speed at which shifting begins. I) Shifting shocks are encountered or smooth shifting does not occur. 2) Shifting occurs slowly in response to the condition of the engine throttle. The above two problems are due to incorrect throttle pressure or other factors involved in throttle pressure.

In road tests, if any abnormality is noticed in the 2 range, it is necessary to adjust the brake band. If by inspection the brake band is in good order, check the servo piston for any sign of oil leakage from the seal.
4)

stances, may be due to the line pressure being too high. • Slippage or inability to operate the car may, in most cases, be due to loss of oil pressure for the operation of the clutch, brake band or control valve.

Check for the 4WD function

3) Checking for shift patterns
1) In the D range, shifting should be made as DI -+ D2 -+ D3 smoothly and vice versa; it should not be made in the R range. 2) Kick down should activate properly_ 3) When the select lever is shifted from the D range to the 2 or 1 range, shifting should be made as D2 -+ 2 (1 2) -+ II' Engine compression can be utilized as a brake at 12 and II. 4) Shifting should not occur while the select lever is at the 1 range. 5) With the shift lever in the 2 range, the 2nd gear is engaged and 2nd speed is maintained. 6) The select lever should be locked when placed in the Prange.

With the car in the 4WD mode, turn the vehicle in a circle while lightly depressing the accelerator pedal, and then shift the vehicle into the FWD mode. When the vehicle is shifted into the FWD mode, a light shock should be felt. Whenever the transfer clutch facing is replaced with a new one, the above test should be conducted, for the run-in purpose, two to three times with the vehicle set in the 4WD mode and with the steering wheel fully turned.

I)

Measuring the line pressure

1) Temporarily attach the Oil Pressure Gauge ASSY to a suitable place in the driver's compartment, remove the blind plug located in front of the toeboard and pass the hose of the Gauge ASSY to the engine compartment.

3) Line Pressure Tests
If the clutch or the brake band shows a sign of slippage or shifting sensation is not correct, the line pressure should be checked. • Excessive shocks during upshifting or shifting takes place at a higher point than under normal circumI Pressure gauge hose A 13·223 2 Hole in toe board (blank cap hole) 3 Brake pedal

Fig. 7-56 Measurement of line pressure

7-39
----'

AUTOMATIC TRANSMISSION AND DIFFERENTIAL
,---

Tool No. 398573600

Tool Name Oil pressure gauge ASSY
Throttle position

Unit: kPa (kg/cm 2 , psi) Full -4.0 (-30 -1.18 Before* 1 cutdown 834 - 981 (8.5 - 10.0, 121-142) 1,000 - 1,157 (10.2 - 11.8, 145 - 168) throttle 6.7 kPa 50 mmHg, 1.97 inHg) After cutdown 539 - 637 (5.5 - 6.5, 78 - 92) 579 - 677 (5.9 - 6.9, 84 - 98)

Minimum throttle *2

2) Using the socket wrench (7), remove the pressure check plug from transmission cover (or intermediate case.) 3) Attach an oil pressu.re adapter to the pressure check plug hole in transmission cover (or intermediate case.)

Range

Before cutdown 294 - 392 (3.0 - 4.0, 43 - 57) 1,000 - 1,157 (10.2-11.8, 145 - 168)

After cutdown 294 - 392 (3.0 - 4.0, 43 - 57) 579 - 677 (5.9 - 6.9, 84 - 98)

D

2

R

1,373 - 1,569 (14.0 - 16.0,199 - 228)

461- 559 (4.7 - 5.7,67 - 81)

NOTES:

Fig. 7-57 Removing the pressure check plug

*1: The "cutdown point" refers to those points where the line pressure in each shift range (1, 0, 2 and R) changes in steps or where the pressure modifier valve activates. The "before cutdown" refers to the state of the line pressure in which the engine is running at low speeds and the car speed is below approximately 15 kmlh (9 MPH), while the "after cutdown" refers to the state of line pressure in which the engine is running at high speeds and the car speed is above approximately 35 kmlh (22 MPH). *2: The line pressure, while the engine is idling, corresponds to the oil pressure of the "before cutdown" with the engine at the minimum throttle operation.

3)

Interpretation of line pressure

1) Car in the FWD (front-wheel drive) mode
A13-453

Fig. 7-58

Installing the oil pressure adapter

Symptom Low

Probable cause

Tool No. 498897000 498597000

Tool Name Oil pressure adapter Socket wrench (7) Engine at idle (1,500 rpm) in N range

• •
• • •

Oil pump worn or clearance improperly adjusted. Leakage in oil pressure circuit. • Pressure regulator valve inoperative. Leakage at vacuum hose or vacuum diaphragm or diaphragm too long. Pressure regulator valve jamming. If pressure fails to rise even though vacuum pressure drops, check to see if diaphragm rod was not installed. In most cases problems may be due to jamming of vacuum throttle valve, pressure regulator valve or pressure regulator plug.

High

4) Connect the oil pressure adapter and the tip end of the gauge ASSY. 5) Run the engine and check the line pressures with the engine at a minimum-throttle and full-throttle operations. 2) Line pressure in each select range

Pressure will ,not rise. Engine at full throttle

Pressure rises but does not enter specified range.

The following table indicates the relationship between the line pressure and throttle position in each select range.

NOTE:

Change of the diaphragm rod by one rank or [0.5 mm (0.020 in)] causes the line pressure to change approximately 29 kPa (0.3 kg/cm 2 , 4 psi).
7-40

AUTOMATIC TRANSMISSION AND DIFFERENTIAL
2) Car in the 4WD mode the transfer clutch oil circuit to determine the cause of the problem.
;-~,,--I

If an abnormality occurs in the 4WD
operation, check the line pressure in Symptom

Reverse cI utch pressure

Probable cause • Transfer pipe disconnected. • Rear shaft seal ring not installed.

Engine at idle (1,500 rpm) in Neutral

Pressure difference between 4WD and FWD operation modes is more than 29 kPa (0.3 kg/cm 2 , 4 psi). Pressure difference between 4WD and FWD operation modes is less than 29 kPa (0.3 kg/cm 2 , 4 psi).

r;~
ir:J~~--.-J

Forward clutch pressure

JS:
A13-456

Fig. 7-62

• Solenoid or transfer valve inoperative.

5. Dismounting
1) Open engine hood and hold it securely by a stay. 2) Remove spare wheel.

4) Governor Pressure Test
If the governor valve operation is questionable as a result of road tests, conduct the governor pressure test. 1) Remove the test plug from the right side of the final reduction case and, in its place, install the Adapter. Tool No. 398893600 Tool Name Adapter

Car speed km/h (MPH). Less than 10 (6) 40 (25) 80 (50)

Governor pressure kPa (kg/cm 2 , psi)

NOTE:

Do not put the spare wheel or a hand on the air cleaner case to prevent damage of air cleaner case.
3) Disconnect battery cable from negative ( -) terminal. 4) Remove spare wheel supporter. 5) Disconnect diaphragm vacuum hose. 6) Disconnect speedometer cable, and unfasten clip on speedometer cable. 7) Disconnect wiring connections. a. Back-up lamp switch connector. b. Ground cable (on the car body). c. Starter harness.

0(0,0) 127 - 186

(1.3 - 1.9, 18 - 27)
363 - 461 (3.7 - 4.7, 53 - 67)

[For reference] Locations of other oil pressure check holes.

NOTE:

Do not disconnect the battery cable from the starter.
8) Remove four bolts connecting torque converter to drive plate through timing hole.
A13-454

Fig. 7-60

pressure

A13-455

NOTE:

Fig. 7-59 Checking governor pressure

Be careful that the bolts do not fall into the converter housing.
9) Disconnect oil cooler hose from transmission.

2) Install the Gauge ASSY in a suitable location in the driver's compartment and pass the gauge hose to the engine compartment and attach the Adapter to the hose end. 3) Warm up the engine by idling for several minutes until the oil reaches its operating temperature. While the car is being driven, shift to the 2 range and check the governor pressure. Standard governor pressure

NOTE:

To prevent the oil from running out of the hose, plug the open end of the hose.
10) Remove starter with battery cable, and put it on bulkhead. I I) Remove upper bolts which secure engine to transmission; loosen lower nuts. 12) Loosen nut [by approximately

Line pressure 2 Reverse clutch pressure 3 Forward clutch pressure

A13-337

Fig. 7-61

7-41

AUTOMATIC TRANSMISSION AND DIFFERENTIAL
10 mm (0.39 in)] which retains pitching stopper to the transmission side, and tighten nut by an equal amount on the engine side. Slightly tilt engine backward in order to facilitate removal of transmission. 18) Remove stabilizer. 19) Remove bolts which secure left and right transverse links to front crossmember, and lower transverse links. 20) Drive both left and right spring pins out of axle shaft. be noted that a cap be placed on the airbreather to prevent infiltration of the steam into the transmission and also the cleaning job be done away from the place of disassembly and assembly. 4) Disassembly, assembly and cleaning a. Disassemble and assemble the transmission while inspecting the parts in accordance with the Troubleshooting. b. During job, don't use gloves. Don't clean the parts with rags: Use chamois or nylon cloth. c. Pay special attention to the air to be used for cleaning. Get the moisture and the dust rid of the air as much as possible. d. Complete the job from cleaning to completion of assembly as continuously and speedily as possible in order to avoid occurrence of secondary troubles caused by dust. When stopping the job unavoidably cover the parts with clean chamois or nylon cloth to keep them away from any dust. e. Use kerosene, white gasoline or the equivalent as washing fluid. Use always new fluid for cleaning the automatic transmission parts and never reuse. The used fluid is usable in disassemble and assemble work of engine and manual transmission. f. Although the cleaning should be done by dipping into the washing fluid or blowing of the pressurized washing fluid, the dipping is more desirable. Assemble the parts immediately after the cleaning without exposure to the air for a while. Besides in case of washing rubber parts, perform the job quickly not to dip them into the washing fluid for long time. g. Apply the automatic transmission fluid (ATF) onto the parts immediately prior to assembly, and the specified tightening torque should be observed carefully. h. Use vaseline if it is necessary to hold parts in the position when assembling. i. Refer to the Service Data in Chapter 2. for the serviceable limit.

NOTE:

Do not tighten the nut more than 10 mm (0.39 in).

NOTE:

Discard and do not re-use the spring pins.
21) Pushing wheels toward the outer side, separate axle shaft from drive shaft. 22) Remove mount retaining nut from rear crossmember. 23) Securely support transmission by placing a jack under it. 24) Remove crossmember.

A4·113

Fig. 7-63

13) Disconnect O 2 sensor harness and unclamp it. 14) Raise the front end of car by placing a jack on the jack-up point in front of side sill. 15) Remove front exhaust pipe ASSY as follows: a. Disconnect hot air intake hose. b. Loosen nuts which secure exhaust pipe ASSY to the eXhaust port of engine. c. Remove bolts which secure front exhaust pipe to rear exhaust pipe. d. Remove bolts which secure front exhaust pipe to bracket on car body. e. Supporting front exhaust pipe ASSY, remove nuts from the exhaust port of engine. Exhaust pipe ASSY can now be removed.

25) Remove two nuts which secure engine to transmission, and move transmission away from engine just enough so that transmission mainshaft does not interfere with engine. Lower jack and dismount transmission, exercising care not to strike it against any adjacent parts.

6. Disassembly, Inspection and Assembly
GENERAL DESCRIPTION
When disassembling or assembling the automatic transmission, observe the following instructions. I) Workshop Provide a place that is clean and free from dust. Principally the conventional workshop is suitable except for a dusty place. In a workshop where grinding work, etc. which produces fine particles is done, make independent place divided by the vinyl curtain or the equivalent. 2) Worktable The size of I x 1.5 m (40 x 60 in) is large enough to work, and it is more desirable that its surface be covered with flat plate like iron plate which is not rusted too much. 3) Cleaning of exterior Clean the exterior surface of transmission with steam and/ or kerosene prior to disassembly, however it should

NOTE:

Be careful not to strike the oxygen sensor against any adjacent parts during removal.
16) Drain out ATF and then disconnect oil supply pipe.

NOTE:

Be careful not to damage the O-ring.
17) Move the select lever to the "P" position, and at this point, mark the location of the connector nut and separate the manual lever from the linkage rod.

7-42
j,L I

AUTOMATIC TRANSMISSION AND DIFFERENTIAL
j. Replace gaskets, seals, lock washers,
staking nuts, servo apply pipe and servo release pipe with new ones whenever they are disassembled. k. Drain ATF and differential gear oil into a saucer so that the conditions of fluid and oil can be inspected. of gasoline. (unleaded gasoline or kerosene) c. Blow in the compressed air to wash the interior and then drain the gasoline. d. Pour 0.5 Q (0.5 US qt, 0.4 Imp qt) of ATF. e. Blow in the compressed air and drain the ATF. 3) Remove the temperature switch with a wrench.

NOTE: Ensure that the harness is detached from .the clamp in advance.

2 TORQUE CONVERTER SECTION
As torque converter is welded all around it, it is impossible to disassemble it.

3) Installation
Install torque converter straight onto shaft while turning it slowly.
Temperature switch

1) Removal
1) Remove oil pan drain plug and drain the ATF .

3 DISASSEMBLING THE ENTIRE AUTOMATIC TRANSMISSION 1) Transfer Section (4WD Models)
1) Remove the rear engine mount (rubber cushion) and place the transfer unit on a work bench with the oil pan facing down.

A13-459

Fig. 7-66 Removing the temperature switch

NOTE: Check the volume and state (color, smell, etc.) of the ATF.
2) Take out the torque converter ASSY from converter housing taking care of the following. a. Prepare the appropriate saucer under converter housing to receive the ATF which pours out from the torque converter ASSY, turbine shaft and/or oil pump drive shaft. b. When taking out torque converter, turbine shaft and oil pump drive shaft may come out together. In this case take them out straight and gradually not to bend them.

4) Remove the extension ASSY. To do this, remove the eight 8 mm bolts and extract the transfer section together with the extension ASSY.

Fig. 7-64

Transfer unit

2) Inspection
1) Check the one-way clutch function of stator with the spline of stator shaft engaged into stator and replace if defective. It is normal that when turning stator shaft counterclockwise, one-way clutch is engaged, and when clockwise, the clutch is released. 2) Check for the exterior damage, oil leakage, bend and depression, and replace if defective. 3) Completely take off the rust on the pilot and/or sleeve of converter. 4) If the ATF is soiled or excessively deteriorated, wash the interior of torque converter as follows. a. Take off the remained ATF in torque converter. b. Pour 0.5 Q (0.5 US qt, 0.4 Imp qt)

2) Remove the solenoid from the transfer unit by turning it by hand.

NOTE: a. Place a container to receive ATF remaining in the extension. b. Be careful not to drop the rear drive gear thrust plate and transfer drive gear ASSY. c. Remove the washer from the bearing bore on the upper side of the intermediate case. d. Do not place the opening of the extension ASSY down, as this may cause the rear shaft ASSY to drop.
2) Transmission Case Section
1) Remove the rear extension ASSY.

NOTE: a. Be sure to remove the solenoid first. b. Ensure that the harness is detached from the clamp before separating the transfer unit from the engine. c. Remove the "0" ring together with the harness.

(4WD)
2) Drain AFT. (AFT should be drained when the transmission is dismounted from the vehicle.) 3) Carefully pull the turbine output shaft and oil pump drive shaft straight out. If they are hard to remove by hand, wrap their splines with a cloth or vinyl tape and extract them using pliers. Be careful not to damage the splines. 4) Disconnect the oil cooler pipe from the transmission case. 5) Remove the lead wire clips. To do this, remove the nuts which secure the transmission case to the final reduction case, and remove the

A13-458

Fig. 7-65 Removing the solenoid

7-43

AUTOMATIC TRANSMISSION AND DIFFERENTIAL
downshift solenoid, transfer solenoid and temperature switch lead wire clips. 6) Remove the vacuum pipe and ground lead wire. To do this, remove the bolts which retain the governor cover and disconnect the vacuum pipe and ground lead wire. 7) Remove the oil supply pipe. Disconnect the oil supply pipe from the transmission case. Ensure that ATF is drain out before disconnecting the pipe. in order not to damage the oil seal. (4WD) 4) Separate the transmission case section from the final reduction case section.

4 TRANSFER CASE SECTION (4WD)

A13·463

1) Disassembly
1) Remove the washer from the upper surface of the intermediate case at the bearing bore location.

Fig. 7-70 Removing the ball bearing and driven gear UN

NOTE:

Be careful not to lose the "0" ring located at the end of the pipe.
8) Drain the differential gear oil completely. 9) Also drain ATF remaining in the transmission case and place the transmission on a bench with the housing down, as shown in the figure.

5) Remove drum AY using Remover (499717000).

A13-464 A13-461

Fig. 7-71

Removing the drum

Fig. 7-68 Removing the extension ASSY

6) Drive the ball bearing (30x72x 12) out, using Remover (499717000).

A13-460

2) Remove the rear shaft ASSY from the extension case.

Fig. 7-67 Placing the transmission on a bench

NOTE:

Be careful not to damage the oil seal located at the rear of the extension.

NOTE:

a. The automatic transmission and the differential sections are not separated from each other under normal circumstances. b. However, if the two must be separated, follow the disassembly procedure of the final reduction case section to separate the two, and place the automatic transmission section on Stand (399933610).
3)

Fig. 7-72 Removing the ball bearing

Rear shaft assembly
A13·462

7) Disassemble the transfer clutch ASSY. Pry off the snap ring (inner: 98.5) and remove the front pressure plate, three plates UN3, two plates 3 and rear pressure plate.
Front pressure Drum CP Clutch driven plate 3 plate Rear pressure Clutch drive \ plate plate UN3

Final Reduction Case Section

Fig. 7-69 Removing the rear shaft ASSY

1) Remove extension ASSY. (4WD) 2) Remove oil pan and control valve. (4WD) 3) Wrap vinyl tape around the spline portions of the drive pinion rear end

3) Remove the seal ring. 4) Using Removers (8998641 (0) and (499717000), drive out the ball bearing (20x52x 15), washer (20x38x4) and transfer driven gear UN.

~

I

~- " ,

[?t;l (10] .....

()]>~
A13-466

Inner snap ring

Fig. 7-73 Component parts of the transfer clutch ASSY

7-44

AUTOMATIC TRANSMISSION AND DIFFERENTIAL
6) Rear drive shaft seal ring Replace if the seal ring is worn or otherwise damaged.

..-Q)

'in

"C

... c:
0

~I I

~
__ J

(I)

:0

ill
<II

3) Assembly
1) Transfer clutch ASSY Apply a coat of recommended ATF to all parts and assemble all parts in the order of disassembly. a. Assemble the bearing (30x72xI9) and drum ASSY to the rear shaft. b. Install the rear pressure plate, plates 3, plates UN3 and front pressure plate.
Installer (899874100)

U:

a:
(I)

A13-470

Fig. 7-77 Relative locations of the pressure plates

A13-467

Fig. 7·74 Removing the snap ring

2) Inspection
Wash the disassembled parts and check for the following: 1) Bearings Replace any bearing if: a. The balls, outer race or inner race are damaged or rusted. b. Various parts of the bearing are worn excessively. c. The bearing does not spin smoothly or is noisy even after being lubri· cated with gear oil. d. Other abnormalities are noticed. 2) Transfer gear Backlash 0.051 - 0.125 mm (0.0020 - 0.0049 in)

c. After parts have been assembled, measure the clearance between the outer snap ring (98.5) and front pressure plate and select a suitable pressure plate to ensure the clearance is within specifications. Transfer clutch 0.4 - 0.8 mm clearance (0.016 - 0.031 in) Available front pressure plates Part number 447677000 Plate thickness mm (in) 4.7 (0.185) 5.0 (0.197) 5.3 (0.209) 5.6 (0.220) 5.9 (0.232)

A13-468

Fig. 7-75 Assembling the drum ASSY

447677001 447677002 447677003 447677004

NOTE: a. Use a suitable Installer when driving the drum into place.

Replace the transfer gear if: a. The surface is chipped, worn or otherwise damaged. b. The roller surface is worn or otherwise damaged. c. The bore of the transfer driven gear UN or the end face is damaged. 3) Rear drive shaft Repair or replace if the sliding surface of the transfer driven gear UN is excessively damaged. 4) Plates UN3 and 3 Replace if plates or surfaces are worn* or damaged.

Special tool: Installer 899874100 Special tool: Installer 499277000 Special tool: Installer 398177700 b. Direct compressed air into the oil hole to ensure that the piston moves properly.
A13-471

Fig. 7-78 Measuring the clearance

NOTE:
*: If the measured clutch clearance

NOTE: Direct compressed air through the oil hole to move the drum two to three times.
2) Using the installer, install the transfer drive gear UN, washer (20x38x4) and ball bearing (20x52xI5). Special tool: Installer 398177700

during disassembly exceeds 1.3 mm (0.051 in). • Always replace plates UN3 together with the pressure plate and adjacent steel plates.
5) Extension oil seal (35x50xll) Replace the oil seal if the sealing lip is deformed, hardened, worn or otherwise damaged.

A13-469

Fig. 7-76 Checking the piston for proper movement

NOTE: a. Pay attention to the directions of the front and rear pressure plates. b. Always use recommended ATF to coat parts with oil.
7-45

. Snap ring SpeCIal tool: 899754lO2 press

AUTOMATIC TRANSMISSION AND DIFFERENTIAL

NOTE: Before installing, apply a coat· of recomended ATF to the sliding surfaces of transfer drive gear UN and rear drive shaft.

Low & reverse brake gauge

6) Install the rear drive gear thrust plate and transfer drive gear CP onto the intermediate case.

NOTE: When installing the thrust plate, be sure to align the notch in the plate with the mounting bolt.
A 13·473

Press
(899754102)

S TRANSMISSION CASE SECTION

1) Disassembly
Installer
(398177700)

I) Remove the converter oil pan. 2) Remove the downshift solenoid and vacuum diaphragm.

A13·472

Fig. 7-80 Measruing dimension "m"

NOTE: a. Also remove the diaphragm rod. b. Remove each O-ring at the same time.
3) Remove the servo apply pipe and servo release pipe. 4) Remove the control valve ASSY. 5) Remove the transfer valve. To remove, separate the bending portion of the transfer pipe clip from the transfer pipe, disconnect the pipe and remove the two bolts which secure the transfer clutch body. For disassembly, inspection and inspection of the transfer valve, refer to the instructions under the heading "On-Car Service".

Fig. 7-79 Installing gear UN and ball bearing

b. Using the same tools described in item a. above, measure dimension "M" .
Low & reverse brake gauge

3) Install the seal ring onto the rear drive shaft. 4) Install the rear shaft ASSY in the extension case.
A 13·475

NOTE: a. Be careful not to damage the bushing and oil seal near the rear end of the rear drive shaft. b. After the rear shaft ASSV has been installed, do not place the opening of the case down as this may cause the rear shaft ASSV to drop.
A13·476

5) Select a suitable washer (42x51 xt) so that the clearance between the rear shaft ASSY and intermediate case is with specifications. Standard clearance between rear shaft ASSY and intermediate case

Fig. 7-81 Measuring dimension "M"

A 13·477

Fig. 7-82 Removing the transfer pipe

0- 0.3 rnrn (0 - 0.012 in)

c. The thickness (t) of the washer (42x51xt) can be determined by the following equation: t = (M + 0.2) - (0 to 0.3) - m Select suitable washers (up to three pieces) from the table on the right to obtain the specified thickness. Part number 803242010 803242011 Thickness mm (in) 0.2 (0.008) 0.5 (0.020)

NOTE: Always install new transfer pipe and its clip during each ASSY.
6) Remove the oil pump ASSY. a. Tighten the adjusting screw until the reverse clutch is lightly held by the brake band. b. Remove bolts which secure transmission cover (intermediate case) and, using a plastic hammer, lightly tap the periphery of the case until the oil pump ASSY is removed.

a. Measure dimension "m" (shown in the figure) using Depth Gauge (498147001) and Low & Reverse Brake Gauge (398643600).

7-46

AUTOMATIC TRANSMISSION AND DIFFERENTIAL NOTE: Perform steps 17), 18) and 20) below, if needed.

A13-478

Fig. 7-83 Removing the intermediate case

NOTE: a. Be careful not to lose the thrust washer located at the end of the oil pump carrier. b. There are six needle thrust bearings, three thrust washers and three toothed thrust washers in the reo moval steps until 16). Be careful not to lose these parts during disassembly.
7) Move the transfer drive shaft upward and remove transfer coupling from the rear spline of the drive pinion. Then, extract the transfer drive shaft as shown in the figure below.

17) Remove the selector arm. 18) Remove the manual plate and parking rod. 19) Remove the transmission case. a. Wrap a vinyl tape around the rear splines of the drive pinion to prevent damage to the oil seal. b. Remove the nuts securing the transmission case to the final & reduction case, and separate the transmission case from the final & reduction case by lightly tapping the periphery of the former case with a plastic hammer.

Fig. 7-86 Checking the passage in the air breather

A13-482

Fig. 7-87 Correct direction of the oil seal

When installing the oil seal, use Drive Pinion Oil Seal Installer (499247000).

A13-480

Fig. 7-85 Removing the transmission case

20) Remove the parking pawl, parking pawl shaft and parking shaft support plate.
A13-479

NOTE: a. Pay attention to the direction of the oil seal. b. Before installing the oil seal, apply a coat of oil to its periphery. c. Tilting of the oil seal should be kept to a minimum.

Fig. 7-84

Removing the transfer drive shaft

Tool No.

Tool Name Oil seal puller Drive pinion oil seal installer

2)

Inspection

8) Remove the band servo piston CP with Plier (398663600). 9) Remove the strut band. 10) Remove the brake band ASSY, reverse clutch ASSY and forward clutch ASSY. 11) Remove the connecting shell. 12) Remove the center support ASSY by using two 6 mm bolts. 13) Remove the planetary input gear and planetary input gear 2. 14) Remove the planetary gear ASSY and low & reverse brake plates. 15) Remove retaining plate 2. 16) Remove the planetary output gear.

398308700 499247000

I) Transmission case and transmission cover (intermediate case). a. Replace transmission case and/or transmission cover (intermediate case) if cracks, damage, etc. are noticed. b. Repair if the mounting surface is dented or gouged. c. Check the drive pinion oil seal (21x33x6.S) and oil seal breather for scratches at the passage location and, if necessary, replace. To remove the oil seal, always use Oil Seal Puller (398308700) and drive the oil seal out as shown in the figure.

-------------A13-483

Fig. 7-88 Removing the oil seal

7-47

I r T ..8 (0.315) 8. 7-91 (4992571 00) Retaining plate 2 Part No. 4 H 74..283) 7..45 - NOTE: a. 3) Gaskets.8917 .. Be careful not to damage the sealing lip of the oil seal. 6 Retaining plate 2 7 Piston 2 8 Center support 4 Gauge (398643600) 9 Snap ring 5 Snap ring 10 Base (499687000) 1 Driven plate 2 Drive plate 3 Depth gauge . Apply a thin coat of ATF to the guide in advance. If facing is excessively worn or otherwise damaged.5 kg-m.0 (0.2. center support ASSY and snap ring into case in that order. parking pawl return spring and parking pawl to case in that order and retain with clip after inserting parking pawl shaft from the front side. "0" rings &nd seal rings.0 (0.=~.~11. a.1" I * I I· ql 01.291) 7. Thickness mm (in) 444267001 A13·485 7. reverse the order of disassembly.307) 8..35 in). 4) Checking the operation of oneway clutch Make certain that the clutch turns clockwise only. screw the 6 mm bolts in the center support. Putting the component parts on Base (499687000) as shown in the figure.4 (0..2 (0. driven plates. F .. 4 Quantity of driven plates . When installing the center support. select a proper retaining plate 2 so that "H" is within specifications. If found loose. retaining plate 2. replace the brake and! or brake band. 444267005 444267006 444267007 444267008 7) Installation of low & reverse brake parts Install snap ring.1..\ ( Drive pinion oil seal guide A13·302 TT-'--'=c:r.. cracked or otherwise dam· aged.. I Fig. and then install it into the transmission case while turning the center support gradually. 2) Installation of parking rod and parking lever Connect parking rod and parking lever and retain with clip.05 mm (2.6 (0.276) 6. install parking lever to parking lever pin and retain with clip. If the "0" ring and seal ring are folded. After hanging parking rod on the notched portion of parking shaft support plate with its cam portion positioned at the back of parking pawl..AUTOMATIC TRANSMISSION AND 01 FFERENTIAL 3) Connect the transmission case and final reduction case. Tightening torque Fig. b.. 7-48 1. 18 ft-lb) NOTE: 2) Low & reverse brake and brake band.8 (0.268) Fig.323) 7. Install new gaskets during each ASSY.. 5) Installation of the planetary gear ASSY 6) Selection of retaining plate 2 This is for determining the proper retaining plate 2 so that the clearance between piston 2 and driven plate is within specifications.. drive plates.9153 in) = 73. 1) Installation of parking pawl and parking pawl shaft Install parking rod support plate. as viewed from the front side with the planetary carrier ASSY assembled to the center support.2 (0.. b. Install Drive Pinion Oil Seal Guide 499257100 onto the splines of the drive pinion rear end and secure the transmission case to the final reduction case with the eight 8 mm nuts. c. Check for tightness of the two straight pins (8x 18) driven into the transmission case used for align· ment with the differential. remove the two using a wooden or plastic hammer and install new ones. Quantity of drive plates . replace. 7-89 Installing the oil seal 25 N'm (2.299) 7. apply a coat of Lock Tite to their mating surfaces and drive them into the transmission case 9 mm (0.. 7-90 Connecting the transmission and final reduction cases 444267002 444267003 444267004 NOTE: Before installing the straight pins.. 3) Assembly To assemble.. a.

measure the clearance between piston 2 and driven plate.8 (0.4) . 7-93 Measuring dimensions "L" and I'M" Reverse clutch end play 0.0. Total end play 0. used at the oil pump carrier end. 803021048 803021049 803021040 803021044 A13-487 803021045 803021046 803021047 Low& reverse brake gauge NOTE: When handling the brake band.2xt) from those listed in table on the right. Too much opening causes separation and damage of the facing.e thickness of washer which is installed between forward clutch ASSY and clutch hub is 1. The thrust bearing (20x35x2. as shown. If difficulty is encountered in in· stalling the center support.020 in) Gauge (398643600) a. Measure dimension "L". 7·94 Measuring end play "Q" ~~~~~~~~ \:il Total end play Oil pump carrier Reverse clutch end play A13·081 Fig.25 to 0. d. using Depth Gauge 498147001 and Low & Reverse Brake Gauge 398643600.8) should be installed. When installing the center support. a. as shown. The center support is engaged with the transmission case by splines at one p()sition.2 (0.50) .8 mm (0. Select a suitable thrust front clutch washer so that the end play between the reverse clutch drum and oil pump carrier is within specifications.0. 12) Installation of brake band Match the projected portions of the brake band with the knotches in the transmission case to install the brake band. 7-49 .063) 1. Install the snap ring (134 mm) with its open ends positioned sideward or upward.50 . A13-489 NOTE: When measuring dimension "L". 13) Measure the total end play in the axial direction.2 mm (0.2xt) to be 14) Measure the end play of the reverse clutch drum. Determine the thick· ness of the washer (21x31. loosen the bolt that fixes the transmission case to stand. 7·92 Measuring position of end plays Gauge (398643600) c.039) 1.- l AUTOMATIC TRANSMISSION AND DIFFERENTIAL b.079) 2.047 in).4 (0.(0.0472 in) clearance 9) Checking the operation of low & reverse brake Apply air into the oil hole in low & reverse brake to see that the piston moves properly. above. c. be careful not to open its open end too much. Measure dimension "M". using Depth Gauge 498147001 and Low & Reverse Brake Gauge 398643600. Make certain that th. Using the same tools as those in a. Brake band Transmission case ~~~~~~~~Gauge (39864360( A13-490 Fig.087) Part No. The total end play should be within specifications.0 (0.25 . ensure that the thrust bearing (20x35x2.031 in) b.0.20 mm reverse brake (0. Low & 0.0098 .5 .0.1.8) is not installed. 10) Installation of connecting shell and clutch hub Install connecting shell and clutch hub as an ASSY to the spline of reverse sun gear and forward sun gear. measure dimension "Q".0 (0.071) 2. T = (L + 0.Q Thickness [mm (in)] 1.047) 1. Determine thickness T of the thrust race by the following equation and select the suitable washer (21 x31. The clearance should be within the specifi· cations.0197 . be careful not to damage the one way clutch and bushing by the end of the center support.6 (0.020 .5 mm (0.0. 11) Installation of forward clutch ASSY and reverse clutch ASSY Install forward clutch ASSY and reverse clutch ASSY in that order. 8) Measuring the clearance between piston 2 and driven plate After assembly.2 (0.055) 1. A13-488 Fig.

b. 21) Assemble the vacuum diaphragm ASSY.5.8 N·m (0. measure dimension "m". With the band servo piston assembled to the servo piston cover. Tighten nut to the specified torque. 20± 1.8 ft·lb) A13-492 Fig. 17 .5 kg-m.5 to 0.AUTOMATIC TRANSMISSION AND DIFFERENTIAL b. b.m Select a suitable washer from those listed in the table on the right. Attach the Rod Diaphragm Gauge Set to the transmission case and screw it in until it butts up against the throttle valve.2. Install the brake band strut correctly.7 kg-m.8) . 7-97 Servo return spring Always use a new spring pin. Be careful not to damage the "0" ring located at the periphery of the A13·090 =(M + 0. a. Assemble the thrust bearing (20x35x2. 7·99 Construction of the gauge set 7-50 .6 . 4. 18) Adjusting the brake band ASSY. 25 .9 kg-m. Fig. and install to transmis· sion case.44 N'm (3. 6. Transmission NOTE: Do not tighten both the adjusting screw and lock nut to more than their specified torque settings. Apply vaseline to the washers which have been selected in steps 13) and 14) and affix them to the oil pump carrier.4) . servo piston cover. Torque (Valve body attaching bolt) 6 . ensure that the mating surfaces of transmission cover (intermediate) and transmission case gaskets are clean from oil.3 mm (0. and attach the servo piston cover with the inner snap ring. and select a suitable diaphragm rod from those listed in the following table. 7·98 Installing control valve ASSY A13-494 NOTE: Fig.012 in). 15) Installing the transfer drive shaft.20 ft-lb) bolts 17) Assembling the band servo piston and servo piston cover.26 N·m Tightening torque of case mounting (2. t NOTE: a. paying attention to its orientation. Be sure to install the servo return spring on the piston in advance. Then tighten the lock nut (lOx8) to 26±2 N·m (2. insert the transmission case into place. using the piston rod as a guide. Using the same tools as in a.4 ft·lb). Thickness t of the thrust front clutch washer to be used can be determined by the following equation.3 . 34 . Secure the transfer coupling to the transfer drive shaft with the spring pin and engage the shaft with the drive pinion at the splines.5 ft-lb) and back-off the screw two rotations.8) to the forward clutch.(0. and install manual plate.5 . 23 .4.0. Install the oil pump ASSY. Tighten the brake band adjusting screw to a torque of 9 N·m (0. being careful not to drop the washers. above.33 ft-Ib) Torque 20) Installation of control valve ASSY Adjust the groove CD to the manual plate pin (V. 7-96 Installing the transfer drive shaft 19) Installation of manual plate Adjust the clearance between manual plate and spacer by shim(s) until it is Fig. Read the scale of the Rod Dia· phragm Gauge where it aligns with the end face of the holder.8 kg·m. Before installing the oil pump ASSY. A13-479 A13-497 Fig.2 kg-m.7±0.3 . 7-95 Measuring end play "rn" c. / " A13-491 Low & reverse brake gauge (398643600) 16) Assembling the oil pump ASSY. within 0.

7-103 7-51 .2461 .31.34) 1) Reverse Clutch 1 Between 1 and 3 3 Between 3 and 5 5 493210110 493210111 493210112 493210113 493210114 Reverse clutch drum 34. Diaphragm rod length mm (in) 34 ( 1.201) 30. Using Clutch Spring Compressor (398673600) and Pliers (399893600). 7-102 Removing snap ring A13·498 Fig.4 .AUTOMATIC TRANSMISSION AND DIFFERENTIAL Dimension "L" (Measured) mm (in) Below 30. 7-100 Installing the servo apply pipe Fig. Before assembling and/or installing these parts.5 (1.5 (1. 2. driven plates (1).4 N'm (0.65 .31. Before installing the oil pan. be sure to clean the oil from the mating surface of the oil pan and gasket.55 (1.2264 . Apply air into the oil hole to remove the piston.05 (1. 3 4 5 6 7 Drive plate Driven plate Dish plate Snap ring Spring retainer 8 Coil spring 9 Check ball A13-093 22) Assembling the downshift solenoid ASSY.4.2067 . Insta" new pipes at each assembly. Remove the coil spring retainer (j) and coil springs CID.3. NOTE: Install a new gasket at each assemblv. and remove the retaining plate ®.398) 36 ( 1. 7-101 Sectional view of reverse clutch NOTE: Do not forget to install the "0" ring. Be careful not to deform or bend the pipe. 3.358) 35 ( 1.65 . drive plates @.38) ® 35.35 .61 in) as measured from the mating surface of the converter oil pan.0. Be sure to check the operation of parts.3 ft-lb) I) Disassembly Pry off the snap ring CD with a screw· driver.05 (1.42) 31.45 kg-m. pry off the snap ring ® from the coil spring retainer (J). Ensure that the pipes' height (at points where the pipes are supported by the oil pan) does not exceed 41 mm (1. Fig.15 . A13-094 6 TRANSMISSION COMPONENTS The transmission section contains many small parts which are similar in configuration and are machined accurately. Pliers (399893600) Compressor (398673600) Fig. NOTE: Do not forget to install the "0" ring.1.2618) I Snap ring 2 Retaining plate Install the vacuum diaphragm together with the selected rod. Tightening torque of converter oil pan 23) Assembling the servo apply pipe and servo release pipe.1. Install the downshift solenoid ASSY in the bore on the front side of the transmission case turning it by hand.5 (1. b. 24) Installing the converter oil pan.2421) Piston Gauge Indication Part No.05 (1. Lightly drive the pipes into their proper positions.2618) Above 32. place them in neat order so that they may be assembled properly to their proper positions.5 . and dish plate (5).2224) 31.1.32. NOTE: a.

reverse the disassembling procedure.0.. 1. Be sure to align the driven plate missing tooth portion with the oil hole in the clutch drum. If it is not. drive plates @.80 mm (0. Install the driven plates to the clutch drum.'4"*"'''''''*~·_'' __ :f?___ ·'' ' _' ' ' '3' 'i<'' '__ "'rql"l'.'f•. Retaining plates are available in six different sized as follows: '~ . 7-109 Removing snap ring Fig.449 in) 11..4 mm (0.. 7-106 Measuring ring-to-plate clearance Fig...457 in) A13·099 . 453710100 453710101 453710102 453710103 453710104 453710105 Forward clutch drum <V Piston @ Snap ring ® Rctaining'plate CD @ Drive plate @ Dri~en plate (i) Dish plate ® Coil spring retainer @ Coil spring Fig.433 in) 11. Check the clearance between the snap ring CD and retaining plate ® to ensure that it is within the specifications.6 mm (0.-_ _ _ _ _. return spring is fatigued OJ '~. b. 7-108 Sectional view of forward clutch c..417 in) 10.1. " Retaining plate 10. Part No.441 in) 11.·.2 mm (0. n"'''''_-_______.. . applying the ATF onto all the parts.. driven plates ® and dish plate (j). Install the reverse clutch ASSY to the oil pump carrier. Using the same disassembling procedure as that for the reverse clutch. 3) Assembly To assemble. Apply air into the oil hole to see that the reverse clutch moves properly as shown in the figure. 7-52 !<p" l' -0' .j. retaining plate @... 7-107 Testing reverse clutch b..0709 in) 7 Reverse clutch drum O-ring @ Lathe cut seal ring ® Reverse clutch piston @ Return spring @ Spring retainer CD (i) Snap ring <V ® @ @ (j]) @ Dish plate Driven plate Drive plate Retaining plate Snap ring 2 Snap ring Retaining plate A13·097 Fig.6 mm (0..425 in) 11. a. remove the snap ring ®..0630 .1. Drive the piston out by applying air into the oil hole.________-- . Fig.. broken or spring retainer IS de· formed.AUTOMATIC TRANSMISSION AND DIFFERENTIAL Reverse clutch clearance 2) Forward Clutch 1. Replace defective parts if snap ring is worn. change the retaining plate with a proper one.It·....60 .0 mm (0. 1) Disassembly a.'-""'_ 1. e1*''''''''' . I Pliers (39989600) 2 Compressor (398673600) A13·100 Fig. 7-105 Inserting clutch plates b. Replace the clutch drive plate if the facing is worn or damaged..__. Remove the snap ring from the coil spring retainer ®... 7-104 Reverse clutch components NOTE: I r 2) Inspection a..8 mm (0.

. Blowing out piston Snap ring Re taining plate Fig.:...:. b.7-113 Testing forward clutch 3) Center Support Assembly 1 Snap ring A13-273 2 Center support Center support COMPL Lathe cut seal ring Piston 2 Thrust spring ring c:u:.----I \ _ _ _ _ _ _ _---. Replace other parts which are worn or damaged .. <D Forward clutch drum (i) Washer (j) Thrust bearing @ O-ring @ Lathe cut seal ring @ Forward clutch piston (i) Return spring @ Spring retainer (j) Snap ring (jj Dished plate V ® Dri~n plate I. 7 6 @® Forward clutch clearance 1. Remove clutch piston 2 by applying air into the oil hole in center support.. If necessary. 7-11C?. a. Be sure to apply the ATF to all parts when assembling.:R.••.. .:N_S~M_I_SS_I_O_N_A_N_D_ _ DIF_F_E_R_E_N_T_IA_L _ _ _ _ _---'\ _ 1) Disassembly a.:.:.:O:..A.:I.. After assembly. 7-115 Removingsnapring b.~~ O-ring 2) Inspection Refer to the topic under the reverse clutch previously described. check the clearance between the snap ring CD and retaining plate ® to see that it is within the specifications.:.:U:.M:.T:.00 . Apply air into the oil hole to see that the forward clutch moves properly. Replace low & reverse return spring if it is fatigued. Check seal ring and O-ring for damage.C_T:.'F 3 4 5 6 7 8 9 10 11 12 Piston La the cu t seal ring O-ring Thrust spring ring Low & Reverse return spring Snap ring Driven plate Drive plate Retaining plate Snap ring Thrust spring ring Low & reverse return spring A13·104 Fig.0... reverse the order of disassembly.50 mm (0.. 7-116 Low and reverse brake components Fig. replace.:. (398623600) Seat Compressor (398673600) (399893600) Pliers A13-101 1 2 Fig. Install the forward and reverse clutch assemblies to the oil pump carrier. @ Dri~ plate @ Retaining plate @ Snap ring Fig.. 1 Pliers (399893600) 2 Compressor (398673600) 3 Seat (398623600) A13-105 Fig. 7-111 Forward clutch components A 13-103 Fig..1. 7-114 Cross-section view of center support 2) Inspection a.:A.. 7-53 . Use the following tools to remove the snap ring from the center support.:.0591 in) ~/// \~@ A13-272 b.0394 .:T:. c...:.:A. 7-112 Measuring ring-to-plate clearance . 3) Assembly To assemble forward clutch.

0. c._ _ ..0016 in) b.3600) To assemble the center support ASSY.'l. use Installer (399543600).~I''.04 mm (0. d. Replace oil pump shaft 2 if the shaft portion or contacting surface with inner gear is damaged. Check the bushing and two needle roller bearings (15 x 21 x 12 mm) located in the oil pump carrier. 2) Inspection a. Installation of needle bearing and bushing (i) When installing the middle needle roller bearing....1. Replace the O-ring and seal rings if they are damaged. A13·111 NOTE: When disassembling the oil pump. (399543600) Oil pump carrier Needle bearing A13·113 A13·109 1 2 3 4 5 Transmission cover Oil pump carrier Outer gear Inner gear Oil pum p drive shaft II • Oil pump carrier (399903600) Needle Bearing Remover 2 Fig. I 2 Inner gear Outer gear A13·110 Fig. Check the inner and outer gear tooth faces for damage or wear. If they are damaged. Remove the inner and outer gears from the oil pump carrier. ·"'1'''1'----------.AUTOMATIC TRANSMISSION AND DIFFERENTIAL 3) Assembly Installer 2 (398863600) Installer (39954. Clearance between inner/ outer gear and transmission cover (intermediate case). '. 3) Removal and installation of needle bearing and bushing a. I"""". 7-54 '''··I. 1 . 7-120 Installing needle bearing 4) Oil Pump Assembly I) Disassembly Remove the bolts and disassemble the oil pump carrier and transmission cover (intermediate case).. 7-121 Installing needle roller bearing and bushing 4) To Measurement of clearances check clearances. replace... If necessary.. t . a. use Gauge (398643600) and Thickness Gauge Fig. and be careful notto damage the seal ring during assembly. use Installer (399543600) and Installer 2 (398863600) as shown in the figure.. 7-117 Oil pump components (499667000). Be sure to apply the ATF onto all parts when assembling. . Replace oil pump carrier and/or transmission cover if the contacting surface with inner gear or outer gear is damaged.. replace..• . note the positions of the side faces of inner gear and outer gear so that they may be installed with their side faces facing the same way.. and drive out the bushing and two roller bearings at one time with Needle Bearing Remover 2 (399903600).0008 .0.02 ... . as shown in the figure. .. reverse the order of disassembly. 7-118 A 1 3· 112 Fig.. b. Fig_ 7-119 Removing bushing and needle roller bearings Standard clearance 0. Removal of needle bearing and bushing Set up the oil pump carrier as shown in the figure. use the same tools as those used during disassembly. Replace the gears as a set if the clearance exceeds 0.___________ .0031 in). (ii) When installing the bushing and remaining needle roller bearing..~ iI'··~d"""'I"'H"''' __''''''#'_·''''W"""". .-...08 mm (0.----____. Needle bearing Oil pump NOTE: For center support ASSY..

25 mm (0.14 . When inserting the oil pump carrier into the cover. Apply the ATF to the O-ring located on the periphery of the oil pump carrier.0063 in) Standard clearance 0. b. Then.21 mm (0.15. be sure to align the bolt holes.0020 . Place the oil pump carrier as shown in the figure. replace the gears as a set.6295) 434610101 434710101 15. 7-122 Measuring clearance (1) Fig.20 mm (0.6295 . Radial clearance between outer gear and oil pump carrier.25 mm (0.6 . b. Clearance between seal ring and groove.6291) 434610102 434710102 15. c. and d. After installing the oil pump to the transmission case. When installing the inner and outer gears.98 (0.AUTOMATIC TRANSMISSION AND DIFFERENTIAL Inner gear Outer gear Thickness mm (in) 434610100 434710100 16 .0. be sure that the faces of the gears face as before disassembly.15. 7-124 Measuring clearance (3) b. 4.0.0098 in). Standard clearance 0.0. set the inner and outer gears properly.98 . A13·119 Fig.15.0083 in) Replace the gears as a set if the clearance exceeds 0.99 . Fig.0.8 kg-m. 7-125 Measuring clearance (4) Fig.16 mm (0.3 .8 ft-Ib) A13·115 Torque Fig.0. Standard clearance 0.0. press gradually so as not to damage the O·ring.0098 in).0.5. pay at· tention to the assembling direction of the O-ring.0079 in) If the clearance exceeds 0. and insert the oil pump drive shaft II into the oil pump carrier.0. Clearance between cresent tooth tip of outer gear.0055 .6291 . 7-127 Assembling oil pump (2) Fig. 6 -8 N·m (0.04 . NOTE: a.0016 . When assembling the intermediate case and oil pump carrier. Apply the ATF to the side faces of the gears. fit the oil pump drive shaft to the oil pump drive shaft II and then check that the oil pump gears can easily be rotated with hand. 7-126 Assembling oil pump (1) 7-55 .6287) NOTE: a. b.99 (0. c. 7-123 Measuring clearance (2) 5) Assembly a. When installing the transmission cover.0.6299 . tighten the cover with the bolts.0.05 .97 (0.

When reassembling. Standard clearance Clearance CD ® If clutch seizure.16 N·m (1. long pinions. c. ) in the figure. replace. disassemble the control valve ASSV for inspection. 1O-12ft-lb) 7-56 Mf*t I lit . plate and upper valve body. Install thrust bearing to planetary carrier. NOTE: Fig. push the T bar with finger to insert the one-way clutch until a snap i!. Remove the one-way clutch from the outer race. replace. flush all parts. brake band burning.60 mm (0. Torque specifications should also be observed. 7-128 Component parts of planetary gear I) Disassembly Remove the bolts securing the one-way clutch outer race to the planetary carrier. or oil contamination i'i encountered.0. As these parts are similar in shape. Check the planetary carrier-to-thrust washer clearance to see that it is within the specifications. Spring-loaded parts should be also handled carefully. Pay particular attention to see that the installed parts face properly. Check the needle bearings and thrust washers for damage.4 . 2) Inspection Check gear faces for damage. b. If necessary. Secure the one-way clutch retainer in the outer race. thrust washer lIs. and thrust bearing.0276 in). 1 Carrier 2 Thrust washer 2. spacers. Fig.AUTOMATIC TRANSMISSION AND DIFFERENTIAL 5) Planetary Gear 6) Control Valve Assembly 6J~® 1 2 3 4 5 Thrust bearing Needle bearing Spacer Short pinion Planetary carrier A 13·307 6 7 8 9 One-way clutch Long pinion Outer race Lock plate 10 11 12 13 Bolt Thrust washer II (Rear) Thrust washer (F ron t) Planetary pinion pin The control valve is composed of parts which are accurately machined to a high degree and should be handled carefully during disassembly and assembly.6 kg-m. 7-129 Measuring clearance 0. If necessary.. I) Disassembly a. Torque 14 . When installing the one-way clutch on the outer race. they should be arranged in neat order on a table after disassembly so that they can be easily installed to their original positions. as springs may jump out of place when the parts are disassembled or removed. reverse the order of disassembly. felt on the finger. A13·308 Fig. Make sure that the valves are clean and free from any foreign material before assembly.70 mm (0. To assemble the planetary gear. Oil strainer Remove the bolts and nut securing the oil strainer. Check the one-way clutch sprag for wear or damage. Valve bodies and plate Remove the bolts. the parts and valves should be dipped in a container filled with the ATF. and separate the lower valve body. 7-130 Removal of oil strainer NOTE: Do not use a cross·head screwdriver. replace.0059 . Push the pinion pin out toward the one-way clutch side. b. If necessary.1.~ " and the bolt is marked ( . and detach the oil strainer.0236 in) 3) Assembly a.0. replace. thrust washers. Check the bushing at the one-way clutch outer race for wear or damage. and detach the short pinions.15 . Extreme care should be taken so as not to drop valves on the floor: Before assembling. If the clearance exceeds 0.. The nut is marked . needle roller bearings.

spring. c.. 7-131 Removal of lower valve body I 2 3 4 5 6 7 8 Side plate 1-2 shift valve 1-2 shift spring 2·3 shift plug 2-3 shift spring Pressure modifier spring 2-3 shift valve Pressure modifier valve A13-367 When removing the plate. 7-134 Exploded view of shift and modifier valves 1 2 3 4 5 6 Solenoid downshift valve Throttle back-up spring Solenoid downshift spring Throttle back-up valve Vacuum throttle valve Side plate e. 7-133 Removal of side plate 7-57 . of wire Fig.--. Pressure regulating valve and second lock valve. Manual valve Fig. throttle relief spring and steel ball. be careful not to lose the following parts located in the lower valve body: Orifice check valve. 7-137 Spring A 13·128 Fig. Solenoid downshaft valve. Fig. 7-132 Removal of manual valve 2) Inspection Replace the control valve ASSY as a set if excessive defect is found in the following parts. throttle back-up and vacuum throttle valves A 13·127 Fig. AUTOMATIC TRANSMISSION AND DIFFERENTIAL f. NOTE: Do not use a cross-head screwdriver. • Seized valves • Fatigued valve spring or check valve • Damaged oil strainer • Leaky plate • Valve body with damaged oil passages • Valve body with damaged threads Description of springs in valves. 7-136 Exploded view of solenoid downshift. 2 3 4 5 6 Pressure regulating sleeve (including plug and spring seat) Pressure regulating spring Pressure regulating valve Second lock valve Second lock spring Side plate A13-130 No load Specified load Oia. throttle back-up valve and vacuum throttle valve. d. 1-2 shift and 2-3 shift valves and pressure modifier valve. 7-135 Exploded view of pressure regulating and second lock valves A13-132 Fig. I 2 Spinner handle A13-125 A13·129 Fig.

0 (1.197) 5.129 (0.0 (0.60.0 (0. 3.1) 27.4. 7-138 General exploded view of control valve ASSY 7-58 .6 (0.197) 5.0 (0.10 (0.9 (5.5 (1.417) 22.220) 4.5 (0.83) 0.0 (1.5 (0.0 (0. 1.453) Specified load N (kg.043) 23.23) 5.846) 6. mm (in) Mean Dia.5 (1.0 (0.7 (0.051) 1.AUTOMATIC TRANSMISSION AND DIFFERENTIAL Specifications of springs in control valve ASSY When installed Spring name Wire Dia.236) 6.5 (0.5 (0.0 15.32) 21.413) 8.0 (0.60.5 (2.8.008) 6.0 (1.55 (0.0 16.92.02) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Manual valve Second lock spring Second lock valve Pressure regulating sleeve Pressure regulating plug Spring seat Pressure regulating spring Pressure regulating valve Vacuum throttle valve Throttle back-Up spring Solenoid downshift valve Throttle back-up valve Solenoid downshift spring Pressure modifier spring 2-3 Shift plug Pressure modifier valve 2-3 Shift spring 2-3 Shift valve 1-2 Shift valve 1-2 Shift spring A13-368 Fig.022) 0.12.83 (1.0.022) 0.055) 21.0 (0.40.48(2.19.01.0 13.0 16.5 (0.492) 21.0 32.1.693) 18.669) 18.728) 32.625.2) Detent manual Pressure regulating Pressure modifier 1-2 shift 2-3 shift Throttle back-up Solenoid downshift Second lock Throttle relief Orifice check 1.0 14.5 (0.2 (0.276) 43.73 (l.031) 0.024) 0.035) 0.748) 11.0 (0. 1.0 5.315) 6.6.866) 33.260) 41.88 (0.0 (0.3 (0.925) 9.740) 12.09) 18.0.0 (0.319) 26.32) 5.0 (1.827) 19.4.6 (0.2) 1.256) 5.0 12.8 (1.016) 0.5 (0.0 14.8 (0.2 (0.236) 10.5.8 (0.55 (0.189) 15.630) 17. lb) 53.354) 16.378) 13.0 (0.9 (0.0 (0.0 18.8 (0.2 (0.244) 6.028) 0.047) 0. 1.88 (0.4 (1.4 (0.614) 36. of coil mm (in) Effective turn Free length mm (in) Specified length mm (in) 26.

Be sure to install the side plates: Torque (Side plate attaching screw) 2.3. Observe the following instructions.4 .4 N'm (0. Remove oil level gauge before removing differential ASSV.3. and valves.2. When assembling minor parts. in figure before. Fig. 7-139 Installation of orifice check and throttle relief valves Wrap vinyl tape over the shaft splines to avoid damaging the oil seal. 3) Remove the bolts securing the governor cover.25 mm) with the left one. such as valve springs.25 . Place a container to receive the oil. spring. A 13-135 Fig. When pulling out governor ASSV. b. 6) Pry out the snap rings from the axle drive shafts in the differential case_ 7) Remove the lock plates.5 . a. After completing assembly of control valve ASSV. Apply the ATF to all valves when installing.0. b. Install the orifice check valves. and take it out of the final reduction case. 2.4 kg-m.AUTOMATIC TRANSMISSION AND DIFFERENTIAL 3) Assembly To assemble the control valve ASSY. and detach the governor body ASSY as shown in the figure. Torque (Oil strainer bolt) 3 .45 kg-m. Do not confuse the right roller bearing (37 x 72 x 18. reverse the order of disassembly. c. but lightly push them into place with hand.0. 7-142 Removal of governor valve assembly NOTE: NOTE: NOTE: Do not misplace the check valve and relief valve. 8) Move the differential ASSY to one side.2. Assemble the upper and lower valve bodies.4 N·m (0.5 ft-Ib) 2) Remove the 10 bolts combining the final reduction case and the converter housing.5 .4. A13-499 Torque (Control valve bolt) 2. When tightening parts. wrap it in paper to prevent dust from accumulating on it. Install the oil strainer.3 ft-Ib) cases. 7 FINAL REDUCTION CASE SECTION 1) Removal 1) Place the final reduction ASSY with gasket on Stand (499937000).3 .8 .8 .4 N'm (0. 7-141 Differential unit a.35 . Fig. 7-140 Reamer bolts for positioning valve bodies d.0.0. and engage it with Stopper (398781600) to securely lock the reduction drive gear. fix them in position by two reamer bolts at . be sure to observe the specified torques.5 ft-Ib) Torque (Reamer bolt) 3. 5) Remove the 3 bolts securing reduction gear oil seal holder.2 .3. a. 1.5 . 2.25 . refer to the general exploded view and detailed description of valve springs.-marks in the figure. Put Shaft (398653600) into the reduction drive gear. and detach the axle shaft oil seal holders and the axle drive shafts as an ASSY. Remove the drive pinion lock nut 7-59 . NOTE: NOTE: Before tightening bolts to combine the upper and lower valve bodies. 1. Do not force valves into place. throttle relief spring and steel ball to the lower valve body. Then secure them with the two appropriate bolts and nuts. turn it to the right slowly.4 N'm (0.9 ft-Ib) 1 2 3 4 5 Governor body assembly Bolts Governor sleeve Gasket Governor cover A13-311 b. A small amount of oil will flow out when separating the 9) Drive pinion.35 kg-m. NOTE: A13-395 Fig.35 kg-m. 4) Parking actuator.2.

assemble them properly. Repair if a mating surface is scored or seized. d.5 kg-m. pay attention to keep the reduction driven gear free from interfering with the case. Be sure to align the projection of retainer flange with the groove of case. on the final reduction case. Press the retainer until the end surface of retainer flange reaches that of case. 7-145 Installing the holder 5) Secure the final reduction case to the Differential Stand with two bolts [tightening torque: 10 N·m (1. Remove the snap ring from the end of the speedometer shaft. b. oil seals. 7-60 n t tpn 1 r 1 1 . 2) Gaskets. because worn tooth surface of abnormal tooth contact. and press out drive pinion. Tightening torque of holder 25 N·m (2. CD ® NOTE: Do not forget to install the "0" ring on the periphery of the holder. and detach the driven gear and steel ball. Press out the reduction driven gear and bearing retainer as an ASSY from the transmission side by pressing the driven gear with an appropriate size of steel rod or pipe. 7-144 Pressing retainer 6) Install speedometer driven gear. Press 2) Check Wash all parts and carefully inspect them as follows: 1) Cases Replace if cracked or damaged. O-rings Replace gaskets at every removal. will become a cause of gear noise. which is difficult to find on external appearance. 3) Installation 1) When final reduction components are disassembled. 2) Press thrust bearing retainer with front bearing cup preset in it and reduction driven gear into final reduction case by using Installer (499427000) and Handle (498477000). 18 ft-Ib) NOTE: a. 7-143 Loosening drive pinion lock nut c. and snugly tighten the 8 mm bolts at three places. 7 ft-Ib)) and tighten the three holder retaining bolts to the specified torque. differential gear. 10) Speedometer driven gear. Pay attention to the reduction drive gear end which protrudes from the mating surface. 12) Stator shaft NOTE: Check the gears carefully. a. 4) Gears If damage or abnormality are recognized on the tooth surface of hypoid gear. 4) Using Reduction Bearing Installer (499247200). replace bearings as an ASSY. 7-146 Tightening the holder 1 2 3 4 Final reduction case Handle (498477000) Installer (499427000) Thrust bearing retainer Contact th is surface closely A 13-315 Fig. 3) Install the transmission case's front gasket and reduction drive gear NOTE: The staking may be left as it is. 7) Make certain that the run-out at the tip of reduction drive gear shaft is within specifications by turning it with Shaft (398653600) and Handle (899924100). Remove the snap ring from the speedometer shaft. Wrench (35 mm) Replace O-rings if the sealing lips are folded. Stopper (398781600) 2 Shaft (398653600) 3 Socket Wrench (899984103) A13-313 Fig. Fig. If necessary. Replace seized or cocked bushings. deformation of lip or any other abnormality are recognized. NOTE: Be careful not to damage the gasket. During this operation. A13-500 Fig. reduction gear and governor gear. torn of deformed. Replace bearings which show abnormal color on the roller face. b. replace them with new ones. Replace oil seals if getting loose of spring. 11) Reduction drive gear.0 kg-m. press the holder into the bore in the final reduction case. 3) Bearings Check bearings for damaged roller face and abnormal wear.AUTOMATIC TRANSMISSION AND DIFFERENTIAL with Socket (499987100). Remove final reduction case from Stand.

7-147 Measuring of run-out A13-344 Drive pinion spacer Part number t NOTE: Use Puller (399523600) as an attachment.625 (0. NOTE: a. The starting friction torque of the drive pinion is 1. with the tool installed) by sliding Spacer in the axial direction to the extremes with the help of Magnet Base (498247001) attached Dial Gauge (498247100) as shown in the figure. Attach Pulley (498567000) on the hexagonal head of Holder. c. c. 7 to 9 ft-Ib). c. Don't tighten Holder excessively. 446107001 446107002 446107003 446107004 446107005 446107006 446107007 446107008 9.725 (0.5 kg-cm. Using Socket Wrench (499987100) tighten Holder (399913603) with an open end wrench put inside the case to lock as shown in the figure.3848) Unit: mm (in) Drive pinion shim Part number t 441967001 441967002 441967003 0.775 (0.3780) 9. b. The torque to give the specified preload is approximately 10 to 12N·m (1.3829) 9. If the selected thickness is thicker than the calculated one. Reduction gear Fig.3839) 9. Spacer (399913604). Install the front bearing cone.650 (0.6 (0.0 (0.62 N·m (12.0. 8) Preload adjustment of drive pinion bearings a.8 (0. 7-151 Measurement of clearance to select a shim and spacer Fig. 7-61 J .001] + 0.23 to 1. Dial Gauge should be fixed firmly as shown in the previous figure. A13-156 ~! I Fig. the preload will be greater than what is indicated by the spring balance.024) 0. The selected shim and spacer should be installed after adjusting the pinion height. 10. 7 to 9 lb) to give the specified preload.~@/.07 unit: mm Thickness of shim plus spacer to be installed H Number stamped on Spacer (399913604) h Movement of Spacer (399913604) in axial direction (dial gauge reading) Unit: mm (in) Fig.3 in-Ib). t = 0.750 (0. b.031) 1. If the shim and spacer which are installed are thinner than the thickness calculated by the formula.9 to 14.0 to 1.3819) 9. 7-149 Tighten holder d. and rear bearing cone in this order onto Master 2 (499917200) in final reduction case as shown in the figure.2kg-m.08 mm (0 .7-150 Measurement of preload NOTE: a.3789) 9.0.3809) 9.039) Taper roller bearing Final reduction case A 13-153 Fig. 7-148 Preload adjustment of drive pinion CD ® o I Spacer 2 Holder 3 Master 2 (399913604) (399913603) (499917200) CD ~I . Thickness of shim plus spacer to be installed should be determined by the following formula.600 (0. and tighten Holder so that the tension of the spring balance reads 29 to 39 N (3 to 4 kg.675 (0. Select a combination of a shim and a spacer from those in the following table.5 to 16.0031 in) 10 + h + [±H x 0. the preload will be smaller than the reading on the spring balance.700 (0.AUTOMATIC TRANSMISSION AND DIFFERENTIAL Run-out (reduction drive gear shaft) b. Measure the maximum clearance between Spacer and the rear bearing which is preloaded (that is.3799) 9.

. Select shim(s) from those in the table. b. Install the drive pinion with the reduction driven gear in place and install the shim and spacer determined during the preload adjustment.* __ ""'4"'".0069) 0.i"Wo. c.. ._1_"".. 87 ft-lb) Shim thickness Measurement by thickness gauge Figure on Gauge (398643600) Figure on Master (499917002) Unit: mm A13·311 Fig... and Socket Wrench (499987100). Install the shim(s) selected in the drive pinion height adjustment to the drive pinion. since it can result in oil leakage from the periphery of the axle shaft oil seal holder.0197) CD ® @ .0098) 0..jr~'-+~'""'«-""""'*". 7-152 Measurement of drive pinion height clearance c.. I4 .._~'f""I ____'-I-""""'________---. With the devices for preload measurement installed and tightened as described in "r'. 7 to !"'II:-.250 (0. Thickness of adjusting shim(s)( 1 to 3 pieces) to be installed can be obtained by the following formula.--.I" . 7-153 Adjustment of drive pinion height 10) Installation of drive pinion...... 7-155 Tightening of drive pinion lock nut 11) Recheck of preload.. 7-62 Fig.. .' ' ' ' .0108) 0.275 (0.41~·j'lf·. @ 1 2 3 4 5 6 7 8 9 10 Gauge (398643600) Master (399913601) Taper roller bearing Reduction drive gear Spacer (399913604) Holder (399913603) Master 2 (499917200) Taper roller bearing Case (differential & reduction) Reduction driven gear ® A13-151 I Socket Wrench (899984103) 2 Shaft (398653600) 3 Stopper (398781600) A 13-345 Fig. Stopper (398781600).AUTOMATIC TRANSMISSION AND DIFFERENTIAL 9) Adjustment of drive pinion height a.. Installer (899580100) 2 Installer (899874100) A13. and press the front bearing cone (the same one as used in the preload adjustment previously described) into drive pinion using Installer (8995801 00) and Installer (899874100). If the reading of the spring balance is not within 29 to 39 N (3 to 4 kg. a.150 (0.001] T N G L 1 Gauge (398643600) 2 Master (399913601) 3 Thickness gauge Do not press the bearing retainer with Installer.I t: . Drive pinion height adjustment is made by shim(s) inserted between the front bearing cone and the back face of the pinion gear.'' ' . Recheck the preload by attaching Pulley (498567000) to the lock nut as shown in the figure.0118) 0. tighten the nut to specification as shown in the figure and stake the lock nut.. 7-154 Installation of front bearing cone NOTE: T =N + [±G x 0.175 (0. Damaged surface must be reconditioned with oil stone.0079) 0. Install the lock washer and lock nut. Applying oil around Master makes its setting easier. Torque (Lock nut) 118 N'm (12 kg-m. Unit: mm (in) Shim 2 Part number 442182511 442182512 442182513 442182514 442182515 442182516 442182517 442182518 t 0.225 (0.q.0059) 0.. set Master (399913601) and Gauge (398643600) to measure the clearance N between Master and Gauge using Thickness Gauge (499667000) as shown in the following figures... 1_ _ _ _ _ ----'' 11'..200 (0. NOTE: a. Using Shaft (398653600)..001] + [±L x 0. and the rear bearing cone onto the drive pinion. etc.0089) 0. When inserting Master into the hole of the final reduction case be careful not to damage the hole surface.300 (0. Fig. b.500 (0. a.318 b.

18 mm gea~ and drive (0. friction torque is within the following range. NOTE: When installing the governor valve. 13) Measurement of backlash between crown gear and drive pinion. b. Attach oil seal holder lock plate and back off holder on the crown gear side approx. 1. 1.23 .1. A13·161 NOTE: Fig. Install gasket and governor cover with the mating surface of governor cover clean.7kg-m. Temporarily tighten the lock plate on the crown gear side. and install Handle (899924100) to give the shaft 2 or 3 turns. ~ 805026010 031526000 Spring balance c.5 kg-cm. Check the clearance between the differential pinion shaft and the axle drive shaft to see that it is within the specifications. 10. and tighten the lock plate temporarily.2 . and tighten holder on the opposite side. If correct adjustment has been made. Apply a coat of vaseline to needle bearing for governor shaft and the sealing lip of oil seal. Replace the gasket with new one at every disassembly. Place the lock plate on the holder and tighten it to the specified torque. Install axle shaft oil seal holder with Wrench (3997801 I I). a. Tighten cover attaching bolts to the specified torque.9 . and screw in the holder on the crown gear side until it lightly bottoms. Insert the differential ASSY without axle shaft into final reduction case. e. Remove the O-rings on the axle shaft oil seal holders.0. Repeat this operation several times to locate the proper position. When rechecking the preload by using Socket Wrench (499987100) and beam type torque wrench.3 in-Ib) Fig. 16 . Check the hypoid gear backlash to see if it is within the specifications. \0 . insert Shaft (398653600) into the splined end of the reduction drive gear.0453 .5 to I notch. Turn Handle (899924100) several times. and attach Magnet Base (49824700 I) with Dial Gauge (498247100) to Stand. attach the washer to the governor cover with vaseline. and turn the gear several times.1.5 . Install the right and left axle shafts and secure with the snap rings.0039 . 7·156 Recheck of preload b.12 ft-Ib) Torque NOTE: a.14. IS) Installation of governor ASSY.2.0071 in) pinIOn 14) Crown gear tooth contact patterns. 14 .0. 7-63 . Before installing the cover. observe whether the starting.2 mm (0 . Install Handle (899924100) and Shaft (398653600) to the reduction drive gear. Install governor ASSY.5 notches. loosen the holder until the a-ring groove is appeared. move the gear in forward and backward directions to obtain gear contact patterns.008 in) Two snap rings are. h. readjust. Perform the same job with the opposite axle shaft oil seal holder.62 N'm (12. Pay attention to the Rand l marks of the oil seal.25 (0. d. NOTE: Pay attention not to damage the axle shaft oil seal holder bores in final reduction case.AUTOMATIC TRANSMISSION AND DIFFERENTIAL 9 Ib) select another shim and spacer combination.1.0. 12) Installation of differential ASSY.16. b.20 ft-lb) Before measuring preload. stake the lock nut at two points. then fit the O-ring into the groove and tighten in the holder to the position where the holder has been tightened to. Part number Shim Shim + Spacer Snap ring Thickness: mm (in) 1. Screw in the holder opposite the crown gear by 0. a. After rechecking the preload.0.17 N'm (IA-1. Screw in the other holder until it bottoms.27 N'm (2. b. Refer to the figure for various gear contact patterns. available for the adjustment of the above clearance.0. b.8 kg-m. f. g. Apply a coat of Prussian blue over the three or four tooth faces of the crown gear.0. If proper gear contact patterns are not obtained.0394 . a.0433) 1.10 (0. 7-157 // A13·320 Wrench (399780111) NOTE: Torque (Lock plate) 22 . 10 .0492) Pulley (398563600) Backlash between crown O. be careful not to damage the seal ring and oil seal lip inside of the final reduction case.00 . Specified clearance 0.15 .

Gear Teoth Contact Pattern Checking item Correct tooth contact Tooth contact pattern slightly shifted toward toe under no-load rotation (When loaded....<1<o~"4"'~~''''·_'''''''1 ·_'. b.. . Install the actuator with the spacer on final reduction case. This may cause chipping at heel ends. Apply a coat of differential gear oil on the reduction drive gear shaft before mating the cases to facilitate the insertion of the reduction drive gear shaft into the stator shaft oil seal. .k>"" l.. contact pattern moves toward heel.''______. This may cause chipping at toe ends.___________ . Contact pattern Corrective action This may cause noise and chipping at tooth ends. Heel contact (Outside end contact) Contact area is small.AUTOMATIC TRANSMISSION AND DIFFERENTIAL Crowr.. a.3 ..7 kg-m.. Clean the mating surface. ..20 ft-lb) Torque 18) Installation of parking actuator. '.26 N·m (2..) Face contact Backlash is too large. Adjust as for flank contact.2.fjI h*-<-_"Ij. Fig.3 .---___ ·· .. .~ * A13·164 Adjust as for face contact.7 kg-m. 17-20ft-lb) 17) Mating of final reduction case and converter housing. c. 7-158 Tooth contact of crown gear 16) Installation of stator Install the stator shaft to housing with the gasket with the flange of the upward. Toe contact (Inside end contact) Contact area is small. 17 .___________"_"'".26 N·m (2. Flank contact Backlash is too small. .. .2. . Increase thickness of drive pinion hight adjusting shim in order to bring drive pinion close to crown gear.1'_. Replace the gasket with new one. This may cause noise and stepped wear on surfaces. shaft. . the converter in place and shaft facing Torque 23 . Reduce thickness of drive pinion hight adjusting shim in order to move drive pinion away from crown gear.k. 7-64 ~".. 23 ..

7·162 Installing the bearing / . drive the bearing holder (incl. 7·165 A13·505 2) Governor Valve Assembly Refer to "9. are damaged or when the passage in the air breather for the oil seal is blocked. using Installer 499247100. 7·160 Removing the drive gear Fig.l!\ a/ . 4) Pry the snap ring off the reduc· tion drive gear._- - ----A13-508 l Fig. b. Disassembly A13-508 Fig.- --. drive the oil seal into holder. bearings. 8 FINAL REDUCTION COMPONENTS 1) Reduction Drive Gear When gears. 1) Press the bearing into the holder and install the snap ring. 3) Install the snap ring and.0 ft·lb) NOTE: When separating the final reduction case from Stand. Spacer (499267100) Torque 8 . HOId~C~ (8"dO' I. 2) Using a press.J =-=ll ~rr Reduction drive gear A13-502 ~--~-<-~--Fig.. 7·161 Removing the bearing 1) Using a flat·bladed screwdriver. .8 . 7·163 Installing the reduction drive gear 7-65 .8 . and press it out. detach snap ring. disassemble and correct. . Always install the two oil seals with their backs facing each other. When installing the snap ring. -. the bearing) into the reduction drive gear.I kg·m. 7·159 Removing the snap ring 2) Press the drive gear and ball bearing (from the holder) out. be careful not to damage the oil seal surface. 3) Differential Assembly Refer to Chapter 6 "Manual Transmis· sion and Differential". oil seals." in 2. 5.I I N'm (0. etc..1. using the special tool and remove the bearing using Guide (498847000) and Remover (499717000). Assembly NOTE: a. Installer is also used when installing the bearing cup. be careful not to damage the gasket. On·car Service_ Fig.8.AUTOMATIC TRANSMISSION AND 01 FFERENTIAL 3) Press the oil seal out. Guide 498847000 and Spacer 499267 100. 4) Drive Pinion Rear Bearing Cup Attach Installer (399513600) to the end face of the bearing cup from the inside of the case. using Guide (498847000). 7·164 Driving the oil seal into place A13-504 Fig. A13-503 A13·506 Fig.

""~-""'"". and drive the speedometer shaft out of the case by lightly applying hammer blows to it... remove drive pinion front bearing cone as shown in the figure. Fig..._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ . 7·170 Installing bearing cup 7-66 !" I • I I . * Axle shaft oil seal holder A13·162 NOTE: Make sure to remove governor shaft beforehand..:~~~~~~ Taper roller bearing cup 9) Needle Bearing at Reduction Drive Gear I) Remove bearing from the front side using Remover (399863610) and Handle (498477000) by press. Press oil seal into holder with Installer (399790100). • Be sure to bring both ends of holder and cup into contact. NOTE: Fig."'''_ . . press it with In· staller (899580100) and Installer (899874100)... 7·167 When assembling.149 1 Replacer (498517000) 2 Front bearing cone A 13-323 Fig. Remove oil seal from holder with Represser (498107000). 7·169 Removal of bearing cup from axle shaft oil seal holder Fig.. Press the oil seal until the step· ped portion of press contacts with that of final reduction case. In assembling. 7) Bearing Cup and Oil Seal in Axle Shaft Oil Seal Holder I) Bearing cup a. Remove a washer remaining in the case. 2) Press bearing into case using Re· mover (399863610) and Guide (498807000) as shown in the figure.11 #' ". (399703600) Axle shaft oil seal holder T7'~~7777m~.. 7·171 Press Installer Oil seal Press (499827000) Final reduction case A13·324 NOTE: Don't press the bearing retainer with Installer.Puller 5) Drive Pinion Front Bearing Cone Using Replacer (498517000).AUTOMATIC TRANSMISSION AND DIFFERENTIAL Final & reduction case Drift Installer . 7·168 Removal of drive pinion front bearing cup When assembling. be sure to press the bearing cup until its end surface of flange contacts the final reduction case.. (399513600) (398437700) 2) Oil seal a. 6) Drive Pinion Front Bearing Cup Press out drive pinIOn front bearing cup with Drift (398437700).. lu \. After installation of the oil seal. '7'7"// /'7?" A 13.. 7·166 Removal of drive pinion rear bearing cup / / A13·151 Note that the right and left oil seals are different. ~. press the cup with Installer (499427000) until its end surface contacts thrust bearing retainer.~~~) . NOTE: Outer race A13·148 Fig.. b.. ~ . Fig. apply a coat of differential gear oil to the sealing lip. install the speedometer shaft with the washer into the case and drive the oil seal in by applying hammer blows on Press (499827000).. " I I "".. Remove bearing cup from holder with Puller (399703600) as shown in the figure.. b. Press bearing cup into holder with Installer (499427000) until its end contacts the end of holder as shown in the figure. (499427000) / ~~~0.j. .'_ r1''''''''1'1''r _ _ _""_ _ _ _ _.... The oil seal will be removed together with the shaft. To install.. .7:. 8) Speedometer Shaft and Oil Seal Remove the snap ring from the tip of the speedometer shaft.il~"\.

4 .9 . I 2 3 4 Nut Needle bearing Oil seal Puller Set (499527000) 11) Bushing and Oil Seal in Converter Housing A13-326 1 Converter housing 2 Drift (398437700) or the equivalent with 58 to 60 mm (2. 2) Remove needle bearing and oil seal with Puller Set (499527000) as shown in the figure.1. be sure to install seal ring. Press W I Final reduction case 2 Needle bearing A13-369 • 3 @ Fig. 7-177 Pressing bushing 5) Install governor sleeve to case and tighten bolts to the specified torque.0. 7-175 Installation of oil seal Fig.172 Installation of needle bearing 1 2 3 4 Final reduction case Oil seal Installer (399793600) Puller Set (499527000) 10) Oil Seal and Needle Bearing of Governor Shaft I) Remove bolts securing governor sleeve to the case and remove the governor sleeve. 7-176 Removing bushing 7-67 . 3) After putting Guide (499257100) on the spline portion of drive pinion rear end. 9 ASSEMBLY OF THE CD® Manufacturer's • [}--® ENTIRE AUTOMATIC TRANSMISSION 1) Joining the Transmission Case Section to the Final ___ Reduction Case Section 1) Set the final reduction case section with converter housing downward. join the transmission case Needle bearing 2 Final reduction case 3 Installer (399793600) 4 Puller Set (499527000) A13-327 Converter housing 2 Handle (498477000) 3 Replacer (498107000) 4 Bushing A13-329 Fig. a. 7-178 Pressing oil seal Fig. Manufacture's mark side \ ® I I ! @ @ I /-- NOTE: CD 3 a. Pay attention not to damage the contact surface of housing. Torque CD 4. b.AUTOMATIC TRANSMISSION AND DIFFERENTIAL • Remover (399863610) Guide (398833600) 4) Install oil seal with Puller (499527000) and Installer Set (399793600) as shown in the figure. Apply the ATF around the oil seal lip.5 kg-m. When installing governor sleeve to case. 7-174 Fig. When pressing oil seal. b.6 ft-lb) 4) Press oil seal into housing by using Drift (398437700) as shown in the figure. A13-328 1 2 3 4 Converter housing Handle (498477000) Replacer (498107000) Bushing Fig. be careful not to incline it. 3 Oil seal A 1 3-331 Fig. 2) Remove bushing by using Re.3.36 in) outer diameter. NOTE: NOTE: 3) Install needle bearing with Puller Set (499527000) and Installer (399793600) as shown in the figure. Make sure to install governor sleeve into case with its drain hole facing downward.28 to 2.placer (498107000) and Handle (498477000) as shown in the figure . 2. 2) Clean the mating surfaces of the cases. 7-173 Removal of needle bearing and oil seal on governor shaft 1) Remove oil seal from converter housing with thin minus screwdriver or the like. 3) Press bushing into housing with Replacer upsidedown as shown in the figure.5 N'm (0.

Tightening torque 25 N·m (2. Be careful not to A4-134 Fig. Apply a coat of grease to the splines of the transmission mainshaft in advance. Also install transfer drive shaft. NOTE: Always install the solenoid securely with your hand-not by any tool. Tighten the clip (one place) for the transfer solenoid harness with one of the eight bolts. with the oil supply ports positioned as shown in the figure. Apply a thin coat of ATF to Guide beforehand. 17 . Tightening torque 18 N·m (1. turbine shaft and pump drive shaft.AUTOMATIC TRANSMISSION AND DIFFERENTIAL section to the final reduction case section.8 kg-m. 14 . 6) Install vacuum pipe. 23 . Install the temperature switch with the gasket in place and tighten to the specified torque. Attach the "0" ring to the bore in the extension case and install the transfer solenoid.118 N·m (9. 3) Install the rear crossmember on the car body as follows: a.12 kg-m. and secure the crossmember to the car body with the bolts.2. 1) With car body and engine in the same position as when they were removed. 18 ft-Ib) allow transmission to strike any adjacent parts while raising jack. Tighten the rubber cushion retaining nuts. NOTE: a. 7-179 Turbine shaft and oil pump drive shaft NOTE: Take care not to damage the oil seal in the converter housing. 13 ft-lb) NOTE: a. Torque NOTE: a. b.0 .0 .87 ft-lb) b. 3) Install the temperature switch.5 kg-m. Be sure to install the seal ring. 2) Install the transfer solenoid. Using the selected washer in the intermediate case.4 kg-m.8 kg-m. support transmission on jack just behind engine. ground wire and oil cooler pipe. The turbine shaft and pump drive shaft must be installed from the front of the transmission.25 ft-lb) bolt: 18 N·m 1.26 N·m (2. Oil pan 5) Install the turbine shaft and oil pump drive shaft to the transmission. Be careful that the parking rod and parking actuator engages properly and the sealing lip is not damaged when assembling the cases. Remounting Fig. Oil pump drive shaft ~Oil supply port • To torque converter Turbine shaft c:e if \ \ f9 1/ 25 N·m (2. oil supply pipe. Install the torque converter ASSY onto the stator shaft. Vacuum diaphragm ASSY c. 20 . 7-180 Installing crossmember 7-68 .3 .3. install the extension ASSY and tighten the eight 8 mm bolts to the specified torque. 8 mm 10 (1. Tightening torque To oil pump • . 2) Carefully raise jack until transmission is aligned with engine. Servo apply pipe and servo release pipe e. c. b. Down shift solenoid valve d. 65 . If the mainshaft is hard to align with the engine. Control valve b. 5) Install the rear engine mount rubber cushion and tighten the two 8 mm bolts to the specified torque.20 ft-Ib) 2) Joining the Transfer Case Section to the Transmission Case Section 1) Install the extension ASSY. b. Engagement of the reduction drive gear and planetary output gear will be completed easily by giving a slow and staccato turn to the axle drive shaft. simultaneously turn the left and right transmission drive shafts until the mainshaft splines engage with the engine.0 7Torque 12 mm bolt: 88 . a.5 kg-m. Align the rubber cushion guide with the guide on the crossmember. 4) Fasten the harnesses with clamps. ( Oil supply port Oil supply port A13·169 7.33 N·m (2. 18 ft-lb) A4-138 D .7 kg-m. 13 ft-lb) Torque NOTE: Always use a new gasket. 4) Install the following parts to the transmission case. and secure it to engine.

3 kg-m.69 N·m (6.38 ft-Ib) Front exhaust pipe to bracket: 25 . 18 .8 .25 ft-Ib) A4-126 NOTE: a.22 N·m (1.3 ft-lb) A4·128 A4·144 Torque Fig. set the select lever at "N" position.6 . and secure it with the bolts.0 kg-m.AUTOMATIC TRANSMISSION AND DIFFERENTIAL 4) Remove the jack from underneath the transmission. 43 . Always use new nuts. Install a new gasket to the exhaust port of the engine. 13-16ft-Ib) NOTE: Always install a new spring pin.5. and temporarily tighten the exhaust pipe retaining nuts.1. Tighten the nuts securely. Position the exhaust pipe on the bracket on the car body. 7 .29 N·m (2. re-tighten the bolts and nuts securely. Fig. 31. After making sure that the exhaust pipe ASSY is properly positioned.2 . and insert the bolts into the holes from the front side. 10 .6 N·m (0.5 kg-m. Torque A4-120 Fig. 7-185 Installing oil supply pipe A15·015 A4-125 Fig.5 .18 N'm (1. • Tightening torque for cable cover: 3 .3 .0 kg-m. insert the linkage rod into the manual lever. 7-181 Installing axle shaft 7) Using a screwdriver.8 kg-m. 9) Move the select lever to the "P" position. b.3. properly align the bolt holes on both the left and right transverse links with the crossmember.7.34 N'm (2.0. Be sure to position the two center bushings with their slits facing the rear side of the car and the two outer bushings with their slits facing the inside. 7-183 Installing stabilizer 11) Install the front exhaust pipe ASSY as follows: a. and then tighten the nut. 7-184 Connecting linkage 6) Align the spring pin holes on the axle shaft and drive shaft. Temporarily tighten the front and rear exhaust pipes with the new gasket in place.51 ft-Ib) Torque 7-69 . c.0 .6 kg-m. 19 . and drive the spring pin into the holes.3. 18 .3 . 8) Install the stabilizer. Torque Front exhaust pipe to engine: 25 . d.22 ft-Ib) Front exhaust pipe to rear exhaust pipe: 42-52N·m (4.2 kg-m. 5) Clamp the parking brake cable to the body. Tighten the nuts to the specified torque after finishing all work and lowering the car to the floor.4.0 .2. b.13 ft-Ib) Torque 59 . 2. 7-182 Installing transverse link Fig.

crank the engine until the drive plate mounting hole is brought to the center of the timing hole. A4-096 Torque Fig.13 ft-lb) A4-093 Fig.1. Loosen the nut until the pitching stopper on the bracket (on the engine side) is free to move. 7-188 Connecting torque converter and drive plate A4-105 17) Adjust the pitching stopper as follows: a. Torque A4-116 A4-112 Fig. 7-190 Connecting speedometer 7-70 . 14) Lower the car body to the floor.to retain the torque converter and drive plate.26 N'm (2. 7-186 Installing front exhaust pipe 16) Install the torque converter and drive plate as follows: a. 15) Tighten the bolts and nuts which retain the engine to the transmission to the specified torque.5.18 N'm (1.2. Then. 13) Connect the hot air intake hose. 7-189 Adjusting pitching stopper 12) Securely connect O2 sensor harness to O 2 sensor and clamp it. 17 .7 . Tighten the rear nut until the rubber cushion-to-washer clearance is within specified value. d. Using a jack.one bolt at a time for each turn . 7-187 Tightening bolts and nuts 10 . retighten the cable by approximately 30°.087 in) c. and tighten the front nut securely. 23 .7 kg-m. c. and tighten it hard with your fingers.3 .AUTOMATIC TRANSMISSION AND DIFFERENTIAL NOTE: Be careful not to strike the oxygen sensor against any adjacent parts during installation.8 . Rotate the wheel until the holes on the torque converter and drive plate are properly aligned.2. A4-117 Fig. install and tighten the bolts. Attach a wrench to the rear nut.40 ft-lb) Torque 18) Connect the speedometer cable to the transmission. 7 .2 mm (0. NOTE: Be careful not to drop the bolts into the torque converter housing.20 ft-lb) A4-113 Fig. raise the car body just enough to clear the floor. 46 . Also install the starter. Specified clearance 1. Then. b.0 .071 . Using a wrench.5 kg-m. 34 .8 kg-m. b.54 N·m (4.0. using pliers. Crank the engine with a wrench and securely tighten all four retaining bolts .

24) Start the engine and add ATF up to the specified level.J . 7·192 Connecting oil cooler hose A4·115 Fig. 25) Start engine. A4·118 Fig. install spare tire. 21) Connect the diaphragm vacuum hose and oil cooler hose. 7·191 Connecting vacuum hose 7-71 _ .AUTOMATIC TRANSMISSION AND DIFFERENTIAL 19) Route the speedometer cable underneath the pitching stopper with the battery cable. 23) Check the transmission oil level and. Check exhaust pipe connections to ensure there is no gas leakage. 27) Check the operation of shift lever or select lever for smooth gearshifting. if necessary.-. add oil. 20) Make all necessary wiring connec· tions. NOTE: Be sure to connect the ground cable. 28) After all work has been com· pleted. and clamp it on the pitching stopper. 26) Check the operation of clutch for smooth engagement and disengage· ment. 22) Connect the battery ground cable.

3. 2. . ft-Ib) T1: 1..-_ _ _ _ _ _ _ _ _ _ _ _ _ __ .fif''''5W''''O~?1_''''I'''' _ _ _ __ _ _ _ _ _.".""'"' .45 .20 (1...3 . '.9 .94) Botton (Non-4WD) Spring Grip Screw & washer Selector lever rod Speing Indicator ASSY Bulb Spring pin 10 Selector lever CP (Non-4WD) 11 Cotter pin 12 Washer 2 3 4 5 6 7 8 9 13 14 15 16 17 18 19 20 21 22 23 24 25 Bushing Flange nut Plate Flange tapping screw Bolt Boot Spacer Inhibitor switch Washer Spring washer Bolt Rod (Non-4WD) Nut 26 27 28 29 30 31 32 33 34 35 36 Connector Flange screw Bushing Qevis pin Rod (4WD AT) Switch Grip Spring Spring Button (4WD AT) Selector lever CP (4WD AT) A19-157 Fig_ 7-193 i<.8 (0..2 . _. 9 .75.8.".0) T2: 4 .4) T5: 71 .0..27. I'.. Component Parts 4WD AT I I Non 4WD I 4 @ -.8) T3: 12 . ._''''''''_I.0.5.9 . .7.13.0.4 (0...6 (0.3 ..2. 7-72 "'_~..0. II ~ I. Transmission Control System 1.>'! .AUTOMATIC TRANSMISSION AND DIFFERENTIAL 7·3.4 .2.13 ."h'. 52 ..2. 0.127 (7.4 ..5.2 . G G @ @ Tightening torque N·m (kg-m.14) T4: 4.

4) Install the grip and button to the selector lever temporally. Disassembly 1) Remove rod.AUTOMATIC TRANSMISSION AND DIFFERENTIAL 2.138-0. Fig.8mm (0. 1 Rod 2 Grip 3 Indica~or 4 Inhibitor switch A19'075 Fig.. 7·194 4) Remove screws and selector lever ASSY. then disconnect the selector lever from plate. The spacer should be inserted between guide plate and bracket. 3) Remove rod from transmission selector arm. they should be moved smoothly. a. 7·198 Selector lever bushings Fig.. Apply grease 01'\ both sliding part ends of rod.150 in) dia. 7·197 Driving out spring pin NOTE: Do not remove the bushings from selector lever. a. 2) Confirm the following parts for operating condition before assembly. the screw holes should be aligned in line. then insert it into selector lever. NOTE: 4.. Insertion of the spacer into the selector lever . they should be moved smoothly. Assembly 1) Clean all disassembled parts... e. 7·195 2) Drive out the spring pin to the position where it is detached from the guide plate as shown in figure.. 7·199 A19·026 5. 2) Disconnect electric connectors for inhibitor switch and indicator illumi· nation light. When pushing the grip on selector lever by hand. Sliding condition of the button in the grip. Inspection 1) Inspect the removed parts by comparing with new ones for deforma· tion.. 2) Assemble rod to selector lever. it should be insert· ed lightly by fingers. taking care not to make damage on con· nected parts. 3) Remove selector lever installing bolt and detach the boot by pushing it from underneath. 1 2 3 4 Guide plate Spring pin Selector lever installing bolt Boot A19-076 Fig. Be careful not to damage the con· nected parts. Operation of the selector lever and rod . damage and wear.5 .. Insertion of the grip on the selector lever . take out NOTE: Before removing. indicator and inhibitor switch from selector lever ASSY. Removal 1) Detach parking brake cover and console box. c. 7·200 7-73 ---'-' I . Correct or replace if defective. A19·027 A19·079 Fig. 7·196 Driving the spring pin A4·143 Fig. . d.J 3. grip. Load Rod [3.3. and drive the spring pin out from rod. b.. set the selector lever to "N" position. -----------1 Guide plate 2 Bracket 3 Spacer A19·078 Fig.

. d. 4) Assemble selector lever to plate. Bushing c. Spacer Coat grease on the surface of spacer.j.j ~ L.0 kg-m. Boot Coat grease on sliding surface of the boot. A19-032 A13-25l Fig. .AUTOMATIC TRANSMISSION AND DIFFERENTIAL b..~--"tFRT3Rli __ ·-J""'·_""r"'".. I nsert groove Into the plate firmlV..11 'If·1 . 7-204 Inserting boot Fig. stop the spring pin at opposite side surface of the arm as shown in figure. fix the moving plate by inserting a 2 mm (0. and insert the bolt. '~"" \. a... rod into the knock pin hole while matching a hole of moving plate and knock pin hole at the case..-_"'"_________""'''1'_''''''____________________ F.~ I PUSh .. 7-201 Installing spring pin 3) Assemble the following parts to selector lever. c. 7-202 a. b... Insert the boot into the plate by pushing boot edge with fingers. 7-206 1 2 3 4 Spacer A19·0S0 Fig...~ ..08 in) dia. ~ . Torque (Flange nut) 1 Flange nut 2 Spacer 3 Bolt 4 Plate complete Spring pin A19·0S2 Fig.t"'. Install the selector lever to the plate complete. 7-205 A19-0Sl Fig. 7-207 7-74 '----T ! I.2. . Spring Apply grease to prevent noise.20 N'm (1. Fig. a. In order to prevent the spring pin from contacting with the guide plate. Tighten flange nut to the specified torque.r" '1 '-1 t . If there is no knock pin prepared on the inhibitor switch.. Drive in the spring pin to the same level of arm outer surface. Match the oblong hole of selector lever and the spring pin hole of rod. ® 1 2 3 4 5 6 7 Moving plate Case Knock pin Harness Connector Locator Bolt hole A19-0S3 Fig. 12 .. Press the spring pin into the selector lever and rod from arm side. I. 9-14ft-lb) c.-.. A19-029 5) Assembling inhibitor switch.2 .. 7-203 I Arm 2 Pressing direction 3 Spring pin 4 Rod b.

9 . Front . 9) Assemble the following parts to selector lever. 4. 1.2. Pull out the 2 mm (0. b. '·209 A18·085 A18·087 1 Bulhinl 2 Rod 7) Assemble the grip. Fig.8 kg·m. be sure to bend it. • Contact between indicator and selector lever. 1 Grip Torque 2 Sprlnl 3 Button A 18·081 Fig. Insert the spring into the but· ton and insert it into the grip from the spring side.27 kg·m. '·211 4 Cotter pin A 111·0811 Fig.. Washer d. \ . 0. Apply grease on the sliding part of the grip and button.0. d. Connector Insert the connector from trans· mission side. spring and button to selector lever. b. the moving plate pin to arm hole..4 . c.5. inspect the fol· lowing items by shifting the selector lever from "P" to "1" range while pushing the grip button. Bushing Apply grease to the inside and side surface of bushing. Bushing Apply grease to the inside and side surface of bushing. • Matching of the pointer and position mark. 0.2.AUTOMATIC TRANSMISSION AND DIFFERENTIAL b.. '·212 a. 2.13 . 6) Assemble indicator to plate. Insert the grip on the selector lever while pushing button in the grip.r-""'Oo<. 2 Connector 3 Wilber 4 Cotter pin A111·088 Fig.-. Set the button to driver's side. Washer d.6 N'm (0.6 N'm (0. • Selector lever shifting force.9 . Cotter pin Be sure to bend cotter pin.3 .. Instanatlon 1) Install the following parts to transmission selector arm.8 N'm (0.0. '·213 7-75 .0 ft·lb) 8. Cotter pin After inserting the cotter pin into rod hole.0 ft. Torque 1 Locltor 2 Movilll plate pin 3 Sprinl pin position 4 Guide pllte AHI·OB.8 ft·lb) p N PUlh IIlIhtlV to "P" pOlltlon a.9 . Torque (Flange screw) 1.lb) screw should be used. '·208 c.2.20 to 0.08 in) dia.13 .24 in) length 1 Bushinl Fig. '·210 10) Screw in one nut fully to the threaded part of rod. 5 to 6 mm (0.o \ --r-'@ a. c. 8) After assembly.27 kg·m.2. rod (knock pin) at the inhibitor switch. and spring. 2) Pass the rod through connector and tighten a nut temporarily.0. b. At the position where the selec~or lever is shifted in the "N" range and pushed to the "P" side lightly. then tighten screws to the speCified tor· que with the torque driver. then tighten the bolts to the specified torque. Rod c. 3 Wilber Fig. match the locator to bracket hole.3 .

45 . and make sure that the lever does not move to "R" posi· tion. @) Try to move the lever to "2" A19·148 Fig. 7-217 @ Proceed to set the lever to "D" position while pushing the button. The lever moves smoothly through all the positions.9 N (0. 7-214 b. 7 .5. While holding the nut A with a spanner.18 N·m (1. set the nut A apart from the connector by 1 ± 1 mm (0.2 to 0. 7-216 position without pushing the button and make sure that the lever does not move to "2" position.4 .4 ft-Ib) Torque c. 4.4 to 1.1. a. • Front A19-074 Fig.AUTOMATIC TRANSMISSION AND DIFFERENTIAL 3) Install selector lever assembly to the body. 7-76 Console box A19-073 Fig. engine can be started. 7·218 A19-150 NOTE: At this time.13 ft-Ib) Fig. 3.3 . and at the same time. @ Take your hand off the lever and button.4 N'm (0. 7-220 . tighten the nut B. Casted boss A19·091 Guide plate Fig.7. the select lever spring pin must be kept at the position of the guide plate as shown in the following illustration. There must be no position between "P" and "N" positions wherein the reverse lamp is lighted. Tighten flange tapping screws. Set the selector lever in "N" position.0. In UN" or "D" position of the lever with the engine stopped. the select lever pin must be kept at the position of the guide plate as shown in the following illustration.7 kg. 4) Set the transmission selector arm in UN" position where the center of connector is aligned with the casted boss on transmission case. Torque (Nut) 10 . b.04 in) as shown in the above illustration. Affix butyl rubber tape around the through hole but inside the four thread holes. 7·219 NOTE: At this time.8 kg-m. make sure that the lever operates properly as follows. a. CD Set the lever to "N" position while pushing the button. @ Try to move the lever to "R" position without pushing the button. make sure the operation of the lever according to the following procedure. While pushing the rod lightly by a finger [2. a. The reverse lamp lights with selector lever at only "R" position. 7) Connect electric connectors for inhibitor switch and indicator illumi· nation light.51b)]. 7-215 5) Adjust connection of rod with selector arm as follows. 9) Install the console box and the hand brake cover. The engine can be started with selector lever at only "N" or "P" position. b.04 ± 0.75 kg-m. Fig. ell Take your hand off the lever and button. A19-149 8) Check inhibitor switch operation as follows_ a. c.0 . Guide plate Fig. 0. Transmission case 6) After completing installation. b.0 to 6.

7-233 A 13-190 499267100 Spacer Oil seal holder 398833600 Guide Needle bearing 498477000 Handle Bearing cup. 7-222 A13-516 Fig. 7 -4. 7-236 A 13-518 7-17 .13-211 @ Fig. 7-230 ~ m Fig. total endplay. 7-226 ~ ~ A13-194 Fig. 7-234 A13-189 ST-150 499247200 Installer Final reduction case 399513600 Installer Drive pinion rear bearing cup 399863610 Remover Needle bearing 399913604 Spacer Drive pinion Fig. 7-232 A14-079 Fig. 7-221 A13-511 Fig. needle bearing. 7-223 A13-517 Fig.AUTOMATIC TRANSMISSION AND DIFFERENTIAL. drive pinion front bearing retainer and impeller bushing. Special Tools for Differential 499987100 Socket Wrench (35) Drive pinion 398653600 Shaft Drive pinion and reduction drive gear 498517000 Replacer Drive pinion front bearing core 399913601 Master Drive pinion Fig. 7-228 A14-046 Fig. ST-152 Fig. oil pump. axle shaft bearing cUP. 7-231 ({[a. and thrust bearing retainer 499247000 Installer Drive pinion oil seal I Fig. 7-224 6 A. drive pinion height 398437700 Drift Drive pinion front bearing cup 499427000 Installer Drive pinion front bearing cup. 7-227 A 13-196 ~ Fig. Special Tools 1. 7-229 ST-151 Fig. 7-235 A13-187 398643600 Gauge Low & reverse brake. 399913603 Holder Drive pinion 0 Fig. 7-225 A 13-192 Fig.

AUTOMATIC TRANSMISSION AND DIFFERENTIAL 399780111 Wrench Axle shaft oil seal holder 899924100 Handle Re. isA5·1. 1·242 Fig. g :9[ A ~ ~ Fig. 1·243 ST·158 9 Fig. 399790110 Installer Roller bearing (Differential) Axle shaft oil seal 499897000 Pliers Snap ring 899524100 Puller Set Roller bearing (Differential) 499937000 Differential Stand Final reduction section Laj Fig.. '·248 A13·188 A13·515 Fig. 1·260 A13·50. 1·261 I -. '·252 . 1·245 A12·1'3 Fig.. 1·231 A12·18.. 1·239 ST·1. 499827000 Press Speedometer shaft oil seal 498247001 Magnet Base Backlash of gears 399520105 Seat Roller bearing (Differen tial) 499917200 Master 2 Drive pinion cI' Fig. ! Fig. 1·238 A12·175 ~ A13·51.duction drive gear 398781600 Stopper Reduction drive gear 899580100 Installer Drive pinion i aJ - I ~ Fig.. 1·244 Fig. 1·241 A12·171 -.. Q Fig. '·240 Fig.12·18' e~ ST·1iS7 Fig. Fig. 1·246 C. A13·510 899904100 Remover Differential case 498247100 Dial Gauge Backlash of gears 399703600 Puller Axle shaft bearing cup 498847000 Oil seal Guide Oil seal holder • i ~ . 1·249 A12·17.2 J'Q. 1·241 A12·1 •• ~ FIg.1 Fig.

7·253 A 1 3·S1 2 - 498567000 Pulley Preload check (~) Fig. 7·255 A13-514 7-79 .AUTOMATIC TRANSMISSION AND DIFFERENTIAL 498807000 Bearing Guide Needle bearing ~ Fig. 7·254 A13·513 - 499247100 Oil Seal Installer Oil seal holder Q Fig.

.Q (j? A13-203 ~ A13-209 Fig.... Special Tools for Transmission 398534800 Adapter 2 Line pressure 398603610 Socket Brake band 399893600 Plier Reverse clutch....AUTOMATIC TRANSMISSION AND DIFFERENTIAL 2. reverse clutch. :r)J... 7-80 .. .. ' ' lj 'Q f._!. @ ~ Fig..:¢::.! ~~!~--.. 398308700 Puller Transmission case oil seal ff{J[fJ Fig. 7-257 Fig. 7-263 A13-208 Fig.' .. lJLi r". forward clutch and low & reverse brake 399793600 Installer Final reduction case 399248700 Installer 2 Transmission case oil seal ~ ~ ~ C) - '. 7-264 A13-207 Fig... 7-265 ST-160 Fig.. 7-256 .. forward clutch and low & reverse brake 499527000 Puller Set Final reduction case Fig.. low & reverse brake and oil pump etc.. -..'...~.. 7-262 C ~ E_ _ ~ o ... ...... A13-338 398573600 Oil Pressure Gauge Assembly Line pressure and governor pressure 498147000 Depth Gauge Low & reverse brake 499687000 Base Low & reverse brake 499717000 Remover Rear shaft bearing ~ Q A13-201 c . 7-271 \ A13-216 '11 ij-" .. r ST-159 d A13-210 Fig.""""_ _ _ _ __ _ _ _ _ _ _ _ _ _ _ __ '~-'1 .... 7-267 ~ A13-214 a Fig.--. 7-261 ST-146 Fig..~ _ _"-.. -~ Fig.. 7-259 A13-205 Fig. 7-269 A13-524 398893600 Adapter Line pressure and governor pressure 398623600 Seat Center support assembly 499667000 Thickness Gauge Forward clutch. 7-266 Fig..... -""..a. 7-268 ~ .. 7-270 A13-215 398663600 Plier Governor valve 398673600 Compressor Reverse clutch......I""-_ _ _ _ _ _ _ _ _". 7-258 A13-202 Fig. 7-260 Fig.

7-276 Fig. 7-275 A13-212 ~ Fig. 7-271 A13-520 398863600 Installer 2 Needle bearing on oil pump carrier 498897000 Adapter Measure the line pressure 9 Fig. 7-279 A13-522 7-81 . 7-274 A13-213 ~ Fig. 7-280 A13-523 Fig.AUTOMATIC TRANSMISSION AND DIFFERENTIAL 499337000 Vernier Calliper Vacuum diaphragm rod selection 399903600 Remover 2 Needle bearing and bushing on oil pump carrier 499917300 Gauge Set Vacuum diaphragm rod W---~c:=>A13-217 ~ Fig. 7-278 A13-521 399543600 Installer Needle bearing and bushing on oil pump carrier 499257100 Oil Seal Guide Drive pinion oil seal ® Fig. 7-272 ST-158 498107000 Replacer Impeller bushing on converter housing 498597000 Socket Wrench (7) Plug ~ Fig. 7-273 ST-155 c:=TI Fig.

. ' ... . __il... _ _.._.... 4._ _... .........._ _ _ _ .' 1!_·_'' ' '+' ' ' ·. ..-. .. _ .... .. ."~.1' .._ .. _ .. ' .. . .. -ttt· y·._ -....~''''I~'''~' "'_ _ _ ~ __ _____ ''''' ' f'_' ... ....·........._ ·.....

7 II Inlplctlon ..•. . • • • • • • •• 8....•• 8-13 DRIVE SHAFT ..••.•...8 8.... 8... I •••••••• I ••• I ••••••••••••••••••••• • I •••••••••••• I •••• I •••• II •••••• I • • • • • • • • • • • • • • • • • • • I • • I •• I •••••••••••••••• I I I • I •• I I I I •• I •••• I •• I • I I • I ••• I •••• I •• I I •••••• I •••• I I • I I 1. 8-1& 2.•... .•.. Service Dati .. Speciflc.•. ..•••.. t ••• I •••••••• I ••• I ••••••••• I ••••• I •••••••••••••••••••••••••••• I ••••••• I •••••••• I ••• II ••• I •••••••••••• 8-4.•.. Mounting . • • .. • • .•••••.4 REAR DIFFERENTIAL ..••.••.1 •• 1'1 I •• I' • I •• I' •••••• I I" •• I' •• I ••• I •••••••••••••••••••••• I ••••••• I ••••• 8-8.' • I • I ••••••••• I I I •••••••••••••• I ••••••••••••••••••••• I • I ••••••••• I I •••• I •• I ••••••••••••••••••••••• I 8-2. SPECIFICATIONS AND SERVICE DATA.••.•..& 1. Propeller Shaft •.... ....•. Di. I •• I I ••••••••• I ••••••••••••••••••• alEIAAU .8 7. 8-1& PROPELLER SHAFT •.. 8-&. 8-17 8-18 2.7 4.. '. Dllmountlng Differantlal Alllmbly . ..... Component Parts of Differential Alllmbly •...nlmbly 8-18 4.... 8..2 COMPONENT PARTS •••••. 8.. . .••••••.••..••. .tiona .• 8.•.••. .2 1. On-c....•••. 8-18 TROUBLESHOOTING •••. AUlmbly . A. ...•.. 8. 8-3.. 8.. . .•••••••.••• 8.•.••.& 2.. RemovII. Inspactlon. 8-1& 31 Dil.•..•. Relr Differential . ..•• 8-1& 1.•••. 8..... .••••..••••••.r SlrviCiI. 8.CHAPTER [g) REAR WHEEL DRIVING SYSTEM (4WD MODEL) Page 8-1. ..mbly . 8. 8-18 SPECIAL TOOLS •• I •• I ••••• I '. • .•.Mmbly 8-18 51 Instlnatlon..Z Z.8 3.•• 8-17 1.••. . I • I I ••••••••••••••••••• I •••••••••• I I ••••••••••••••••••• 8-7.••....•...••••••••..

4 . 4.75Ib) 2.4 mm 56.0 mm 57.6 mm (2.33mm 2. 1.0996 in) (0.9 x 1.500 x 0.0972 in) (0. Service Data Rear differential Front & rear bearing preload at companion flange bolt hole New bearing Used bearing Preload adjusting washer length Part No.0909 in) Preload adjusting spacer length 56. Specifications ~ Rear reduction gear Final Rear differential Side gear Pinion gear Tooth number of gear Gear ratio Type of gear ~ Type Distance between joints Propeller shaft Tube outer diameter x tube thickness Hatchback Station Wagon and Brat 2-joint type 1.6.0965 in) (0.35 mm 2.0917 in) (0.45 mm 2. 383695201 383695202 383695203 383695204 383695205 383695206 19.057 mm (41.28.85 . Specifications and Service Data 1.49 mm 2. 8-1 Construction of propeller shaft 2.55 mm 2.0933 in) (0.87 .0941 in) (0.16.9 kg.5 x 1.6 mm 56.6 .39 mm 2.47 mm 2.236 in) (2.6 mm (2.2 mm (2.1004 in) (0.252 in) 8-2 .1012 in) (0.61 in) 1.713 x 0.34 .0 . 383705200 383715200 383725200 383735200 383745200 383755200 383765200 383775200 383785200 383795200 383805200 383815200 383825200 383835200 383845200 Part No.0925 in) (0.900 Hypoid 16 10 V 1/ Straight bevel gear 63.7 kg.41 mm 2.31 mm (0.0980 in) (0.2.8 mm 57.53 mm 2.213 in) 56.72 in) 39/10 3.43 mm 2.2 mm (2.4lb) 8.244 in) (2.59 mm 2.136 mm (44.228 in) (2.0957 in) (0.063 in) A14·040 Fig.0949 in) (0.220 in) (2.1.1020 in) (0.67 N (0.REAR WHEEL DRIVING SYSTEM (4WD MODEL) 8-1.57mm 2.3.37 mm 2.4 N (2.0988 in) (0.063 in) 68.51 mm 2.

1 .25 mm (0.1311 in) (0.01 ± 0.1382 in) (0.0004 in) 8-3 ----! .1276 in) (0.0.0315 in) 0.0004 in) (0.0827 ± 0.05 mm (0.01 ± 0.7 US pt.85 mm (0.1252 in) (0.0787 ± 0.8 Q(1.20 mm (0.04 2.30 mm (0.45 mm 3.21 mm 3.008 in) Side gear to thrust washer clearance Side gear thrust washer thickness 0.1358 in) (0.02 2.63 mm 3.0295 .36 mm 3.0118 in) 0.5 N·m (I5 kg.66 mm (0.1441 in) (0.42 mm 3.1264 in) (0.39 mm 3.33 mm 3.85 .0335 in) 0.0843 ± 0.0811 ± 0.0.75 .0004 in) (0.00 mm (0.30 mm 3.1287 in) (0.20 mm (0.02 mm (0.50 mm (0.01 ± 0.1217 in) (0.12 mm 3.0795 ± 0.01 ± om ± 0.0803 ± 0.0819 ± 0.0079 in) 0.80 .1417 in) (0.12 2.1299 in) (0.004 .14 ± 0.00 2.0.6 mm (0.0835 ± 0.0.40 mm (0.REAR WHEEL DRIVING SYSTEM (4WD MODEL) Pinion height adjusting washer thickness Part No.1406 in) (0.1228 in) (0. 622033000 622033010 622033020 622033030 622033040 622033050 622033060 622033070 Limit Maximum Paint color White Yellow Red Green Blue Light Brown No paint Pink 2.0008 in) or less Drive gear to drive pinion backlash Drive gear runout on its back surface Oil capacity Propeller shaft Tube runout Joint bending resistance Axial play of journal Axial play adjusting snap ring thickness Part No.10 . 383495200 383505200 383515200 383525200 383535200 383545200 383555200 383565200 383575200 383585200 383595200 383605200 383615200 383625200 383635200 383645200 383655200 383665200 383675200 383685200 Part No.1323 in) (0.1240 in) (0.90 mm (0.0004 in) (0. 383445201 383445202 383445203 Part No.0315 .80 mm (0.08 2.0.27 mm 3.0.0004 in) (0.4 Imp pt) 0.06 2.0004 in) (0.60 mm 3. 13 in.0039 .01 mm mm mm mm mm mm mm mm (0.48 mm 3.09mm 3.0335 .0.15 mm 3.1346 in) (0.0197 in) 0.0098 in) 0.18mm 3.01 ± 0.0157 in) 0.2 mm Side bearing standard width Side bearing retainer shim thickness 0.10 2.51 mm 3.0079 in) 0.0354 in) 20.cm.01 ± 0. 1.0.57 mm 3.24 mm 3.0004 in) (0.1429 in) (0.lb) 0.0020 in) 0.024 in) 1.1370 in) (0.1394 in) (0.0004 in) (0. 383475201 383475202 383475203 383475204 383475205 Limit Rear differential ( continued) 3.0.7874 in) 0.0.54 mm 3.1335 in) (0.

. 8·2 Construction of rBlr drive system 69·78 31·36 18·215 39·49 (7. 5 Splnelle 6 Brelther CIP 7 Pick Ina 8 Pick Ina 9 O·rlna 10 Sprlna pin 11 Bolt 12 Sprlna wllher 13 Nut 14 Snip rlna 15 Cro.mbly 17 Bolt .13·18) (4..23·27) (1..0·6.mbly 16 Dltrerential mount member .mbly 4 Bolt compl.0·8.2·3...mbly 18 Brlcket compl.) 20 Brlcket II... (L..8·2.15.H.mbly 2 Ditrerentlailiaembly 3 Drive Ihaft (R) II.151 ·158) (3. ft·lb) T1: T2: T3: T4: Fig.29·36) 1 Propeller lhaft II. Joint . Component Parts Tightening torque N·m (kg-m.7...REAR WHEEL DRIVING SYSTEM (4WD MODEL) 8·2.. (R..H.) 19 Brlcket compl.0." .0.mbly (F) 21 Wllher 22 Dltrerentlal mount bolt 23 Wllher 24 Wimer 25 Stopper 26 Self lock nut 27 Self lock nut 8-4 lit sq..

8.8. ft-Ib) T1: 167 .25 (1.20.78 (7.9 .6. Rear Differential 1.0.14 -19) T3: 69 . Component Parts of Differential Assembly 'Selective parts Tightening torque N'm (kg-m.1.2.5 .2.7) A14-098 1 Side gear 2 Pinion mate gear 3 Pinion crown gear set 4 Differential carrier S Pinion mate gear washer *6 Pinion height adjusting washer 7 Rear bearing *8 Bearing preload adjusting spacer *9 Bearing preload adjusting washer 10 Front bearing 11 Spacer 12 Pilot bearing Fig_ 8-3 Component parts of differential assembly 13 Front oil seal 14 Companion flange 1S 16 17 18 19 20 21 *22 23 24 Drive pinion nut Side bearing Side bearing retainer Differential case Side oil seal Pinion mate shaft Side bearing retainer O-ring Side bearing retainer shim Bolt (8x20x14 mm) Pinion shaft lock pin 2S Lock plate 26 Bolt (lOx20xl2 mm) *27 Side gear thrust washer 28 Rear cover 29 Stud bolt 30 Plug 31 Plug cpo 32 Bolt (lOx30x18 mm) 33 Washer 8-5 .6. 51 .196 (17.58) T4: 9 .0 .REAR WHEEL DRIVING SYSTEM (4WD MODEL) 8-3.9 .123 .0 .0.12 (0.145) • Stake the pinion nut after tightening T2: 19 .

s by using 6 mm (0. Tighten drive pinion nut within the specified torque range so that the turning resistance of companion flange becomes the same as that before replacing oil seal. 8-5 Removing drive pinion nut Torque (Drive pinion nut) 167 ~ 196 N·m (17.J.O. i. Install companion flange.. from spindle of trailing arm with trailing arm lowered fully and detach inner D.O. c. On-car Services 1) Replacing Front Oil Seal a. Measure turning resistance of companion flange. 8-8 Fitting oil seal f. e.058 Fig. h. j. Remove drive pInIOn nut while holding companion flange with Flange Wrench (398427700).0 ~ 20. from differential spindle and then remove drive shaft assembly. NOTE: Apply chassis grease between the oil seal lips. Remove wheels. 8-7 Removing oil seal h.145 ft-Ib) A14·010 Fig. 8-4 Measuring turning resistance of companion flange e. Puller Assem bly (398527700) 2 Oil seal Fig. Loosen both wheel nuts. c. d.1. Reassembling procedure hereafter is the reverse of the disassembly. Remove oil seal. i. Puller Assembly (39852 7700) A14·059 Fig. 2) Replacing Side Oil Seal a. Drive in a new oil seal with Drift (398437700). Extract companion a puller. g. NOTE: Apply chassis grease between the oil seal lips. Remove two bolts which fix the upper portion of shock absorber to the body in unladen condition. . NOTE: Measure turning resistance after making sure that the companion flange turns smoothly.24 in) diameter of steel rod. flange with k. NOTE: Stake drive pinion nut after tightening. j.O. Fit a new oil seal. Fig. b. Remove oil seal. A 16·180 Fig. Jack up the vehicle and support it with rigid racks. Drain gear oil b. Loosen differential spindle set bolt by using Wrench (925560000) and remove spindle with packing. Fig. g. Jack up rear wheels and support the vehicle body with rigid racks. Detach outer D.8-10 Removing oil seal f.J. 123 .0 kg-m. Drive out spring pins of inner and outer D.REAR WHEEL DRIVING SYSTEM (4WD MODEL) 2. Reassembling procedure hereafter is the reverse of the disassembling. d. 8-6 Removing companion flange 8-6 . 8-9 Driving spring pins out 1 Companion flange 2 Spring balance A 14.. Detach propeller shaft from companion flange.

oil seal and sleeve yoke. When replacing side bearing. pay attention not to damage the sliding surfaces of rear drive shaft (extension) spline. b.8-16 Removing side bearing cone 8-7 ) . and extract right and left side bearing retainers with a puller. c. 2) Replacing Side Oil Seal.) a. Extract bearing cone with Puller Set (399527700). should be kept together with its mating retainer. Never mix up the right and left hand bearing cups and cones. Dismount differential assembly by lowering jack. c. NOTE: Be careful not to permit the teeth to contact with the case. Remove spindles by loosening bolts with Wrench (925560000).8-15 Removing side bearing cup h. Dismounting Differential Assembly a. Runout of drive gear at its back surface. Remove rear cover by loosening retaining bolts. b. Attachment (398457700) 2 Side bearing retainer A14·013 A14-062 Fig. Assembly" for inspection procedures. and backlash. f. b. e. Insert the cap into the extension to prevent mission oil from flowing out immediately after removing the propeller shaft assembly. Support differential assembly with jack and remove two nuts at the center of differential mount member assembly. 1 Puller Assem bly (398527700) 2 Bearing cup Fig. pull bearing cup from side bearing retainer. NOTE: Each shim. c. which is installed to adjust the side bearing preload. When removing propeller shaft assembly. inspect on the following items before disassembling. Fig. 8·12 Removing rear cover 4. d. j. Prepare an oil can and cap since the mission oil flows out from the extension at removing propeller shaft assembly. NOTE: a. Drain gear oil by removing plug. Remove four nuts fIxing differential assembly to bracket assembly Attachment (398217700) ~ A14-061 Fig.REAR WHEEL DRIVING SYSTEM (4WD MODEL) 3. Turning resistance of drive pinion. set At· tachment (398457700) to differentia! carrier. Disassembly 1) Inspection before disassembling To detect real cause of trouble. ') Puller Set (399527700) 2) Disassembling a. i. (F). to f. Set -Attachment (398217700) on vise and install the differential assembly to Attachment. h. Pull out differential carrier." g. Tooth contact of hypoid drive gear and pinion. Follow the same steps as those for "2. Do not attempt to disassemble the parts unless necessary. NOTE: a. Mark right and left side bearing retainers in order to identify them at reassembly. Fig. Set Puller so that its claws catch the edge of the bearing cone. 8-13 Removing side bearing retainer Fig. Remove side bearing retainer attaching bolts. 8·14 Removing drive gear g. 8-11 Installing differential Differential carrier A14·014 b. Remove propeller shaft assembly. (Refer to "6.

1 1*. q. Fig..REAR WHEEL DRIVING SYSTEM (4WD MODEL) i. 8-19 Removing drive pinion o. I) Drive gear and drive pinion a... replace as a set. Drift (398467700) ® 1 2 3 4 @ @ A14-021 1 Lock plate 2 Differential carrier 3 Drive gear Fig.. NOTE: A14-019 r. . damage... Inspection Wash all the disassembled parts clean. 8-21 j. 1.. preload adjusting spacer and washer.. do not drive it out forcibly before unstaking it.. NOTE: Place the replacer so that its centerrecessed side faces the pinion gear. or other defects.-+-... .. side gears and thrust washers.... .. Replace the gear if excessively worn or incapable of adjustment.. 8-17 Removing drive gear A 14·017 Drift (398467700) Rear bearing cup Front bearing Pilot bearing Removing pilot bearing Fig.·...___________--__________ .."...• . m. Remove rear bearing cone from drive pinion by supporting cone with Replacer (398517700). NOTE: The gears as well as thrust washers should be marked or kept separated left and right. ... or other defects are evident on tooth surface. When replacing bearings.". find out the cause and adjust to give correct tooth contact at assembly... Replace if crack. I Rear bearing cone 2 Replacer (398517700) Fig."'_ _ ..... Extract the companion flange with a puller.'. Repair or replace defective parts as necessary. '_t. Remove front oil seal from differential case. or seizure is evident. and examine them for wear.. Replace if thrust washer contacting surface is worn or seized. Slight damage of tooth can be corrected by oil stone or the like. score.._t1.. Drive out pinion shaft lock pin from drive gear side. Tap alternately wlth brass bar._'.. . i 4~" I .8-18 Driving out lock pin k. . tap front bearing cup and rear bearing cup in this order out of case by using a brass bar.. • 1It ------. Remove drive gear by spreading lock plates and loosening drive gear bolts... Fig. If crack. . Remove pilot bearing together with front bearing cone. Hold companion flange with Flange Wrench (398427700) and remove drive pinion nut. '-< . b. 2) Side gear and pinion mate gear a. . and front and rear.. 8-20 Removing rear bearing cone A14-063 NOTE: Hold the drive pinion so as not to drop it p.•'"*...... n._. score. 8-22 Removing cups of front and rear bearing A14·018 S.. Slight damage of the surface can be corrected by oil stone or the like. Draw out pinion mate shaft and remove pinion mate gears. The lock pin is staked at the pin hole end on the differential case.. If abnormal tooth contact is evident._ . b.. .... •. 8-8 . Press the end of drive pinion shaft and extract it together with rear bearing cone..~"" '" #l J "'4-.. A14·0n Fig.

75 lb) at companion flange bolt hole Fig. b. 123 . install preload adjusting spacer and washer.4N (2. Apply gear oil when installing the bearings and thrust washers. lock Dummy Shaft with Block (398507704) as illustrated here.4 . 4.0 . Block (398507704) 2 Dummy shaft (398507702) Fig. c. and tighten drive pinion nut while measuring the preload with spring balance as shown in the figure.85 .3. f. 8-24 Installing bearing cup 6. b. Be careful not to give excessive preload.REAR WHEEL DRIVING SYSTEM (4WD MODEL) Bearing Replace if seizure.196 N·m (17. companion flange. b.9 kg.6. flaw. d. 8-27 Measuring preload Front & rear bearing preload Dummy Collar Dummy Shaft (398507703) (398507702) A14·025 Fig. Keep the shims and washers in order. Check and adjust each part during assembly.6-28. Adjust the bearing preload with spacer and washer between front and rear bearings. e. abnormal noise or other defect is evident. Handle & Drift Kit (397471600) Fig. 4) Thrust washers of side gear and pinion mate gear Replace if seizure. so that they are not misinstalled. abnormal wear or other defect is evident. dragging during rotation. 7) Differential carrier Replace if its sliding surfaces are worn or cracked. Press front and rear bearing cups into differential case. 8-9 . Thoroughly clean the surfaces on which the shims. d. 8) Companion flange Replace if the oil seal lip contacting surfaces have flaws. Apply chassis grease between the lips (*) when installing the oil seal. Turn Dummy Shaft with hand to make it sealed. Replace the oil seal with new one at every disassembly. NOTE: a. Assemble in the reverse order of disassembling.2.67 N (0. The adjustment must be carried out without oil seal. PInion height adjusting washer Preload adjusting spacer Preload ad lust InQ washer \ Fig. front bearing cone. Then. a. washer and drive pinion nut. Insert Dummy Shaft (398507702) with pinion height adjusting washer and rear bearing cone fitted on it into case. rust. and at every disassembling.34 . Pinion height adjusting washer has nothing to do with this adjustment. Dummy Collar (398507703).0 . wear. Be careful not to mix up the right and left hand cups of the bearings.16. Assembly I) Precautions for assembling a. 8-25 Installing Dummy Shaft For new bearing: 19. 6) Differential case Replace if the bearing bores are worn or damaged.0 kg-m. 3) 2) Adjusting preload for front and rear bearings. washers and bearings are to be installed. peeling. 1.20.145 ft-Ib) NOTE: Reuse the used washer if they show normal tooth contact pattern when checked before disassembly. 5) Oil seal Replace if deformed or damaged.1.7 kg. 8-26 A14-064 Torque (Drive pinion nut) 167 .87 . 8-23 Applying grease to oil seal c.4lb) at companion flange bolt hole For used bearing: 8. Select preload adjusting washer and spacer so that the specified preload is obtained when nut is tightened to the specified torque. When tightening the drive pinion nut.

23 .36 (0. NOTE: Make sure that there is no clearance between the case and Gauge.37 (0.236) 57.20 (mm).57 (0.1311) 3. c.2 (2.63 (0.1406) 3.1264) 3.0980) 2. T = 3.31 (0.51 (0.8 (2.213) 56.1004) 2.0.23mm H==+I.0949) 2.66 (0.0933) 2.1020) 2.0972) 2.39 (0. as shown in the figure and apply the specified preload on the bearings.0917) 2.54 (0.1358) 3.45 (0.49 (0.0925) 2.01 -0. Measure the clearance N between the end of Gauge and the end surface of Dummy Shaft by using a thickness gauge.1299) 3.20 + 1.1217) 3.1346) 3.33 (0. a.09 (0. Dummy Collar (398507703) 2 Dummy Shaft (398507702) 3 Gauge (398507701) Pinion height adjusting washer A14·027 Fig.24 (0.0988) 2. 8-28 Installation of Dummy Shaft Dummy Collar and Gauge b.20 == 3. where T = Thickness of pIllion height adjusting washer (0101) To = Thickness of washer temporarily inserted (mm) N = Reading of thickness gauge (0101) H = Figure marked on drive pinion head (Example of calculation) To = 2.20 = 3.59 (0.1276) 3.REAR WHEEL DRIVING SYSTEM (4WD MODEL) Preload adjusting washer Part No.1240) 3. (Refer to 2) Adjusting preload for front and rear bearings.6 (2. 8-10 v • 4) Install the selected pinion height adjusting washer on drive pinion.0941) 2.0965) 2.252) T = To + N . 383705200 383715200 383725200 383735200 383745200 383755200 383765200 383775200 383785200 383795200 383805200 383815200 383825200 383835200 383845200 Length mm (in) 2.40 + 0.30 (0.53 (0.48 (0.1417) 3.40 mm N==0.0.39 (0.1252) 3.33 (0. install a pinion height adjusting washer which is temporarily selected or the same as that used before.) NOTE: At this time.43 (0.01) .1323) 3.4 (2.1382) 3.21 (0.15 (0.1335) 3.244) 57.0 (2.1287) 3.228) 56. Collar and Gauge. and press the rear bearing cone into positif)fl with Installer (398177700).41 (0. Install Dummy Shaft.42 (0. . 383495200 383505200 383515200 383525200 383535200 383545200 383555200 383565200 383575200 383585200 383595200 383605200 383615200 383625200 383635200 383645200 383655200 383665200 383675200 383685200 Thickness 0101 (in) 3.0996) 2.47 (0.45 (0. 383695201 383695202 383695203 383695204 383695205 383695206 Length mm (in) 56.51 (0.12 (0.1394) 3.0909) Preload adjusting spacer Part No.1429) 3.18 (0.57 (0.27 (0. Obtain the thickness of pinion height adjusting washer to be inserted from the following formula and replace the temporarily installed washer with this one.2 (2.42 Result: Thickness = 3.60(0.(H x 0.35 (0.1441) 1.55 (0.220) 56. Pinion height adjusting washers - Part No.1228) 3.42 mm Therefore use the washer 383605200 3) Adjusting drive pinion height Adjust drive pinion height with washer installed between rear bearing cone and the back of pinion gear.1370) 3.0957) 2.1012) 2.

Adjust the clearance as specified by selecting side gear thrust washer. 8-31 A14-068 Installing pilot bearing NOTE: Apply gear oil on both sides of the washer and on the side gear shaft before installing.0.0315) 0. 12) Before installing side bearing. Weight (398227700) and Gauge (398237700). 8-11 Standard bearing width 20. Install drive gear on differential carrier.0. Side gear back clearance 0.::.0 .0.0315 -.2 mm (0. d.0.004 . b.145 ft-lb) Torque (Drive gear bolt) 69 -78 N·m (7.0.8.196 N·m (17.0335) (0. 8-33 Tightening drive pinion nut 7) Insert spacer.0354) CD ®I-----<~ 10) Install washer.75 . 1 Drive pinion a.008 in) 2 Installer (398177700) A14-066 Fig.0 kg-m.20. 383445201 I 383445202 A14-069 1 Installer (899874100) 2 Companion flange 383445203 Fig.00 mm (0. stake the both sides of the hole to prevent pin from falling off.85 .85 (0.0.0 kg-m. 123 . then press-fit pilot bearing with Weight (399780104) and Installer (899580100).0 . 8-30 Installing front bearing cone Fig. NOTE: Apply grease between the oil seal lips. Thickness mm (in) 5) Insert drive pinion into differential case. 8-32 Installing companion flange 0.REAR WHEEL DRIVING SYSTEM (4WD MODEL) ~:---- I ->=---::::.1 .80 (0. drive pinion nut with c.90 (0.0335 . Insert the pinion mate shaft into the differential carrier by aligning the lock pin holes.80 ." I 8) Fit a new oil seal with Drift (398417700). Check the condition of rotation after applying oil to the gear tooth surfaces and thrust surfaces.7874 in) . measure the bearing width by using a dial gauge. and bend lock plate. NOTE: Tighten diagonally while tapping the bolt heads. 51 .0295 . After driving in pinion shaft lock pin. 3 I Installer (899580100) 2 Dummy collar (398507703) 3 Weight (399780104) A14-067 A14-092 Fig.0. into differential carrier. with their thrust washers and pinion mate shaft. 6) Press-fit front bearing cone into case. e. I 1 Installer (899580100) 2 Pilot bearing Fig. Torque (Drive pinion nut) 167 . 8-29 Installing rear bearing cone Side gear thrust washer Part No.0.. install the previously selected preload adjusting spacer and washer.58 ft-lb) 11) Assembling differential carrier Install side gears and pinion mate gears. (Refer to 1) Precautions for assembling) 9) Press-fit companion flange with Installer (899874100) and Weight (399780104). Measure the clearance between differential carrier and the back of side gear.

76-0.01+0. side bearing.76-0. D=3. regard it as zero.76 .76-0.22 =0.55 mm The correct shims are as follows Thickness Q'ty 0. 8-36 Adjustment of side bearing retainer shim 1 Weight (398227700) 2 Gauge (398237700) 3 Side bearing A14-071 Fig. expressed in a unit of 0. Example of calculation Ex. D = 3.15 = 0. Side bearing retainer G A 14-074 Fig.F (mm) T I & T2 : Thickness of left and right side bearing retainer shim (mm) A&B Number marked on differential case. The drive gear backlash and side bearing preload can be determined by the side bearing retainer shim thickness.11 (E or F) Gl & G2: Number marked on side bearing retainer.0098) 0. obtain the right and left retainer shim thickness from the following formulas.0079) 0. differential case.70 mm The correct shims are as follows Q'ty Thickness 0.50 x 1 0.89 mm. 1 A=5.22mm.30 Total shim thickness = 0.01 mm.20 x 1 0.30 0.0118) OAO (0.01+0.50 = 0. NOTE: Use several shims to obtain the calculated thickness.15 = 0.70mm Total shim thickness Ex. B = 3.50 x 1 0.76-E = (2+0+2-3)xO.75 mm Right side T2 = (B+D+G2) xO. For example. F = 0. 383475201 383475202 383475203 383475204 383475205 Thickness mm (in) 0.25 0.REAR WHEEL DRIVING SYSTEM (4WD MODEL) NOTE: Set the dial gauge needle to zero.01 + 0.50 (0.E=O.89 = 0.25 1 x = 0.76 .76-E = (5+3+4-3) x 0. 8-35 Installing side bearing 14) Adjusting side bearing retainer shims a. C=3. value of E or F is as follows.19.01 +0.G2 = I. 20. GI = 2.01+0.00 .30 (0.OI +0. Gl =4.15 mm Left side TI = (A+C+GI-D) x 0. using a standard bearing or block of specified height in advance_ T1 I f a number is not marked.22 = 0.75 mm The correct shims are as follows Thickness Q'ty = 0. if the bearing measured width is 19.0 mm.20 = 0.10 mm Left side TI = (A+C+GI -D)xO.76-F = (5+3+1) xO.0157) 0. Side bearing retainer shims Part No.25 x 1 = 0. C = 0. When replacing differential carrier. b.76-0. G2 =3.E (mm) T2 (Righ t) = (B + D + G2 ) x om + 0. 8-34 Measuring side bearing width 13) Press side bearing cone onto differential carrier with Drift (398487700) and Adapter (398497701) included in Puller Set (399527700). E=0.IOmm F = 0. and side bearing retainer.1 0 = 0.25 (0.09+0.20 (0.50 Total shim thickness = 0.76-0. TI (Left) = (A+C+Gl-D) x 0.0197) A14·073 I Fig.01+0.55 mm 1 Drnt(398487700) 2 Adapter (398497701) A14-072 Fig. (' & D Number marked on differential carrier.8-37 Location of markings 8-12 .25 x 1 = 0.09+0.76-0.10 = 0.2 A = 2.OI+0. B=5. Difference of width of E&F left and right side bearing from standard width 20.

a. Raise differential assembly using a jack.1. Fit the selected shims and O-ring on side bearing retainer and install them on differential case with the arrow mark on the retainer directed as shown in Figure. 0.8 . Differential assembly mounting nut Propeller shaft flange yoke to companion flange Spindle installing bolt 69 -78 N·m (7. 8-40 Measuring runout at drive gear back Oil capacity d. readjust side bearing retainer shims.3. if the increase of the resistance is not within the specified range.2 kg-m.6 kg-m. Remount the differential assembly by temporarily tightening four mounting nuts at the front and two mounting nuts at the rear.09+0. Torque A14·033 f.9 . c. Torque (Side bearing retainer) 9-12N·m (0. 13 . Limit of runout 7. h. Install the differential carrier assembly into differential case in the reverse order of disassembling.20 mm (0. Check the drive gear runout on its back surface. Total shim thickness must be the same to maintain proper preload.10 = 0. After installation fill differential case with gear oil to the upper plug level. 6. Check the contact pattern after rotating drive gear several revolutions back and forth until definite contact pattern develops on drive gear.0.2 .0.76-0.50 x = 0. c.25 x 1 = 0.9 . Recheck drive gear-to-pinion backlash after readjusting shims. 0.7 US pt.0079 in) Backlash 15) Checking and adjusting tooth contact of drive gear. 8-38 Arrow mark on side bearing retainer Dial gauge e. b. g.19 ft-lb) NOTE: Be careful that side bearing cup is not damaged by bearing roller. Paint evenly both sides of three or four teeth on drive gear with red lead. Measure the drive gear-to-drive pinion backlash.76-F = (3+3+3)xO.50 Total shim thickness = 0.1 .5 .0 . Torque (Rear cover bolt 19 . Install rear cover. measure the turning resistance of drive pinion. Mounting a. readjust according to the instructions given in ''Tooth contact pattern" .9 .25 N·m (1.76-0. Use Drift (398437700) to press the oil seal into position. When the contact pattern is incorrect. If the reading is not within the specified range.5. 1.27 ft-lb) 8-13 . d. Turning resistance increase 0. i. correct by decreasing the shim thickness on one side and increasing the shim thickness on the other side the same amount.10 = 0.8. At the same time.10 .75 mm Fig.0020 in) A14·031 Fig.7 ft-lb) Fig.8. Compared with the resistance when differential carrier is not installed. 23 .8 Q (1.2 in-lb) a. 51-58ft-lb) 18-25N.0 kg-m. NOTE: c.m (1.6 kg-cm.0.5 kg-m. install oil seal in side bearing retainer.REAR WHEEL DRIVING SYSTEM (4WD MODEL) Right side Tz = (B+D+Gz)xO. After completing the above adjustment. Apply chassis grease between the oil seal lips.01+0.6 N·m (1 . d. and make sure pinion and drive gear rotate smoothly. Tighten side bearing retainer bolts. 8-39 Measuring backlash Be sure to wipe off red lead completely upon completion of adjustment. 14 . Install other parts in the reverse order of dismounting.18 ft-lb) 31-36N·m (3.01+0.0039 .4 Imp pt) 0.7 kg-m.25 0.05 mm (0. 0. b.2.75 mm The correct shims are as follows Q'ty Thickness 0. b.2.

' tI • • ...1"....) Contact pattern Adjustment ~~ - Face contact Backlash is too large. 1 ' .... 0 $ Contact area is small. Heel contact .-._ _ _ _ _..-... (When loaded.. .......tJ·..a-~..."·i--=-. ~ ~ Adjust as for flank cOfltact. ... 8·41 .. . ._'......... ~ This may cause noise and chip· ping at tooth ends. Fig..I.REAR WHEEL DRIVING SYSTEM (4WD MODEL) TOOTH CONTACT PATTERN Condition Correct tooth contact Tooth contact pattern slightly shifted toward toe under no load rotation............-.. Toe contact 4/ Contact area is small...---___.... q 'io--. I.. ~ y 0 Reduce thickness of drive pinion height adjusting washer in order to move drive pinion away from drive gear.. 41 This may cause noise and stepped wear on surfaces..I. ~ E ~ Increase thickness of drive pinion height adjusting washer in order to bring drive pinion closer to drive gear center.!j ....:-t".. ......_ _. 15 _ _ _- _ _ _ _ _ _. Flank contact Backlash is too small. This may cause chipping at toe ends.. .....~--I~Vfl"" .. ..__ 8-14 ~ :& 0 Adjust as for face contact.....__..-. . This may cause chipping at heel ends.....• ~ "'ITF 'll.... A13·164 . contact pattern moves toward heel.

Detach propeller shaft flange yoke from companion flange of differential assembly. 13 in-Ib) 8-15 . Insert the cap into the extension to prevent mission oil from flowing out immediately after removing the propeller shaft assembly. Inspect each part before disassembling. When removing propeller shaft assembly. I) Replace if the journal portion is worn.6 mm (0.5 N·m (15 kg-cm. oil seal and sleeve yoke. or abnormal anyway. 2.O. 8-42 Construction of rear drive shaft Baffle plate (A) 2 Rear 0. NOTE: When replacing band only. circlip 5 Band boot A 6 0.1. winding up type band (not handy type band) is provided. Propeller Shaft 1. 2) Replace the snap ring if it is damaged or its tension is insufficient. Removal a. b. pay attention not to damage the sliding surfaces of rear drive shaft (extension) spline. damaged. Inspection As a rule. Maximum joint bending resistance 1. 6) Correct or replace if joint movement is not smooth or the bending resistance exceeds the limit.1. 9 Fig." i REAR WHEEL DRIVING SYSTEM (4WD MODEL) 8-4. 5) Replace if runout of the tube exceeds the limit when rotating with the both end supported.0.J. Take out propeller shaft assembly rearward. and correct or replace if any fault is evident. Jack up the vehicle and support it with rigid racks. Drive Shaft Disassemble and reassemble the rear drive shaft assembly in the same assembling procedure as of the D.024 in) NOTE: a. assembly 3 Snap ring 4 0.0. do not disassemble the propeller shaft assembly since it is balanced. Limit of runout 0. b. Prepare an oil can and cap since the mission oil flows out from extension at removing propeller shaft assembly. 3) Correct the loose joint by using a selective snap ring. 4) Replace if any dent or crack is evident on the tube surface.0. of the front axle shaft. c. boot 7 Band boot B 8 Shaft rear 9 Baffle plate B A14·095 8-5.1. c.

0004) 2.01 (0. 8-43 Removing bearing race Selective snap rings Part No.0835 ± 0. 8-16 . proceed in the following order. flange yoke.0004) 2.0827 ± 0.REAR WHEEL DRIVING SYSTEM (4WD MODEL) 3. Torque (Flange yoke to companion flange) Journal axial play 0. 2) Since this joint is of the maintenance-free type.0004) 2.14 ± 0. 8-44 Selecting snap rings 5.00 ± 0.01 (0.02 ± om (0. 2) Remove bearing race by tapping the root of yoke with a hammer.0004) 2. 3) Adjust journal axial play by selecting proper snap rings. tube.01 (0.8 . 4.0803 ± 0. The opposing snap rings must be of the same thickness.0795 ± 0. Disassembly When disassembling or repairing because of sheer necessity.0811 ± 0. Selective snap ring Al~-094 Fig. Installation 1) Reverse removal procedures. 1) Remove snap ring with a flat blade screw driver.04 ± 0.0787 ± 0.02 mm (0.0004) Paint color White Yellow Red Green Blue Light Brown No paint Pink 3) Remove journal from yoke.01 (0.0843 ± 0.2.12 ± 0. 13 .01 (0.0819 ± 0.18 ft-Ib) A14-041 Fig. 622033000 Thickness mm (in) 2.5 kg-m.01 (0. 2) Apply grease to the spline and outside of the sleeve yoke.06 ± 0.10 ± 0. 622033010 622033020 622033030 622033040 622033050 622033060 622033070 NOTE: Be careful not to damage journal when pulling it out from yoke.0004) 2.08 ± 0. Assembly 1) Assemble in the reverse order of disassembling and never fail to align the marks made prior to disassembling.0004) 2. etc_ before disassembly.01 (0.0008 in) or less 18-25N·m (1.0004) 2. and never forget to provide matching marks on the sleeve yoke. refill new grease when reassembling.

• Improper backlash for hypoid gear. Troubleshooting 1. Replace. • Excessive backlash for hypoid gear. Readjust. Replace gasket and apply liquid packing. Repair or replace. damage or incorrectly fitting for spindle. • Excessive preload for side. or front bearing. Retighten and apply liquid packing. or excessively worn sliding surface of companion flange. Readjust or replace. • Loose bolts and nuts such as drive gear bolt. Readjust or replace. • Excessive backlash for differential gear. rear. • Insufficient or improper oil used.REAR WHEEL DRIVING SYSTEM (4WD MODEL) 8-6. Rear Differential Symptom and possible cause Oil leakage • Worn.replace. • Loose bolts on differential spindle or side retainer. Repair or replace. or incorrectly seated front or side oil seal. • Loose oil filler or drain plug. Replace O-ring. or incorrectly fitted O-ring. Replace gear or thrust washer. Damage Damaged parts should be replaced and also other parts should be thoroughly checked for any defect and repaired or replaced as required. Replace gear or thrust washer. Retighten. Readjust. or front bearing. Tighten to specified torque. scratched. Tighten bolts to specified torque. • Loose rear cover attaching bolts or damaged gasket. • Insufficient or excessive preload for side. Replace. Readjust or replace. Replace seized part and fill with specified oil to specified level. Find out what is actually making noise before disassembly. • Insufficient preload for front or rear bearing. • Excessive backlash for differential gear. Noises when starting or shifting gears Noises may be caused by differential assembly. • Loose bolts and nuts such as side bearing retainer attaching bolt. and also other parts should be thoroughly checked for any defect and repaired or replaced as required. • Clogged or damaged air breather. repair or . Remedy Clean. battered. etc. Tighten to specified torque. Scored. • Loose drive pinion nut. wheel bearing. Tighten bolts to specified torque. universal joint. • Damage due to overloading. • Insufficient backlash for hypoid gear. • Wear. side retainer and oil seal. rear. 8-17 J . Seizure Seized or damaged parts should be replaced.

• Improper preload for front or rear bearings. Replace. Replace. Readjust. or chipped front or rear bearing. wheel bearings.. Adjust snap ring. • Seized. or chipped side bearing. . be careful in checking them.. "'lI. Since noises from engine. Replace. • Worn spline of sleeve yoke. Replace. shift gears into four wheel drive and fourth speed position._ . trying to pick up only differential noise. cruising.. • Vibrating differential carrier. Replace.. • Improper backlash for hypoid gear. scored. caused by propeller shaft. Replace. • Worn or damaged universal joint needle bearing. Readjust or replace hypoid gear set. Replace. Retighten. Replace... Inspection methods to locate noises include coasting.. • Loose installation of propeller shaft. . Replace.'4u~~. Remedy • Loose installation of propeller shaft. tires. • Seized. transmission. • Broken pinion mate shaft.. • Seized or damaged side bearing. 8-18 ? " ~. Replace hypoid gear set.•."'. Replace hypoid gear set.•. Replace. Gear noises • Excessive wear or damage of thrust washer. Replace. • Scored or chipped teeth of hypoid gear. and jacking up all four wheels. • Seized hypoid gear. • Improper tooth contact of hypoid gear. 2.. accelerating. scored. • Loose installation of joint.REAR WHEEL DRIVING SYSTEM (4WD MODEL) Symptom and possible cause Noises when curving " Remedy • Damaged differential gear. Tapping when starting and noise while cruising. Perform these inspections according to condition of trouble. Readjust. • Unbalanced propeller shaft due to bend or dent. • Worn or damaged universal joint. and body are sometimes mistaken for noises from differential assembly. Generally vibration increases in proportion to vehicle speed. muffler. Propeller Shaft Trouble and possible cause Vibration of propeller shaft Vibration is caused by propeller shaft during operation and transferred to vehicle body. When listening to noises.. propeller shaft. Retighten.

8-52 A14-049 A14-081 8-19 _J . 8-49 Fig. 8-47 A14-045 ! I ![ Fig. 8-56 I I II • @ Fig. 8-50 5 6 Rolt(899521412) Puller 1)99521702) Hoider ()9952770) Adapler 1398497101) Boll 189952(107) Nul (021008000) Handle Drift Orut 2 @ Fig. A14-046 Fig.\ . 8-55 A14-080 c{)n~~ Fig. 8-53 Fig.. Q I ) ~ Fig. Fig. 8-46 A14-044 Fig. Special Tools 398427700 Flange Wrench Companion Flange I .I Fig. 8-51 A12-187 398437700 Drift 398467700 Drift Drive pinion Pilot bearing Front bearing cone 398507702 Dummy Shaft Pinion height and Preload adjustment 398177700 Installer Rear bearing cone Oil seal .. 8-57 398527700 Pulley Ass 'y Oil seal Side bearing cup CD 399527700 Puller Set Side bearing cone ® @ 397471600 Handle & Drift Kit Front and rear bearing cup ~ A14-075 398507704 Block Pinion height and preload adjustment ~ ~~~~~c _!'ilL---" • 'f" ~ . 8-59 A14-084 Fig.REAR WHEEL DRIVING SYSTEM (4WD MODEL) 8-7.-- . 8-54 ST-143 398417700 Drift Oil seal 899904100 Straight Pin Remover Differential pinion shaft lock pin 398507701 Gauge Pinion height adjustment 398217700 Attachment Set Differential case ~ Fig.=(I) (2) (3) 0 0 ------::::F (j) t (398477701) (398471102) (398477703' 2 3 4 It' J. 8-60 A14-085 Fig. \ \ I) 6 I cw. 8-45 A14-043 - \ ( A14-076 0 A14-082 Fig.) I A14'047 . 8-48 . 8-58 A14-083 Fig.~ 398517700 Replacer Rear bearing cone 398457700 Attachment Side bearing retainer 398507703 Dummy collar Pinion height and preload adjustment - i/-·~ '\ :) 'I.

8-67 ST-032 398237700 Gauge Side bearing 0 Fig. . 8-64 A14-086 l~=~~~_~ ___=~'~lf~.~. 8-65 A14-087 899580100 Installer Front bearing cone Pilot bearing 398487700 Drift Side bearing cone ~-- Fig.8. 8-63 A12-185 ~~ '-Q Fig. 8-62 A 12-179 Fig. A14-088 899874100 Installer Companion flange 925560000 Wrench Differential spindle set bolt q Fig.~'~I~ ___ .-. 8-61 A12-172 Fig. 8-66 0 ({~.---- 4' REAR WHEEL DRIVING SYSTEM (4WD MODEL) - 399780104 Weight Front bearing cone Pilot bearing Companion flange 398227700 Weight Side bearing 0 Fig.2~O_ _ _ _ _~_'~I~~!~' '~R __ _____________ ~ .

... ....... ... ...... ............ 9. ..... .. .. .. 9. .... ............ 9-19 ADJUSTMENT OF POSTURE (4WD Models Onlv) .............J. .. 9-24 COMPONENT PARTS .................... ... ....... .......... 9-11.. BOOT OF FRONT AXLE SHAFT .. ..... 9-15.... 9......5........... ................ ............ ... .. 9-38 • WHEELS AND AXLES • TROUBLESHOOTING ........ ...... ........ ....... ...... ............8....... ...O....... 9-29 REPLACEMENT OF D..... . .... ... . ....... . 9-23 ADJUSTMENT OF REAR ROAD CLEARANCE ...... .... 9-26 FRONT AXLE SHAFT ........... 9-16...... ...1....3... ... ...... COMPONENT PARTS ....... 9-33 REAR AXLE OF 4WD .... .2 • SUSPENSION 9... 9... ......... ...2......9... 9-12.. ... .... 9-13..... ............ ..... 9... ........ 9-18 REAR SUSPENSION .. ..... 9. ...... .. 9-10...J.. ...... ....... 9-32 REAR AXLE (Except 4WD) .. . ....7.................... ... ... 9............................... 9............ 9-41 • SPECIAL TOOLS ........ . ........ ........./D...CHAPTER@ SUSPENSION. WHEELS AND AXLES Page • SPECIFICATIONS AND SERVICE DATA . 9-17 BALL JOINT ........... .. .. 9-42 SUBARU 1 ·k j ........ 9... ..O..4......... 9-35 WHEEL ... 9.6 FRONT SUSPENSION ..6.... .. ... ... .... 9-14........ .... ...... .... 9. 9-25 HOUSiNG .... 9-13 STABILIZER ........8 FRONT SUSPENSION DAMPER STRUT ... 9-17 FRONT CROSSMEMBER ..... .... .....

176 Ib) 490 N (50 kg.34 in) 315 mm (12.33 in) 307. 176 lb) 392 N (40 kg. Sedan and Hardtop Hatchback 4WD Minimum length Station Wagon Station Wagon 4WD and BRAT Hatchback.1 mm (17.0 mm (0.4 kg/mm.5 mm (12.61 in) 133.40 in) 315.79 in) 785 N (80 kg. Sedan and Hardtop Hatchback 4WD Stroke Station Wagon Station Wagon 4WD and BRAT Piston rod diameter Damping force [at the piston speed 0.5 mm (0.66 in) 440.26 in) 124.SPECIFICATIONS AND SERVICE DATA Type Stabilizer McPherson strut type. 110 lb) 21 mm 37 34 Coil spring Typ~ (0.4 3. Sedan and Hardtop Hatchback 4WD Maximum length Station Wagon Station Wagon 4WD and BRAT Hatchback. independent suspension Bar diameter Wire diameter Coil diameter Free length Number of coils Coefficient of spring Front suspension Outer cylinder length Maximum length Minimum length Damper strut Stroke Piston rod diameter Expansion Compression Semi-trailing arm type.8 mm (17. WHEELS AND AXLES .56 in) 5.83 in) Torsion bar spring 28.29 in) 20 mm (0.492 in) 4WD: 12.31 in) 4WD: 521 mm (20.12 in) 319 mm (12.8 mm (12.95 in) 448. 134 lb/in) Other than 4WD: 359 mm (14.3 m/sec (1.97 in) 117 mm ( 4.492 in)] 785 N (80 kg.55 in) 4WD: 412 mm (16. 110 lb)] Rear suspension Shock absorber 9-2 .0 ft/sec)] Expansion Compression Inside serration Number of teeth Over all Effective number 20 mm (0.472 in) 130 mm (5.3 mm ( 4.5 mm (12.80 in) Other than 4WD: 516 mm (20.0 ft/sec)] Ou ter diameter Number of teeth Outside serration Outer diameter Cylindrical double action type Hatchback.3 m/sec (1.5 mm (17.13 in) 4WD: 376 mm (14.43 in) 126.5 mm ( 5.SUSPENSION.22 in) Other than 4WD: 121 mm (4. independent suspension Bar diameter Damping force [at the piston speed 0. 881b) [SW & SW 4WD: 490 N (50 kg.9 23.39 in) 10mm [SW & SW 4WD: 12.51 in) Other than 4WD: 395 mm (15.5 mm(0.89 in) (0.5 mm (16.5 N/mm (2.3 mm ( 4.122 in) 26.5 mm (1.0335 in) 433.79 in) Other than 4WD: 12.76 in) 4WD: 109 mm (4.08 in) 430.11 in) 313.25 mm (1.

51 cu in) Only upward 25 mm (0.15 mm (1.04 in) -3 to 3 mm (-0. GL model: 270 to 295 mm (10.02 to 11.98 in) Only upward 30 mm (1.1921 in) 30.12 to 0.04 ± 0.12 in) -5 to 5 mm (-0. .65 to 10..20 to 30.' Road clearance* I Camber Toe-in Rear Side slip (With one person) Road clearance*2 *1 *2 *3 *4 *5 320 to 340 mm*4 (12.981 mm (0.l Z >l.02 mm (0.0020 in) 0.05 to 30.~ .98 to 20.l Z ~ CI.61 in) GL model: 325 to 345 mm (12.7867 in) 19.45 to 10.1890 to 1.42 in) -25' to 1°05 . 13.01 mm (0.031 in) or less 0.43 to 11.1831 in) 220 cm 3 (220 cc. Sedan and Hard top Camber Caster Toe-in Front Side slip (With one person) 45' to 2° 15' -I ° 10' to 20' Hatchback 4WD Station Wagon 4WD and BRAT Station Wagon 1° to 2°30' -50' to 40' 1° 40' to 3° 10' _1°15' to 15' -1°25' to 5' I ± 1 mm (0.7878 in) 0.1811 to 1.7850 to 0.58 in) GL model: 340 to 360 mm (13.60 to 13.39 to 14.l870 in) 30.31 in) 265 to 290 mm*3 (10.04 in) 2 to 8 mm (0.18 in) .7848 to 0.63 in) -45' to 45' -3 to 3 mm (-0.052 mm (1.12 to 0.r.20 to 0.43 in) 245 to 270mm (9.8 mm (0. "'-' 0 CI.004 in) 30.05 mm (0.1831 to l.935 to 19.20 ± 0. WHEELS AND AXLES ITEM Damper strut Piston rod Bend limit Wear limit of outer diameter Outer diameter (TOKICO) Outer diameter (KYB) Outer diameter (SHOWA) Clearance between outer shell and piston rod STANDARD / .98 in) Measure the road clearance at center of front end face of the transverse link attaching bolt.94 to 19.28 mm (1.0 to 30.24 to 11. I SERVICE LI~IT -~ 0.80 to 13.08 to 0.63 to 11.1 mm (0. .l Inner cylinder Bend limit Wear limit of inner diameter Inner diameter (TOKICO) Inner diameter (KYB) Inner diameter (SHOWA) Oil quantity (4WD) (Other than 4WD) (4WD only) (4WD only) Posture adjustment Front Rear • Wheel Alignment Hatchback.7866 to 0.98 mm (0.39 in) 335 to 355 mm*5 (13. Measure the road clearance at lower face of the crossmember.2 mm (0.02 in) 280 to 300mm (11.·'----<~ SUSPENSION.81 in) OUT 5 ± 1 mm (OUT 0.:.7866 in) 19.12 in) 240 to 265 mm (9.20 in) 260 to 280 mm (10.19 to 13.0008 in) 19. 12.008 in) 0.42 cu in) 205 cm 3 (205 cc.17 in) 9-3 _ -.

_--- ..). - T135/70 DIS ' ..8.8.~: 216l:2..--.. i6-f " ". .8.38») Light -. . .. 155 SR 13 177 (1. 32) 216 (2. .-' Front Rear Hatchback (except 4WD') .+ 1135/70 DIS 4Tx 15 135:(l.26) - -.. .. "T135/70 D 15 _412-(4.8.32) 165 SR l3 ----------- x..2. " l}5/70 SR 13 d.5)JV -------- +------4T x \5 [35' .2..$...17)] Hatchback.. . '~~.38)f x 13 [55 (2.6. -. 26) ~------:~-----~-----~---­ :. . WHEELS AND AXLES • T.< 5-1 x 13 [55 (2.. (138)J ''1-.17)] 4~-J 412(4.... 4~-J x 13 [55 (2.type" tire (T135/70 D 15) for temporary use is prepared for 4WD vehicles as-a spare tire ..32) 177 (1.60) 177(1.60) 185/70 SR 13 -------- 177 (r8.. ~..11:"--!" . . . . . Hardtop (excepf4WD) Hatchback 4WD *1 177 (1.32) . . Load condition . Sedan and.17)1 -------- 4~-1 17T~1.. GL 1~?/70 SR ~3 . 'MOdel Rim size [Rim offset rom (inn STD 155SR13 DL ". - ~ L.""..~(..-~".~ . ./:i 5-J x 13 [42 (1.# '~C"L "'~.17)] -- GL .J3 [55 (2..2.38)] 5-J x [42 (1 4T x 15 [35 (1..8.'8:P6) j~ .r::t 177 (1.26) 175/70SR 13 5-J x 13 [55 (2. T13-5/70 D 15· 4T x 15 [35 (1. " 1111 .8.. .. 165 SR 13 --------- x 13 [55 (2..-' . 26) Full Load --------.8." .17)J ------ 4~-J .SUSPENSION. 26) F1)ll Load Light Load 177 (1._26) 216 (2.~re Si~8.•..'"~" "#I.~nd lnflati9J) Pressure . 26) Full Lood Light Load 177 (1.v.2.2.2.-.17)J 216 (2.

*er.2 .torque N·m (kg-m. i~~:::~ T1: Fig.. Inner bush Inner arm Sbock absorber Center arm Center arm bolt Helper Castle nut Pm .13..'1 1" ~ ~"".13.1 2. ft-Ib) ~ -93 (7. 65 "..: nt parts of rear suspension (Except 4WD) l.87) T3: 88 .9. 9-4 Component parts of rear suspension' (4WD) . 87 .:. 23 ...69).94) T4: 118-147112-15.65 . 54 . '..t . f 11 t' • 12 ·.. 65 . T2: 88-118 (9 -12. Rear SusPension.13 14 .4.0.87-108) T5: 31 ..] Inner bush Inner arm 9 Shock absorber 10 Helper @-----Q:!'. CD / \®f\~ l 1. 2 Rear:bailrli> .2 . Fig.:."".\"a' .147(12 -15.108) T5: 31 . ":Jl..39 (3..4. Tightening torque N·m (kg-m. WHEELS AND AXLES .87) T3: 88 .• susPeNSION..9. ft-Ib) T1: 74 .39 (3.94) T4: 118 . .0. -1 4' Cr()~cp ".>o.65 .4 Torsion bar 6 7 8 9 10 ~ OuHftlmsh .5 .4 .127 (9 .118 (9 . 3 Front bush'" . ::rrQhtening..93 (7..6..5 ""7.L:.! "'.-Q.~ . 23 -29) .29) ~~~~G Station Wagon only ..127 (9 . .69) T2: 88 .5.

. When removing or installing flare nut. (1) Install a bushing to leading rod.9-6 Installing direction of strut mount 2. (2) Install leading rod to rear crossmember. Removal 1) Disconnect ground cable from battery.. 5) Release parking brake. Inspection Check the removed parts for any wear. 12) Disconnect transverse link bush from front crossmember.1. 3.. '" . Torque (3. 2) Apply parking brake.4. and insert D. to drive shaft NOTE: a.39 N·m Torque (3. to differential spindle.i " SUSPENSION.1.3 kg-m. b. A15-076 Fig. ~. . 29 .. 27 . (3) Tighten self-locking nut. Self-locking nuts should be replaced with new one whenever it is removed.9-7 Inserting D. and remove front suspension assembly from body. 15) Loosen nuts connecting strut mount to body.4.. a plate and a self-locking nut. 2) Align the spring pin holes of D.O. 4WD vehicle and vehicle with power ( steering (HatchbaCk. 22 .0. 14) Remove castle nut and ball stud of tie-rod end.1. b. 9-8 A15-146 Fig. soak the bushing to the soap solution for easy installing the bushing to correct position. Installation 1) Install strut mount to body.. 8) Disconnect brake hose from brake pipe at apron bracket. at inner end by using a steel rod of 6 mm diameter. 36 . 10) Disconnect front end of stabilizer from leading rod. 7) Disconnect parking brake cable from brake caliper. 3) Loosen fron t wheel nu ts. Before installing the bushing to the leading rod.0 . use flare nut wrench without fail. 9-8 $2 .J. out of differential spindle. besides install a bushing.42 N·m NOTE: Take care of the installing direction of strut mount. and differential spindle.0 kg-m.1.0.O. support it with safety stands (rigid racks) and remove front tires & wheels.. . 13) Take out transverse link along with leading rod. 4) Jack up vehicle. 9-5 3) Install leading rod to rear crossmember according to the following procedure. ~ . then pull D. Sedan) and Hardtop Fig. Fit air bleeder cap onto brake pipe to prevent brake fluid from pouring. 11) Remove leading rod from rear crossmember.31 ft-Ib) ) Station Wagon..7 . damage and crack. Front Suspension 1. 9) Drive out spring pin of D. 6) Remove parking brake cable bracket from transverse link. NOTE: a. WHEELS AND AXLES 9-2.29 ft-lb) A15-011 Fig. and correct or replace if defective.O.

22 ft-lb) 13) Bleed air from brake system.'. adjust groove on the nut and hole on the ball joint by retightening the nut from 0 to 60 degrees.9 ft-lb) NOTE: a.0.1. 13 . 78 . 9-14 1 2 3 Bracket Leading rod Stabilizer A15-073 12) Install wheels. A15-070 . Make sure that the holes are aligned before driving the spring pin in.7.2 .95 kg-m. and differential spindle by driving spring pin in. 4.13 ft-lb) Fig.9-13 Installing hand brake cable bracket 7) After then.98 N·m (8 . Install the hand brake cable end to the caliper lever.2 kg-m. 18-3IN·m (1.0 . l2-l8N·m (1. there is possibility that the rubber bushing is pinched between the pipe and the washer. In case that the creaking noise breaks out during the self-locking nut fully tightening. Fig.72 ft-lb) Fig.4 .69 N·m (6. 43 .8 kg-m 9 . Torque ( self-locking nut) 59 . 58 . and bend it firmly.O. 8) Connect stabilizer front end through bracket to leading rod. 14) Lower vehicle and tighten selflocking nut which installs transverse link to crossmember. Torque Torque (Castle nut) 25 .10 kg-m. Then.3 N·m (0. WHEELS AND AXLES c.9-11 Installing tie rod end Fig. 9-9 .9. When driving the spring pin in. always use new one. Torque (Hand brake cable bracket installing bolt) 6. Fig_ 9-9 Driving spring pin in 5) Install transverse link temporarily to crossmember by using bolt and self-locking nut.. A15-078 A15-069 Fig.5 .8 .1 SUSPENSION. install new cotter pin into the hole.51 ft-Ib) 10) Install hand brake cable bracket to transverse link.6. NOTE: After tightening the nut to the specified torque. 9-12 A15-077 Torque (wheel nut) 9) Attach brake hose to apron bracket by using clip. loosen the selflocking nut at once and retighten the nut after centering the leading rod. 4) Connect D.3. 9-10 Installing transverse link 6) Install tie rod end ball joint to housing knuckle ann. and then connect brake hose to brake pipe.3. 18 .0 kg-m.0 kg-m.7 .29 N·m (2.23 ft-lb) Torque A15-015 II) Install hand brake outer cable by attaching outer cable clip to brake caliper.J.65 . b.

Specified free length: 319 mm (12. c. and check for lateral inclination of the vehicle. replace the coil spring. b. or other factors. Visual inspection Coil spring NOTE: a. NOTE: It is normal for a trace of oil to be oozing at the oil seal assembly. remove the coil spring and measure its free length. solid surface. Damping Force/Noise Rock the left side of the vehicle up and down. Damper strut Oil leakage Check for oil leaks at or around the lower portion of the strut and oil seal assembly. improper body alignment.56 in) d. Replace the dust cover if it is damaged. damage or deformity. Damage or Deformity Check the strut housing for any cracks. If the free length is not within the specification. Replace the coil spring if it is cracked. If vehicle inclination (to either side) is due to permanent deformation of coil spring. and then rock the right side. If any noticeable lateral vehicle inclination is detected visually. broken or damaged. Inspection and Adjustment for individual parts. determine whether it is due to permanent' deformation of coil spring (s). Make sure that all tires are inflated to the specified pressure. 9-10 . Regarding specific procedures Item to be checked Vehicle posture Description Remarks Park the vehicle on a level. Adjustment Make sure to measure wheel alignment when removing and reinstalling the suspension.( SUSPENSION. check the condition of the strut itself. s. refer to the applicable instructions set forth in this manual. Visual and tactile inspection NOTE: If the up-and-down movement (when hands have been released) continues longer than usual or if any abnormal noise is detected. Cracks. The following chart outlines the basic inspection and adjustment procedures for the entire front suspension system. Refer to instructions for inspection procedures. WHEELS AND AXLES 4. Wheel alignment should be adjusted or checked to the specified values. to check for noise or variances in vehicle posture.

axle and steering linkage and connection • Vehicle height [It is recommended that the difference of vehicle height between the front and rear ends. e. c_ If the side slip is not within the specified range but although the toe-in within the specified value. grease leakage etc. To increase toe-in.] • Stain. deformation etc. Refer to the Specifications for the specified toe-in. turn both tie rods counterclockwise equal amounts (as viewed from the outside of the vehicle). 9-15 78 . 58 . be sure to make a prior inspection of the following points and repair/replace the damaged portions/parts as necessary. and wheel bearings for plav.65 ft-lb) NOTE: a.39 in) in the unloaded condition. If toe-in is not within the specified value. assemble these parts in advance so that the toe-in is near the specified range_ b. Toe-in gauge Description Remarks 1 Lock nut 2 Tie rod Fig. WHEELS AND AXLES Item to be checked Preliminary Inspection Before checking/adjusting front wheel alignment. and repair or replace the part(s) if defective_ d. on front end parts Toe-in Adjustment Wheel alignment Loosen both the left and right lock nuts CD. check the steering gear box.SUSPENSION. • Tire pressure • Wear or damage of tires • Wheel balance • Looseness on suspension • Looseness and smooth operation on axle linkage and connection • Looseness and smooth operation on steering linkage and connection • Shock absorber operation and oil leakage • Damage. Alwavs a"ust the toe-in after steering angle adjustment. on body attaching portion of suspension. 9-11 . ball joints. Both the left and right tie rods are right-hand threaded. If the tie rod and the tie rod end have been disassembled.88 N·m Torque (lock nut) (8 . or the left and right sides is less than 10 mm (0.9 kg-ru. turn the left and right tie rods ® equal amounts until the toe-in is within the specified range. rust.

.. damage or deformity. Damage or Deformity Check the following parts for cracks. 9-16 @ A15-147 NOTE: a. To measure camber and caster... and make sure the vehicle is level.. place the wheel to be measured on the turning radius gauges CD.....SUSPENSION.J . deformed transverse link or faulty parts. if necessary. WHEELS AND AXLES Item to be checked Camber and Caster Description Remarks Neither camber nor caster can be adjusted. cracks or damage... (1) Strut mount to car body (8) Transverse link to (2) Damper strut piston rod to strut crossmember (front) (9) Crossmember to body mount (3) Damper strut to housing (10) Stabilizer to leading rod (4) Housing to ball joint (11) Stabilizer to (5) Ball joint to transverse link crossmember (rear) (6) Transverse link to leading rod (7) Leading rod to crossmember (rear) General Cracks. 9-12 ----.. Looseness Check each mounting portion of the following for looseness and inspect the castle nuts for missing cotter pins.... and then install the alignment gauge @.'~. Repair or replace the parts. Refer to the Specifications for the camber and caster values.". Wheel alignment (continued) Fig.-----------------~--------------.------.=. Set Adapter Assembly @ (925621000 for steel wheel) into the center of the wheel.. check for body alignment. (1) Strut mount (4) Transverse link bushing (2) Damper strut dust cover (5) Leading rod bushing (3) Ball joint boot (6) Stabilizer bushing Visual inspection \.-. (5) Transverse link (2) Damper strut (6) Leading rod (3) Housing (7) Stabilizer (4) Ball joint Visual inspection (1) Crossmembers (front and rear) Rubber Parts Check the following parts for deterioration.. If the camber or caster measurement is not within the specified range. b.

by compressed air. Start the job after cleaning around the oil seal assembly. support it with safety stands (rigid racks) and remove front tires & wheels. Front Suspension Damper Strut 1. Fit air bleeder cap onto brake pipe to prevent brake fluid from pour· ing. 17) Carefully return coil spring unscrewing Puller to the original position and remove Puller after spring is completely extended. sludge etc. When vising the damper strut at its connecting portion to housing. Inspection Check the disassembled parts for crack. vise it through something like wooden block to prevent it from damage. and replace with new parts if defective. 5) Release parking brake. 10) Remove nuts clamping strut mount to body. 7) Disconnect brake hose from caliper body. and detach brake hose. 9) Pull strut out of housing gradually and carefully with housing assembly placed downward.SUSPENSION. Removal and Disassembly 1) Disconnect ground cable from battery. 22) Remove inner cylinder slowly. 15) Remove thrust washer with oil seal and washer (thrust bearing). blow off any dust. NOTE: Fig. NOTE: A15·018 Fig. 8) Remove two damper strut installing bolts. 3) Loosen front wheel nuts. ~ 1 I 14) Pull strut mount out of rod. b. 23) Pour oil out completely by turning outer shell upside down. Clean them by using compressed air only. a. 16) Remove spring retainer (upper). Compress damper strut to its minimum length to prevent piston rod from damage. Whenever removing or installing flare nut. 6) Disconnect parking brake hose from brake pipe at apron bracket. and remove packing. c. Oil seal assembly If oil leakage is found around oil seal assembly while piston rod and inner cylinder are normal. 13) Loosen self-locking nut connecting rod of damper to strut mount by using Wrench [included in Puller & Wrench (925651000)] and 17 mm box wrench. 9-17 a. 2) Apply parking brake. 12) Hold damper strut assembly in a horizontal state. NOTE: Don't use thinner or kerosene for non· metalic parts. 4) Jack up vehicle. NOTE: 00 not strike rod of damper. and check if they move smoothly. check the following. 20) Pull out piston rod a little. b. 9-19 21) Pull out piston rod and rod guide. Fit the hook of Puller to the upper end of coil spring. 1) Damper strut 1) Insert inner cylinder and piston rod into outer shell. I NOTE: NOTE: If strut i~ rusted. 9-13 -----------------~) . 19) Remove oil seal assembly by using special tool (Wrench 925390000). damage and wear. A15·084 A15-086 Fig. replace oil seal as seal kit. Packing--(II4'l"'-"'" (O-ring) NOTE: a. 9-18 Don't pull out piston rod quickly or along with inner cylinder to prevent oil spillage.. Carefully turn in the thread of Puller and compress spring until the strut upper seat surface is separated from spring. apply sufficient "CRC" on housing and strut before pulling strut out. 11) Set damper strut assembly on Puller [included in Puller & Wrench (925651000)] . 24) After cleaning disassembled parts with thinner or kerosene. 18) Remove coil spring. Take care not to drop them. use flare nut wrench without fail. 2. 2) If not. WHEELS AND AXLES 9-3.

9-21 Measuring clearance Clamp outer shell. damage etc.1921 in) "SHOW A" 30.7866 .052 mm (1. WHEELS AND AXLES NOTE: Oozing out of oil is normal. 41b) of force upwards and downwards at its free end through spring balance. 2) If any scratch is found on sliding surface. Indication of dial gauge 0.28 mm (1. and pull out piston rod to its maximum stroke. distortion. (3) Check piston rod-to-outer shell total clearance as shown..30.:::3 10 mm 10. (2) Measure wear and bend as shown. Bend limit 0.01 mm (0.94 .. Set dial gauge.7867 in) "SHOWA" 19.02mm (0. Coil spring One having permanent strain should be replaced with new one. with referring to specifications.20 . 2) If distortion is found on its connecting surface to body.05 . replace it along with washer with new pair. 1 Cylinder gauge 2 Cylinder A15·093 Fig.004 in) "TOKICO" 30. b.935 . Bend limit Fig. and replace it with new one if defective. crack etc. and read dial gauge.7878 in) 4) Oil seal Check the lip of oil seal for wear.1831 in) (1) If leaked oil spreads to near spring seat.0008 in) "TOKICO" 19. Fig.SUSPENSION. crack • and deterioration.19. check piston rod carefully for damage.15 mm (U831 . uneven loading etc.19.0. (2) Oil leakage around welded portion at its lower end. 1 Dial gauge Bend Measuring 2 Piston rod 3 V-block c.05 mm (0. 1 Dial gauge 2 Inner cylinder A15·092 Wear Measuring 1 Piston rod 2 Micro meter A15·090 Fig.1 mm (0.7848 .7850 .30. (1) Check for wear and damage on inner surface and for bend. 3) Thrust washer 1) Check for wear.20. and replace it with new one if defective. damage and deterioration.98 mm (0. 2) Strut mount 1) Check rubber part for creep. 41b) ~~~~t :1g~.1811 . 9-20 Measuring piston rod 0. check coil springs for its free length. Outer shell Replace it with new damper strut if defective.30. (2) Measure bend and wear as shown. replace it with new one. and there is no necessity for replacing oil seal.0.98 .1.0 .031 in) d.8 mm or less (0. uneven wear and bend.9-23 Measuring bore of cylinder 9-14 . Wear limit Specified outer diameter 6) .1. When vehicle posture is uneven although there is not considerable reasons like tyre puncture..7866 in) "KYB" 19.981 mm (0. (I) Distortion.0020 in) 0.2mm (0. and apply 20 N (2 kg.1890 . and replace it with new one if defective. 9-22 Measuring of bend 5) Dust cover If any crack or damage is found.008 in) 0. Inner cylinder Replace it with new damper strut if defective.1. replace it with new one.1870 in) "KYB" 30. check piston rod as carefully as possible. (2 kg.39 in) A15·091 Wear limit Specified inner diameter NOTE: Since slight scratch can cause oil leak. Piston rod Replace it with new damper strut if defective. crack and damage.0.

All models exeept 4WD 205 em' (205 ee.12. Tighten oil seal assembly with piston rod being stretched to its maximum stroke. c. 5) Install rod guide assembly to inner cylinder fIrmly with care of not damaging it by thread of piston rod. 8) Set damper strut on Puller [included in Puller & Wrench (925651000)] . a. Be careful not to use glove or cloth to prevent it from getting dust. 9-27 Tightening oil seal assembly Fig. which is available as genuine parts "seal kit". NOTE: NOTE: NOTE: a.9-24 Pouring oil 4) Attach packing to rod guide as rod guide assembly. n . b. use special tool (lnsta"er 925380000) without fail to prevent oil seal lip from being damaged. 3) Pour oil into outer shell by using measuring cylinder. Use genuine grease contained in "seal kit" for respective make of damper strut. 7) Tighten oil seal assembly by using special tool (Wrench: 925390000) Be careful not to slip off spring. c. 9-29 Compressing coil spring 10) Stretch piston rod to its maximum stroke.42 eu in) Piston rod Packing Rod guide A15·095 a. When installing oil seal. b. and fit coil spring to spring seat correctly as shown. After installing.51 eu in) Oil quantity 4WD 220 em' (220 ee. b.87 ft-lb) Fig. be careful not to drop it or to damage by using plier etc. Fig. and turn thread of Puller to compress spring enough. Since all parts are made with accuracy. Use something like wooden block to clamp outer shell not to damage it. Measure oil with accuracy by using measuring cylinder. Be careful not to damage piston rod. compress piston ring slowly into cylinder by fingers not to damage it. CD ® spring 1 Installer (925380000) 2 Oil seal assembly A15-096 Fig. Apply grease to lip of oil seal. 9-28 Fitting coil spring Fig.118 N·m (10.9-25 Installing rod guide 6) Install oil seal assembly to piston rod with fitting Installer (925380000) on thread portion of piston rod. A15·097 1 Wrench (925390000) 2 Wood block Fig. make sure that packing does not rise from rod guide. b. Fig. NOTE: a.SUSPENSION. b. All5-0153 Torque 98 .9-26 Installing oil seal assembly 9) Fit hook of Puller near upper end of coil spring. WHEELS AND AXLES 1 NOTE: 3. c. 2) Insert inner cylinder with piston rod into outer shell slowly. NOTE: a. When inserting piston rod into inner cylinder. and install dust cover. 9-30 A 16-163 9-15 .0 kg-m. Assembly Damper Strut 1) Insert piston rod into inner cylinder gradually. Use always new oil. 13. Be careful not to spill oil. 12.0 . upper spring seat and thrust washer.

10) Apply parking brake. Torque Torque (Union bolt) 15 .0 kg-m.10.8 kg-m.98 N·m (8.4.0 . 13) Connect ground cable to negative terminal of battery. and temporarily tighten nuts clamping strut mount to body. Torque NOTE: Never use removed self-locking nut. 22 . and tighten wheel nuts temporarily.29 ft-Ib) Fig.5 kg-m. 9-32 Fig. 11) Tighten wheel nuts. and replace it with new one.13 ft-lb) NOTE: Be sure to position oil seal lip to face to coil spring.4. 9-34 12) Bleed air from brake system. 59 -74 N·m (6. 9-36 A15·072 f I I Torque Torque 29-39N·m (3. NOTE: Take care of installing direction of strut mount 2) Push and set stru t into housing gradually and carefully.0 .0 . 1 2 3 4 5 Washer Oil seal Thrust washer Piston rod Upper spring seat A15-100 Bol t installing damper strut bracket to housing Bolt clamping damper strut to housing 29 . 9-35 A15·082 12) Install oil seal and washer assembly on to thrust washer. 43 .0 kg-m. 15) Tighten self-locking nut by using Wrench (included in Puller & Wrench (925651000)] . 22 . Fig.0 .7.4.0 kg-m.2 .(r-- SUSPENSION.39 N·m (3. NOTE: Apply grease on oil seal lip and sliding surface of washer.39 N·m (3.29 ft-lb) 29 . 5) Clamp brake hose with clip on damper strut. 4. Installation 1) Set strut assembly in position.5 . 7) Connect brake hose to brake pipe at apron bracket. 3) Tighten two damper strut installing bolts.54 ft-lb) A15·083 Fig. 9-31 Installing oil seal etc. 58 .29 ft-lb) 8) Install another side damper strut in the same manner. 6) Connect brake hose to caliper body. 13) Install strut mount to piston rod. 78 . 9-33 o } ' 4) Securely tighten nuts clamping strut mount to body.0 .72 ft-lb) Torque (Wheel nut) A1S-076 A15-Q84 Fig. 11-14ft-lb) NOTE: Always be sure to use flare nut wrench. Fig. 22 . and remove it. 9 . 12-18N·m (1. WHEELS AND AXLES 11) Install washer into oil seal with facing grinded surface of washer to lip side of oil seal. 9) Install tires and wheels. 14) Loosen Puller (included in Puller & Wrench (925651000)] gradually. and tighten self-locking nut temporarily.0 kg-m.0 kg-m.20 N·m (1. 9-16 . and lower vehicle after taking ou t rigid racks.2.1.

WHEELS AND AXLES 9-4.9-37 Stabilizer 1. NOTE: Fit a cap onto carburetor to prevent inside of bore from dust. and remove front tires and wheels. Installation Reverse the removal procedure. 4) Jack up vehicle. ® I II 2) Stabilizer Cracks at curved portions. ~-11~ 1'1 . and remove spare tire and wheel. 2) Apply parking brake. 18 . 2) Remove bolt at stabilizer front bracket. Front Crossmember 1. 3) Loosen front wheel nuts.31 N·m (1. Removal 1) Disconnect ground cable from battery. 10) Remove transverse link from front crossmember. 4) Remove brackets and bushings from stabilizer. 13) Lift engine assembly by approx. 14) Remove crossmember installing nuts with crossmember supported by jack. Removal 1) Jack up body at the front.3. Torque Bolt at front bracket Fig. Stabilizer 2. 9-17 11) Remove cushion rubber from crossmember. 10 mm by using chain block.2 kg-m 13 . support it with safety stands (rigid racks). Inspection Check and replace if defective. 9) Remove front exhaust pipe. 7) Remove parking brake cable bracket from transverse link.3. 6) Remove air cleaner assembly and pitching stopper rod. b.23 ft·lb) Nut at rear bracket 9-5. 12) Disconnect steering torque rod from pinion shaft. Stabilizer rear bushing on rear crossmember should be installed by aligning the bushing inner end with the marking on the stabilizer. and remove crossmember downward gradually along with steering gear box. \ 1 2 3 4 5 6 Stabilizer Leading rod Stabilizer front bracket Stabilizer front bushing Stabilizer rear bracket Stabilizer rear bushing A15-160 NOTE: a. . ® 1) Bushing Cracks. 13 .23 ft-Ib) 18-31 N·m (1. 8) Remove cotter pin and castle nut of ball stud on tie-rod end. 5) Remove stabilizer.SUSPENSION.4--I\' II " \ 11 \ 11 @ \\ " " " 3. deterioration or sticking.2 kg-m. 5) Release parking brake. 3) Remove nuts at stabilizer rear bracket.8 . Each bushing must be fitted firmly and fixed with tires on the ground and with no load on the car. and detach tie-rod from knuckle arm.8 .

20 N·m (1.5._------- ~J 13) Connect ground cable to negative terminal of battery.._ ..-_ _ _ _. castle nut and bolt to remove ball joint.0 kg-m. 941 Torque (Bolt) 1.. 7) Connect tie-rod end to knuckle arm of housing..1 . 9-40 A15-077 9·6..51 ft-Ib) -_.24 ft-Ib) -----~ 20-32N. 18 .... Installation 1) Install ball joint onto housing. and any defective part must be replaced...0 kg-m.'O:.. 29 ft-lb) 2.2. WHEELS AND AXLES 2.4...-'~_"''''''+.. 11) Apply parking brake and lower vehicle to the ground...0 kg-m. 43 ._ _ _ _ _ _ _. ..0 -.. and replace it if necessary.... b.14 ft-Ib) . 4) Tighten nuts attaching engine mount cushion rubber to crossmember. 6) Install front exhaust pipe.I . 29 . then insert new cotter pin and bend it around castle nut. 9-18 3) Retighten castle nut further until a slot in castle nut is aligned with the hole in ball stud end.0 kg-m. and lower vehicle.0 . Removal 1) Jack up body at the front to remove wheels. (2. ~..36 ft-lb) NOTE: Check crossmember for cracks and/or damage. 22 . 2) Lower engine assembly by operating chain block.-_ _ _ _ _ _ _I _ _ _ _ _ _- .3... 3) Tighten self-locking nuts connecting steering torque rod and pinion shaft..._ _ _ . The ban joint and boot that have been removed must be checked for wear...SUSPENSION. [ :---1 Torque -'- 59 . .4 . 10 -..5. .4) Install front wheels. .. NOTE: a..n~J ---~--. 12) Tighten nut connecting transverse link to crossmember to the specified torque. Torque (Castle nut) 39 N·m (4.. 2) Connect ball joint to transverse link. damage or crack... 9) Attach air cleaner assembly and pitching stopper rod.. Pay attention not to stick grease to tapered portion of ban stud.b".0 .-- Torque (Castle nut) 8) Connect parking brake cable bracket to transverse link.7.49 N·m (2.. .0 kg-m. Torque 14 -..4. 9-38 A15-104 Fig. 14 -.1. 9-39 A15·103 5) Connect transverse link to crossmember by temporarily tightening nuts for transverse link bushing.69 N·m (6..39 N·m (3.. Fig... Fig. ... Installation I) Set crossmember along with steering gear box in position and carefully support them with a jack.-.29 ft-Ib) A15-161 Fig.. 25 .'.. ----_. ...3 kg-m. Ball Joint 2) Remove cotter pin. _---] 10) Install front tires and wheels.

Support rear differential with jack. a. Rear differential . b. 9-43 Installing torsion bar to outer arm d. and job will be easy. damage. NOTE: Using a steel bar of 6 mm (0.i SUSPENSION. support it with safety stands (rigid racks) and remove rear wheels and tires. b. Removal and Disassembly 1) Remove the two bolts attaching shock absorber upper end to body.Remove 4 nuts installing rear differential at its front end to rear crossmember. 14) Remove bolt and nut connecting inner arm and crossmember. Spring pins at both ends of drive shaft. 9) Lower jack gradually and draw out from beneath vehicle body with rear suspension assembly on it. NOTE: Since transmission oil will flow out when propeller shaft is pulled out from transmission. 3) Loosen rear wheel nuts. 9-42 A4·124 2) Apply parking brake. tire etc.O. Wear. Inspection Inspect disassembled parts for followings. 13) Remove torsion bar from outer arm. prepare appropriate cap and oil catcher in advance of above job. Rear axle shafts on both sides . a. loosen bolts with extension bar supported by tire outer surface. NOTE: Put dismounted rear suspension assembly on soft material like rag. distorsion. Then remove inner end of drive shaft.. gradually drive out spring pins.J. to prevent brake backplate and/or brake drum from being damaged. f. Fig. NOTE: a. 2) Install outer arm along with torsion bar with adjusting engagement of serrations of torsion bar with crossmember and outer arm.Remove outer D. 5) (4WD only) Remove following parts and detach rear drive system. 8) Support rear crossmember at its center with a jack. crack etc.24 in) diameter. To prevent oil flowing out. Rear Suspension 1. c. Insert air bleeder cap to brake hose end to prevent brake fluid from pouring. NOTE: If any damages or cracks are not found in visual check.. 9-19 . and pull out propeller shaft slowly.. and remove four bolts holding rear crossmember. 10) Remove floating bush (except 4WD).J. 12) Remove outer arm along with torsion bar. of drive shaft from rear axle spindle by pushing inside D.-. as inner end of torsion bar engages with serration of crossmember..-. e. c. pay attention not to bend or twist torsion bar. corrugated paper. a. b. 1 Outer bush 2 Torsion bar 3 Outer arm A15·121 Fig.. insert appropriate cap immediately. 3. Assembly 1) Engage outer serration of torsion bar with outer arm temporarily. NOTE: NOTE: When pulling off outer arm from crossmember. perform color flaw check (dye penetrant investigation) on peeled or corroded portion. Four bolts connecting propeller shaft to rear differential. All thread for damage or distorsion. 7) Remove brake hose from brake pipe at inner arm side bracket (on both sides). use suitable flare nut wrench only.Set oil catcher at rear end of transmission. 4) Jack up vehicle. WHEELS AND AXLES 9·7. so that outer arm comes to appropriate position. Oil leakage at lower portion or oil sealing portion of shock absorber. vehicle should be in the unloaded condition. b. and carefully dismount rear differential.O. of drive shaft fully toward rear differential and pushing brake drum downward. Self-locking nuts connecting rear differential mounting member to body g. 2. 11) Remove shock absorber. Whenever removing or installing flare nut. 6) Remove exhaust pipe (front and rear). Propeller shaft . At this time.

Fig. 9-49 Aligning holes A15·162 Fig.93 N·m (7.9-47 Installing shock absorber 118 -147 N·m (12 .51 in) diameter of bar into holes on crossmember bracket and body frame to facilitate the job by aligning the holes.108 ft-lb) 4. A15·119 Torque L -_ _ _ _ _ _ _ _L -_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 74 .69 ft-lb) Torque Fig.9.147 N·m (12.9-45 Installing inner arm Fig.0 .5. 65 -.18 N·m (1. 9-50 A16-117 5) Connect inner arm and outer arm.2 . 54 . 87 . Torque 88-118N·m (9.8 kg-m. Torque 118 .15. Fig.15 kg-m.13 ft-lb) / CD A16-116 ® NOTE: Use suitable flare nut wrench. Installation 1) Support rear crossmember at its center with a jack. and set it in position.1.9-48 Supporting rear crossmember 1 2 3 4 Connecting bolts Outer arm Inner arm Crossmember A15-163 Fig. 4) Install inner arm to crossmember. 9-46 Connecting inner arm and outer arm NOTE: When setting crossmember to vehicle body. 9 .12. 9-51 . 9-20 Fig.5 kg-m. 87 -108 ft-lb) Torque 12 . 9-44 Temporarily locking outer bush 2) Tighten the four bolts holding rear crossrnember at both ends.0 kg-m. 6) Install shock absorber to inner arm at lower end of shock absorber. 3) Connect brake hose and brake pipe on both sides.0 kg-m. WHEELS AND AXLES 3) Temporarily lock outer bush with lock bolt.0 .SUSPENSION. insert 13 mm (0.87 ft-lb) A15·126 Fig.

0. Instal1 propel1er shaft onto rear differential. and then connect with three cushions. 18-25N·m (I. Set rear differential in position with a jack. Al1 models except 4WD: Tighten bolts connecting exhaust pipe (rear) along with muffler and exhaust pipe (front).2 .94 ft-Ib) Torque Torque 5) (4WD only) Install rear differential as follows.127 N·m (9. A15-l07 Fig. a. 23 .3 . 78-98N·m (8.5. 9-54 1 Connecting bolt 2 Cushion Fig.8 .5 kg-m. 4WD: Tighten bolts connecting exhaust pipe (rear) and exhaust pipe (front).3 kg-m.0 kg-m. Fig. 9-57 A15-ll0 Fig.0 . d.0 . 31-38ft-Ib) b.0 kg-m.3 .52 N·m (4.8.4.0 kg-m.3 kg-m.5. steel bar.2. and tighten the four nuts. 31-39N·m (3. 9-55 A4-123 Torque 69 -78 N·m (7. Insert rear drive shafts on both sides onto rear axle spindle and rear differential. 9-52 A15-ll2 c.0 kg-m. 8) Tighten wheel nut firmly.SUSPENSION. 9-58 10) Tighten outer bushing lock bolts with vehicle unloaded. Connect rear differential mounting member to body.29 ft-Ib) Torque A1S-lll Fig.38 ft-Ib) Torque Torque 9) Connect shock absorber upper end to body on each side with vehicle unloaded. 31 . 42 . 9-53 Fig. 88 .0 kg-m. Insert propeller shaft carefully in to rear end of transmission. Then connect with three cushions. 13 .0 .52 N·m (4. Torque (Self-locking nut) 69 -78 N·m (7. 58 -72 ft-Ib) b.13. and exhaust pipe (rear) and muffler. 7) Lower vehicle after taking out safety stands (rigid racks). 51-58ft-lb) e. 42 . Drive spring pins in at both ends of drive shaft gradual1y by using 6 mm (0. a.10. 51-58ft-Ib) f. WHEELS AND AXLES 4) Install exhaust pipe (rear) and muffler in position.24 in) dia. 65 .18 ft-Ib) 6) Install front tires and wheels by temporarily tightening wheel nuts. 9-56 A15-l09 9-21 . Torque A15-l08 Fig.8.

cv. 3) Remove bush by using a press. and replace if defective. WHEELS AND AXLES 11) Always be sure to check and 3) Installation 1) Removal adjust the following: a.. and engage it with inner serration of crossmember or center arm. When installing torsion bars. 3) Press bush into bore until end surface of outer tube of inner bush corresponds to upper end of boss of inner arm.."'TJ. Rear wheel alignment 1) Set inner arm on the press bed through base of installer and supporter as shown so that axis of bore of inner arm becomes vertical. 2) If no defect is found. after two torsion bars in both sides of crossmember are removed. and the torsion bar and outer arm can be removed.. 1) If any flaw is found. confirm color of paint (R.. NOTE: Center arm is adopted on 4WD models only.~~~~I. 2) Set inner bush and shank to bore 3) Installation 1) Apply grease to inner serration and outer serration of torsion bar. 9-22 "-. remove outer arm along with torsion bar from dismounted rear suspension assembly.._ _ _ _ _ _ _ _ _ _ _ _ _ _ _. of inner arm. L.-r...yellow. 1) Set inner arm boss end on base 2) Fit shank CD to outer tube of inner bush. 1 Shank A15·129 2 Base 3 Inner arm Fig. . .H. 2) Inspection 3 Base 4 Inner arm A15-132 Fig. Torsion Bar and Center Arm 2) Inspection Check for crack and damage.-. green) on outer end of torsion bar..~-~_.SUSPENSION.H. NOTE: S.H.._ _ _ _. touch up it with black paint after rasping.. one and L. insert center arm into crossmember.""._ . one will result early breakage of them. 1 Shank 2 Inner bush When disengagement of torsion bar from inner serration of crossmember is difficult. Do not confuse a torsion bar with another one.. 3) Insert torsion bar engaged with outer arm into crossmember. . 1) To remove torsion bar. tap outer end of opposite torsion bar with wooden hammer..H. Rear vehicle height c._ _ _ _ _ _ _ _ _ _ _ _~-_-_. replace it with new one. 2) For 4WD model Center arm can be taken out of crossmember. 9-59 Removing inner bush NOTE: 6.... 9-60 Setting inner arm on press Check removed torsion bars and center arm for crack at its peeled and/ or corroded portion by means of visual check and color flaw check.J . 2) For 4WD models. Confusion between R. Air bleeding of brake system b. Inner Bush 1) Removal Remove inner bush using Bush installer (921390000) as follows....

. ture. 3) Front posture is adjusted by turning four (4) adjusting nuts on the both sides of the struts. Fig.11. NOTE: a.) ( 21 mm (0.. 9-62 Adjusting nuts width across flats.60 . Maximum adjustable height NOTE: a.. Check and/or adiust the toe-in of front wheels to the specified value after turning the adjusting nuts of front strut..18 in) A15-122 I) Measure height of crossrnember pipe lowest point from the ground.61 in) --- m I I I m I I DL Station Wagon 4WD & Brat GL '------------ 265 .-.98 in) 270 .l SUSPENSION.11..17 in) Maximum adjustable height 2-door Hatchback 4WD only upward 30 mm (1.295 mm (10.42 in) 2) If "h" dimension is out of the specified range in the above table. b. 9-61 b.61 in) _.. turn the both nuts on one side of the strut by the same times.290 mm (I0.11.19 .63 -..43 .355 mm (13. adjust "h" dimension according to following method. WHEELS AND AXLES 9-8.345 mm (12. Before adjusting the vehicle pos- 1._---- I) Check the ground clearance by measuring between front end of transverse link attaching bolt and ground.58 in) 335 .290 mm (10..80 13. 9-63 Measuring "H" dimension 9-23 - ------ --------------- j I .13.. Rear Posture Adjustment Vehicles Specified ground clearance "H" STD GL DL Station Wagon 4WD & Brat GL 320 -340mm (12.42 in) -------- only upward 25 mm (0.. ("H" dimension)._-_. GL 270 ~ 295 mm (10...63 ~ 11.83 in) A1S-062 A15-130 Fig.. Adjustment of Posture (4WD Models Only) Ground clearances of front and rear suspensions of 4WD vehicles can be adjusted according to the following procedure. When turning the adjusting nuts.39 . Place the vehicle under unloaded condition on the flat ground. check air pressure of the all tires and adiust to the specified pressure if necessary.. 2.39 in) 325 . f----.13... Front Posture Adjustment Vehicles Specified ground clearance "h" STD 2-door Hatchback 4WD --265 .43.98 in) 340 -360mm (13.14. Fig.

9-24 ~"":. 3) Jack up the vehicle body and remove wheels.. 15) Install shock absorber.. 9-64 9·9. adjust "H" dimension according to following method. 9) Rotate torsion bar and outer arm to shift matching of inner serration by appropriate pitches....tk~'..91 in) respectively. to vehicle body. Therefore.. 12) Connect outer arm and inner arm by installing three bolts.1 . NOTE: Pay attention not to disengage inner serration of torsion bar from cross· member. Change in this distance shows a half of change in rear road clearance caused by adjustment.. 6) Mark on outer bushing.'''·'''''''--I'''II·''''' _ .. 19 mm (0... and then measure in the same manner as step 7). shifting the matching of inner or outer serration by one pitch causes change in rear road clearance by 68 mm or 74 mm (2.. 14) Install wheels..75 in). with brake drum supported by a jack or the like to prevent brake hose from damage.... Service hole on vehicle floor 2 Adjusting bolt of center arm [width across flats.... and rotate outer arm to opposite direction to shift matching of outer serration by appropriate pitches.--------------~-- ___ . by shifting the matchings of inner and outer serrations in opposite directions... various adjustments can b. crossmember and torsion bar so as to identify their original positions... 17) Confirm that rear road clearance is properly adjusted. WHEELS AND AXLES 2) If "H" dimension is out of the specificed range in the above table.. 16) Install lock bolt of outer bushing... and engage inner serration with crossmember. and determine numbers of teeth to be shifted on inner and/or outer serra· tions. 1) Measure rear road clearance..e made. 0 • .. ""'-.. and put the vehicle down on the ground.tM>4<-:~~":'''"i.~~"~. Adjustment with rear suspension mounted on the vehicle can be made as follows... Since numbers of teeth of inner and outer serrations are 37 and 34 respec· tively and distance between torsion bar center and wheel center is approx.t". Adjustment of Rear Road Clearance Rear road clearance can be adjusted also by changing engagement of inner and outer serrations of torsion bar. 3) To adjust rear posture. 2) Remove the bolt which attaches shock absorber to the body at the top of shock absorber.. 4) Remove lock bolt of outer bush· ing.SUSPENSION. 11) Install outer arm to trosion bar and crossmember. 5) Remove three bolts connecting outer arm and inner arm..75 in)] A15-102 Fig. 7) Measure vertical distance between end of outer arm and vehicle body. 13) Carry out same work on the other wheel.-----------------. turn ad· justing bolt from service hole provided on vehicle floor... 400 mm (15.. 8) Pull out outer arm together with torsion bar until inner serration is disengaged completely.68 or 2. 10) Pull out outer arm from torsion bar. Turning to clockwise increases vehicle height and turning to counter· clockwise decreases it.

0 . Except 4WD CD Tightening torque N'm (kg-m. 58 .n ® 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Housing Bearing Oil seal Axle shaft assembly Spring pin Spacer Disc cover Spring washer Bolt Disc rotor Hub complete Center piece Washer spring Axle nut Cotter pin A16-147 Fig. 9-65 Component parts of front axle • Rear Axle 1.WHEELS AND AXLES 9-10.6 -1. WHEELS AND AXLES .72) ® 1 2 3 4 5 6 7 8 9 10 11 12 13 Spacer O-ring Oil seal spacer Oil seal Inner taper roller bearing Brake drum complete Hub bolt Wheel nut Outer taper roller bearing Lock plate Lock washer Axle nut O-ring Cap A 16-148 Fig. 145) T2: 6 -14 (0.10.9-66 Component parts of rear axle (Except 4WD) 9-25 .98 (8.0. ft-Ib) T: 78 . ft-Ib) T1: 196 (20.3 -10.4.4.SUSPENSION. Component Parts • Front Axle ® Tightening torque N'm (kg-m.

.5.5 . 5) Release parking brake.. 145) ----------------. boot.J. \~ \\ \ A16·152 10) Remove ball stud connecting transverse link with h\l\lsing.Y..9-69 Removing strut 9-26 . 6) Disconnect parking brake cable from brake caliper..9-67 Component parts of rear axle (4WD) 9-11. 127 .22. ft-Ib) T1: 172 . Tightening torque N'm (kg-m.-! A16-149 Fig. 3) Remove front wheel cap and cotter pin.. Fig. support it with safety stands (rjgid racks). 4) Jack up vehicle. 7) Remove disc brake assembly from housing....r SUSPENSION.---------. Housing 1. 9) Remove cotter pin and castle nut.. 9·68 Removing brake ASSY 8) Remove two damper strut instal· ling bolts.221 (17. II) Disconnect strut from housing by opelling slit of housing and by lowering housing gradually with care of not damaging C. 4WD CD 1 Packing 2 Rear spindle 3 Inner 0 il seal 4 Ring nut 5 6 7 8 9 10 11 Bearing assembly Outer oil seal Brake drum complete Center piece Spring washer Axle nut Cotter pin . and loosen castle nut and wheel nuts.wheels. WHEELS AND AXLES 2. and remove front tires and. and hang it from a strut with string.163) ----T2: 196 (20... Removal 1) Disconnect ground cable from battery.. and disconnect ball stud from knuckle arm by using a puller. A16-156 Fig. 2) Apply parking brake.

2) Set bearing onto Punch (Installer: 4 Spacer Fig.~ 1 Pre. Do not reuse the oil seal. 1 A16-158 Fig.--- ----~-- --- _. 14) Pull housing off axle shaft. 1 Punch A16-162 2 3 3.'the inner race. b.. 4) A pply an aluminum bar or a brass bar to the inside surface of outer race of inner bearing. A 16-160 1 2 Housing Punch 3 4 Bearing (Outer) Die I 2 Punch Oil seal (Outer) 3 4 Housing Die Fig.35 to 0._. 9-76 Press-in of oil seal 9-27 --. 3) Turn upside down housing. 9-75 Press-in of bearing Press is necessary in assembling. 2) Apply an aluminum bar or a brass bar to the inside surface of inner race of au ter bearing._-. otherwise the bearing will be damaged. 7) Insert oil seal into the groove of Punch so that the oil seal lip faces the groove. 2 Housing 3' Die A16-196 Fig.----- . and apply about 10 to 13 g (0. be care"l.5·164 Fig._-------------- . 9-73 Press-in of bearing Fig.-----_. 1) Move up or down spacer by finger. and take out disc and hub assembly. I NOTE: a. 9-70 Removing housing 3) Pu II ou t spacer. A••embly 1 Housing 2 on seal 3 Bearing A16-195 Fig. 6) Set housing on Die. 13) Remove disc cover. b.SUSPENSION. 9-74 Inserting the spacer 5) The other bearing is pressed in as shown in figure. When knocking the bearing. to apply the bar on all aroun.-. I. spacer and oil seal 925140000) and gradually press it into housing till outer race of bearing comes to contact with stopper. WHEELS AND AXLES 12) Remove castle nut on axle shaft. 9-72 Removing outer bearing Puller (921122000) 1 Spacer Al. Do not knock the bearing by a hard material. Lightly knock the bar by a plastic hammer to drive bearing out of housing together with oil seal. . 9-71 Bearing. Apply sufficient grease on the lip of the inside of oil seal. 1) Set housing on Die (Installer: 925140000). Disassembly NOTE: a. 2. 4) Insert spacer. Lightly knock the bar by a pJastic hammer to drive bearing out of housing together with oil seal. and gradually press it into housing till the face of Punch comes to contact with bearing outer race..46 oz) of bearing grease into inside of housing. be careful to applv the bar on all around the outer race. When knocking the bearing.

I df 1 Torque J 6-14N·m (0. 6) Install disc cover to housing with one bolt. 9-28 . 36 . further tighten castle nut within 60° to align holes of castle nut and ball stud. 11) Fit center piece.51 ft-Ib) Fig. 9) Insert oil seal intq the groove of Punch so that the oil seal lip faces the groove. Torque 29 .39 N·m (3.1 ft-Ib) 7) Install disc and hub ASSY onto axle shaft. 9-78 Installing transverse link ball stud After tightening to the speCified torque. then insert a new cotter pin and bend it around axle nut. 9-80 Installing ¢lamper strut 9) Connect hand brake cable to brake ASSY.39 N·m (3. Fig.22 ft-Ib) Fig.3.3 . 9-82 Fig.1.69 N·m (5. 4. 9-79 Installing "qusing I 1 2 Die A16-164 4) Connect damper strut and housing by installing two bolts. Then insert cotter pin into ball stud and bend it around castle nut.10. Torque A16-166 49 .0 . 8) Install brake ASSY to housing by two bolts. 3) Turn the handle . InstaUation 1) Fit housing onto axle shaft and attach spacer of Installer (925130000) on outer bearing inner race taking care not to damage the oil seal lip. 18 . thus housing is pushed in. Then. 22 .5 . 10) Apply hand brake. A16-168 Fig. and gradually press it into housing.4 kg-m.29 ft-Ib) 5) Connect tie-rod end and housing knuckle arm.0 kg-m.*hile holding the rod end by means .0 -7. 9-77 Press-in of oil seal 4.6 .0 kg-m.29 N·m (2.0 . 22 .4.29 ft-Ib) Torque 29 . conical spring washer and axle nut in this order onto front axle shaft and tighten castle nu t to the speCified torque.4.SUSPENSION.0 kg-m. 9-81 A16-167 Installing brake ASSY Fig.0 kg-m. Torque (Castle nut) 25 . spanner. 2) Install transverse link ball stud to housing. WHEELS AND AXLES 8) Turn upside down housing and set it on Die turned upside down also. connect the rod of Installer to the thread of axle shaft so that housing does not drop off from axle shaft.

a. \ Paint mark 12) 13) 14) tive Install wheels and wheelcaps. inner race. 11) Pull out C. 2. The grease is a special grease (grease for constant·velocity joint).J. b. Disassembly 1) Straighten bent claw of larger end of D. 9-85 Removing circlip Check the removed parts for damage. 3. disassembly of axle is completed. Removal 1) Disconnect ground cable from battery. transverse link and damper strut.J.O.OJ. wear. 4) Jack up vehicle. boot in the same manner. boot. corrosion and etc. If faulty. boot. 9) Take out D. 9-83 Installing axle nut 9·12. To remove the cage from the inner race turn the cage by a half pitch to the track groove of the inner race and shift the cage. by using special pliers. 5) Pry and remove round circlip located at the neck of D.O. Connect ground cable with negaterminal of battery.J. .O. 2) Loosen band by means of screw· driver or plier with care of not damag· ing boot. Do not confuse with other greases.Y. boot. which fIxes inner race to shaft. 145 ft·lb) side No< • R.J. support it with safety stands (rigid racks). 6) Remove parking brake cable bracket from transverse link. cage from shaft and remove D.O. 9-84 Removing boot band 3) Remove boot band on the small end of D. outer race with a screwdriver. 7) Drive out spring pin of D. 2) Apply parking brake. 7) Wipe off grease and take out balls and move cage to the boot side. "'''" Yo side pi. Front Axle Shaft 1.J. 12) Thus.J. 10) Take off D. Put down vehicle from rigid racks.Y. retighten further within 30° until a slot of the castle nut is aligned to the hole in the axle shaft.SUSPENSION. 9-29 ____________________J . 9) Remove axle shaft from differ· ential spindle along with housing. and loosen castle nut and wheel nuts.O. but C." Cotter pin 2 Castle nut 3 Washer spring 4 Center piece A16-197 NOTE: Connect leading rod to transverse link if it was disconnected on removal. 10) Remove housing from axle shaft by using Puller (921122000). 4) Remove the larger end of D. 6) Take out D. 8) Remove disc brake assembly.J. and disconnect tie· rod . and remove front tires and wheels. outer race from shaft ASSY.OJ.O. Washer spring Fig. boot with care of not damaging it. 8) Remove C-type snap ring.J.O. Inspection A18·018 Fig. Torque 196 N·m (20kg'm. 3) Remove front wheel cap and cotter pin. c. Disassemble exercising care not to lose balls (6 pcs). WHEELS AND AXLES NOTE: After tightening the nut to the spec· ified torque. repair or replace. is unable to be disassembled.J. 5) Release parking brake. NOTE: A16-198 Fig.

. 9-30 '~"'~. exercise care so that the air within the boot is appropriate. and ftll it with 60 to 70 g (2.J. 9-90 Installing circlip 1) Install C. (Double Offset Joint) Check seizure. to inner race fixed upon shaft.~ .OJ. Assure that the balls.47 oz)ofspecified grease. boot in specified position. . Cage 6) Insert six balls into the cage pocket. WHEELS AND AXLES 1) 110. When installing D.O...--""""!.-liI~. NOTE: NOTE: Confirm that the C-type snap ring is completely fitted in the shaft groove.-_ _ __ *I .. c..1.71 to 1. Fit the cage with the protruded part aligned with the track on the inner race and then move by a half pitch. Exercise care not to place the matched position of circlip in the ball groove of outer race. 7) Fill 20 to 30 g (0.VJ.O.J.OJ. NOTE: 4.-_ _ _ _ _. 2) Shaft Check excessive bending. 60 g (2.11 to 1. 13) Put a band through the clip and wind twice in alignment with band groove of boots.--'4#n.l2 to 2..06 oz) on the cage pocket A16-018 Fig. wear and excessive play.1. boot..OJ. b.. (Constant Velocity Joint) Check seizure. damage and wear..019 Fig. damage and excessive play.71 to 1.VJ. cage and balls are previously installed. corrosion. cage and inner race are completely fitted in the outer race of D. 4) Install D. -___I _..OJ.06 oz) of specified grease. 4) Boot Check wear. A16-200 Fig. Assembly NOTE: Use specified grease..... position outer race of D. b... 8) Align the outer race track and ball positions and place in the part where shaft. corrosion. 4. Apply the specified grease 20 to 30 g (0. 4Z . Specified grease for constant velocity joint Molylex No. warping and breakage. ..71 to 1.. "~_' . cage onto shaft. a. 3) Insert D. inner race.I . outer race. 11) Fill the boot interior with 20 to 30 g (0.O. since the cage has an orientation. 1 2 Outer race Grease When tightening boot.- -1j."..O. 9) Install circlip in the groove on D. outer race.. 14) Pinch the end of band with pliers. and then fit outer race..'s interior. 9-88 Installing cage 10) Add 20 to 30 g (0.J. outer race with approx.SUSPENSION. Pull the shaft lightly and assure that the circlip is completely fitted in the groove.060z) of specified grease to the D. b. boot at the center of shaft. 9-87 5) Install cage. . damage.V J. . inner race on shaft and fit C-type snap ring with special pliers. 9-89 Inserting outer race 15) Tighten band by using Band Tightening Tool (925091000).. 12) Install boots on D._ _ _ _ _ _ _ _ _ _.OJ. . Also apply grease on the shaft area. The boot grooves shall be cleaned so as to be free from grease and other su bstance. at center of its travel. twisting.2 (pIN 623029980) a.J. NOTE: a._ _ _ _. . A16.12 oz) of specified grease while yawing the joint.9-86 Cage of D. which was preViously fitted. Also fill the interior of C. NOTE: A16-199 Fig.06 oz) of specified grease into the interior of D..O. NOTE: Use a new band. Fig.J. NOTE: Insert the cage with the recess facing the outside. 3) C.O.. 2) Place D.. Hold the clip and tighten securely..

9-95 Installing disc hub I A15·015 Fig. 2) Connect the rod of Installer to the thread of axle shaft and turn the handle while holding the rod end by means of a spanner.1..0.29 ft. 22 . conical spring washer. Installation 1) Insert axle shaft into housing and attach spacer of Installer (925130000) on outer bearing inner race taking care not to damage the oil seal lip. WHEELS AND AXLES NOTE: a. b. thus axle shaft is pulled in.10. and tighten two bolts.0. hand brake cable. 6) Install disc cover on housing with one bolt. 3) Align the spring pin holes of 0. 5) Connect damper strut to housing. 4) Connect 0. NOTE: a.I SUSPENSION. brake hose. and differential spindle.~-~ -- ~-~ --. 10) Install wheel caps in position.39 N·m (3. Installation". 7) Install hub and disc ASSY to axle shaft.J. ! I A16-169 A16~170 Fig.1. Torque 29 .3 . 9) Install wheels and tighten wheel nuts.. 9-91 Installing boot band 15) Tap on the clip with the punch provided at the end of Band Tightening Tool. center piece.----- --~---~--~--. cotter pin. and differential spindle by driving spring pin in.1.V. Torque 6 -14N·m (0. Fig. 4. always use new one.lb) 8) Install or connect disc brake ASSY. 9-31 ~-~~ - -~--- -~ .6 . 9-92 Installing axle shaft Fig.0 kg·m. axle nut. in the same manner.1 ft·lb) NOTE: Tap to an extent that the boot under· neath is not damaged. 12) Connect ground cable with negative terminal of battery. tie rod and transverse link according to the same procedure of "9-11 Housing .4 kg-m. 9-94 Connecting damper strut A16-201 Fig. Make sure that the holes are aligned before driving the spring pin in. b. 17) Fix up boot on C.~ . 16) Cut off band with an allowance of about 10 mm (0.4. When driving the spring pin. 11) Put down vehicle from rigid racks.0 .. 9-93 Driving spring pin in 5.- - ~- - . Former Band Tightening Tool (925090000) is interchangeable with this 925091000.39 in) left from the clip and bend this allowance over the clip.4. Tighten band until it cannot be moved by hand.

opening. 4) Separate transverse link from crossmember by removing the fixing bolt.~<. clean the balls..J.O.J.OJ...J. ' . __. a. Remove front exhaust pipe. 9-96 Removing front exhaust p.O.O.O. 10) Remove boot from axle shaft ASSY. A4-093 Fig. 11) Clean grease thoroughly from axle shaft splines. to axle drive shaft and pull out D. .O. cage and inner race itself.J._.. Fig. from axle drive shaft 1 2 Outer race Grease A16-019 6) Raise the staked ends of boot band on both the large and small ends of D.O.[lIII~llc".1. 13) Clean grease thoroughly from inside D. O.1.. inner race from axle shaft ASSY 7) Slide out the large end of boot from D.... boot with a screwdriver and remove bands.J. 3) Remove front exhaust pipe...O..J.. outer race.9-99 Removing D.¥""'I:.r '. circlip NOTE: Clean the axle shaft splines.. Boot of Front Axle Shaft 1._. Replacement 1) Release parking brake and raise vehicle using recommended lifting points.. ~-_n_"_''''!''''fm ___""'. A 15-165 8) Pull out D.q''''. Replacement of D. by hand. . Loosen nuts which connect front exhaust pipe to engine and hold its flanges loosely on engine.. Disconnect front exhaust pipe from rear exhaust pipe and bracket.O.OJ.O.. 12) Disassemble inner race. _______'..._ . WHEELS AND AXLES 9·13. 2) Disconnect oxygen (0 2 ) sensor cord. inner race on axle shaft ASSY with special pliers and pull out inner race from axle shaft ASSY.( SUSPENSION._~'''''''-------_---. 9-98 Separating D. 9-97 c. A15-166 Fig./D. Fig.~~. inner race and outer race with a brush and cleaning solvent 9-32 -~.-____ • .1.O.J.pe from engine b. boot bands A15-167 Fig.11f7lf-·-·-T"..9-100 Removing D.. outer race from axle shaft ASSY. outer race and pry out circlip from the groove near the D. 5) Drive out spring pin which secures D.9-102 Removing D.. A22-061 Fig.J. 9-101 9) Remove snap ring which secures D. .O.. A16-018 Fig.J.

lock plate and brake drum so as not to drop inner race of outer tapere roller bearing. components 1 ! 9-14. NOTE: a. Outer bearing. WHEELS AND AXLES 2. Assembly".J. 9-103 Assembling D.SUSPENSION. 6) Remove outer race of inner bearing from drum.O. 1) Put a new small boot band on axle shaft. 5) Remove spacer and inner race of inner bearing with a gear puller. Confirm that circlip is completely fitted into the groove by pulling axle shaft outward lightly. 14) Lower vehicle on ground. I I CD A 16·172 1 Outer race of inner bearing 2 Outer race of outer bearing A16-203 Fig. Remove oil seal at this time.06 oz) of specified grease to the boot interior and fit the large end of boot onto outer race. 9) Apply 20 to 30 g (0. aligning the former's ball tracks and balls in cage.J. after prying them by screwdriver. Confirm that the circlip ends are not positioned in any of the ball tracks of outer race. 9-104 Removing spacer and inner race of inner bearing Fig.'s interior. outer race. 8) Apply 20 to 30 g (0. 4) Apply 20 to 30 g (0. 2) Fit a new boot in position on axle shaft.O. Specified grease for constant velocity joint Molylex No.06 oz) of specified grease to the D.71 to 1. Rear Axle (Except 4WD) 1.06 oz) of specified grease thoroughly to the inner surface of D.71 to 1.J. NOTE: When tightening boot. exercise care so that an appropriate amount of air remains in boot. 5) Fit six balls into the cage pockets.71 to 1.9-105 Removing outer race of inner bearing 9-33 ) .O. 12) Connect transverse link with crossmember. 6) Apply another 20 to 30 g (0. 10) Secure the boot ends in position with new small and large bands in accordance with the tightening procedure of "9-12 Front Axle Shaft 4. Clean the band grooves on boot if they are stained with grease or other substance. and loosen rear wheel nuts. then remove lock washer. Removal and Disassembly 1) Apply parking brake. outer race of inner bearing and oil seal can be removed together with drum. 13) Mount front exhaust pipe using new gaskets and connect oxygen (0 2 ) sensor cord.O.J. Fit circlip A15·168 Fig. 3) Pry brake drum cap by screwdriver off drum.060z) of specified grease to the cage pockets. support it with safety stands (rigid racks) and remove rear tires and wheels. 3) Install inner race with cage oriented correctly on the axle shaft splines and secure it by fitting snap ring into the groove of axle shaft with special pliers.71 to 1. II) Install D. and fit circlip in the groove of outer race.2 (P!N 623029980) 7) Install outer race over inner race. onto axle drive shaft aligning their spring pin holes and drive in a new spring pin. 2) Jack up vehicle. 4) Flatten lock washer and loosen axle nut. b. Reassembly NOTE: Use specified grease.

Stepped su rface of the spacer must be faced toward the bearing.9-106 Installing outer race of inner bearing Inner race of inner bearing 2 Spacer 3 O-ring CD @ A16-206 A1S-177 Fig. b.14. '. If faulty.87 .- "'. 6) Install drum. damage and corrosion. Jl· .3. . Fill the hub of drum with approxi. 1.20 lb) NOTE: Apply a little amount of grease to the lips of oil seal.1. 3) Press outer race of outer bearing into drum using tapered roller bearing installer (921130000) and a press.r SUSPENSION.. Inspection Clean the removed parts and check them for wear. Fig. repair or replace. ~j_.lO A16-205 4) After installing a-ring to drum cap. bufFH '1 1Iti IIIiii' 'wmxiV .·. and then turn drum bac k and forth alternately several times to properly seat bearing and ascertain bearing stability.34.45 kg. mately 30 g (1. NOTE: Be su re to use new spacer D-ring without fail.85 . . and turn back nut a little. Measure the starting force as shown. NOTE: Be sure to use new lock plate and new lock washer without fail. Fig. 4) ApplyapproximateJy4g(O..kM.' . Assembly and Installation I) Press outer race of inner bearing into drum using tapered roller bearing installer (925120000) and a press. 3) Bend lock washer. WHEELS AND AXLES 7) Remove outer bearing from drum.9-110 Measuring starting force NOTE: Never exceed the load to the bearing as it may damage it 2) Install oil seal into drum until its outer end is flush with the drum surface. 9-108 Installing spacer and inner race of inner bearing Recommended starting force when measured at hub bolt 8. 9-111 O_L=:-.9-107 Installing outer race of outer bearing NOTE: a. / 3. race of outer 2.- .14oz) of grease to inner bearing and 3 g (0.I~~'. Be sure to use new O-ring. Fig. lock plate. 9-109 Adjusting preload of bearing 2) Turn back nut 1/8 to 1/10 in order to obtain correct starting torque. spacer and inner race of inner bearing onto the spindle of trailing arm. install cap to brake drum by lightly tapping with plastic hammer.11 oz) to outer bearing.g. lock washer and axle nut in this order onto the spindle. Adjusting Rear Wheel Bearing I) Tighten axle nut with tightening torque of 49 N·m (5 kg-m. 9-34 A16-202 Fig. 36 ft-Ib).~~ ·jl 4. Spring balance Fig.22 N (0. Do not use steel hammer etc. inner race of outer bearing.06 oz) of grease. 5) Install spacer a·ring.

18) Remove inner race of inner bearing from spindle by using a press.s by using a steel rod of 6 mm diameter.SUSPENSION.9. 5) Jack up vehicle.38 in) in inner diameter while tapping it with a hammer.O.OJ. Installation NOTE: 1) Install inner race of inner bearing on to the spindle. and press inner race of outer bearing from outside by using a pipe of 35 mm (1. 87 .93 N·m (7. and install outer races of inner bearing and outer bearing and spacer by using press.15. 4) Loosen locking bolts of crossmember outer bushing. because removal of bearing might damage the bearing. 8) Remove outer D. from spindle of trailing arm with trailing arm lowered fully. NOTE: Be sure to renew the oil seal.5 . Inspection Inspect wear and damage of the removed spindle.0 .221 N·m (17. IS) Extract spindle inwardly by tapping it from out side with a plastic hammer. WHEELS AND AXLES 9-15. then remove ring nut by using special tool (Wrench 925550000). NOTE: Apply grease sufficiently on the inner and outer bearing area. 4) Install ring nut to housing. NOTE: Don't remove bearing outer races when replacement of bearing is not necessary. from differential spindle. 7) Drive out spring pins of inner and outer D.5 . Fig.9-113 Staking housing NOTE: 11) Remove brake assembly from trailing arm. . Inner bush bolt Torque 74 . then remove inner D.06 oz) to bearing outer race in housing. 2) Apply grease of 20 to 30 g (0.71 to 1.108 ft-Ib) NOTE: Be sure to replace the oil seal at every overhaul. and straighten staked portion of housing. 13) Remove three bolts. brake drum and bearing.5 kg-m.147 N·m (12. 14) Vise inner arm. NOTE: If a bearing is faulty. NOTE: Be sure to renew the oil seal. 16) Remove oil seal. 8) Mount inner arm to vehicle body. Don't confuse orientation of bearing ou ter races. Removal 1) Apply parking brake. 10) Disconnect brake pipe from brake hose. 127 -163 ft-lb) Inner and outer arms connecting bolts 9-35 . 3) Detach shock absorber from inner trailing arm.1.5 kg-m. muffler and exhaust cover in that order.22. replace it as the bearing set. A16-188 Fit air breather cap onto end of brake hose to prevent brake fluid from pouring out. and loosen castle nut and wheel nuts. 3. 3) Insert spindle from inside. 5) Lock the ring nut by staking a point on the housing surface facing the ring nut groove. 7) Install inner oil seal by using special tool (Installer 925530000). 9-112 Tightening ring nut 2. spacer and outer bearing by pushing inner race of outer bearing through the spindle by a press.0 kg-m. 2) Remove· rear wheel cap and cotter pin. and take out inner arm. Rear Axle of 4WD 1. '>I!~ Torque 172 .69 ft-Ib) 118 . 6) Install outer oil seal by using special tool (Installer 925530000). 12) Remove bolt holding inner bushing of inner trailing arm.OJ. support it with safety stand (rigid racks) and remove rear tires and wheels. Wrench (925550000) A15-169 Fig. 54 . and extract outer race of inner bearing. 17) Insert spindle from out side of housing. 6) Remove castle nut and brake drum. 9) Remove rear exhaust pipe.

16) Install packing to rear spindle. 9-118 Installing D.O. Inner D. 9-36 I. take care not to mount the inner D."""'"__' '_'________-''''"-_______. Be sure to renew the spring pin to be driven in. mate the spline teeth properlv so that the D.. oppositely.. WHEELS AND AXLES 9) Install rear brake assembly to inner arm. b. tighten further within 30° to align holes on nut and spindle.J.. Before driving in the spring pin. and connect brake pipes etc.O.. b.. _1 . When mounting the rear drive shaft assemblv. 15) Engage 0.J. and spindle spring pin hole will align.O.. Bleed air from four wheels without fail. Outer D. NOTE: a. and outer D..O.O. A16·189 Fig.. Before bleeding brake system. . 14) Install packing to differential spindle.51_..'''''_'~''·.J. ~4"""""""'~..0. 9-116 Installing castle nut NOTE: a..~ .s respectively.·.5mm ++If--+-+(2.. 12) Bleed brake system. 10) Connect brake hose and brake pipe.r SUSPENSION. insert cotter pin and bend it firmly with foot brake applied to lock the wheel and axle. 9-114 13) Tighten castle nut. and mount 0.O. ~. when mounting brake drum is not a fault. washer spring and castle nut to spindle in this order. Don't confuse orientation of washer spring. . of rear drive shaft to differential spindle. NOTE: After tightening castle nut to the specified torque.J. ·. Cotter pin Castle nut Washer spring Center piece A16-197 1 2 3 4 Fig. .1_.1.. . 11) Temporarily fit brake drum.J.J.l. NOTE: a. A16-106 70. b.0.O. b.J. aint 17) Drive spring pins in to inner and outer D. . • Center piece side side Washer spring NOTE: a.1. on rear drive shaft onto spindle with trailing arm lowered all the way.. .. When mounting.. Play on spindle experienced... center piece. A16·107.9-117 Inner and outer D.. A16183 Fig.-___-''"'''''_____ . check pedal play and brake fluid level in reserve tank.".O.~_·'''112.776 in) dia. ·~ tt" - . and spindle cD®@@ mark ~ '.. Fig. .~ Nut. confirm alignment of the holes. I I 1t • F: • .

0039 in) Limit Fig.'/' . and oil seals.0035 in) Limit 1 0. ----------~- -----------. 9-120 gK IlgN·m Torque (9 65 12 kg-Ill. When reassembling the rear drive shaft assembly. bring the gauge indicator point to rest <lgainst the 11<1 t surface <It the spindle outer end.06 mm (0. After taking uff wheel. measure the play in the folluwing procedure. Disassembly and reassembly procedure of rear drive shaft is the same as that of front drive shaft.~~ (0.OJ.15 mm (0. mud in the hearing case.0059 in) Fig. To do this./1 ' Fig. oppositely. attach dial g<luge stand tu t railing arm <lnd measure the pl<ly <It <lxle. bearings. b. Checking Rear Axle Each part of axle must be checked carefully before and during overhaul to locate any possible cause of trouble. take care not to mount the inner O. If excessive play is evident. While pushing and pulling the companion flange <It the hack. 9·121 I f the reat! ing excceds the standard limit. 2) Move wheel in and out and right and left to check its play. 9-37 . Stan~a~_d~I_. and make necessary adjustmcnt or replacclll en t. and install lower end of shock absorber. Lower vehicle on the ground. wear of spindle.O. 21) Tighten outer bushing lock bolts. A damaged bearing. Free play at periphery of drum. Locking bolt I A16·067 . 19) 18) 4. and so on are possible c<luses of such trouble. outer arms. 9-122 Measuring pia V at ax Ie (in axial direction) Install wheels.-. and outer D.------.) [I' there is abnorlllal noise or if the rotation is not smooth.0024 in) 0.--- --------------- Free play back at axle (in axial direction) -. I) Jack up body and turn wheel by hand to check it s rotation. check the torque of axle nut. Also check the play at the drum periphery by holding the top and bottom of drum and moving in and out alternately at the top and bottom.J.10 mm (0. WHEELS AND AXLES NOTE: a.SUSPENSION.9-123 Measuring play at periphery of drum --". check dial gauge readings. i)7 rt-Ib) 20) Check and adjust rear vehicle hight and rear wheel alignment.. (At the same time make sure drum does not touch shue. Dial gauge A 16·1)66 Fig. disasselll ble and examine axle carefully. etc. 9-119 Fig. Standard A 15162 0.

remove the wheel nuts after jacking up the vehicle. refer to the section "1-9. 3) Large crack on side wall. Unbalanced wheel does not greatly influence vehicle operation at low and medium speeds. Inspection Check removed wheels for followings. damage or crack on tread and tread wear. If the use of such a tool is unavoidable. Wheel 1. type and load range as originally installed. Tire tread -- -. 3) If the flange portion of wheel rim is deformed or damaged. . replace it with a specified new one. I) Damage and/or warp of rim. Avoid mixing radial. belted bias or bias tires on the vehicle. replace or repair if defective. first apply the parking brake and place a tire stopper under the front or rear of one wheel.r SUSPENSION. This force causes "steering wheel shimmy" or what can otherwise be termed steering wheel instability.:~ " >~: ~'l ? Fig. When jacking the car up by using a garage jack. S. 2) Damaged or warped rim may cause air leakage from tire. and turn the jack handle slowly to jack car up. force proportional to the increase in the wheel revolu tion is applied in the direction indicated by the arrow. 1) Avoid using a hammer to prevent damaging disc wheel and tire.. b. . the steering system can be influenced.9-124 Loosening wheel nuts 2) Set jack at the correct jack-up point. so pay attention to the following. make sure to use only the same size. Disassembly Tubeless tires are prepared for all SUBARU vehicles. and wheel repair work. lateral slippage. glass. however. WHEELS AND AXLES 9-16. Pay special attention to removing and reinstalling tires. ~ t-- ~ • • 1>0. Since damaged or warped rim may cause air leakage from tire. i Ii ~. uneven wheel wear due to insufficient air pressure. that is. tire should be removed or installed carefully not to mar the bead of tire. The tire should be replaced.'-f! OM-656 NOTE: When replacing a tire. I) Loosen wheel nuts with a wheel nut wrench. To prevent possible accident. lifting Points and Procedure". when the "tread wear indicator" appears as a solid band across the tread. A16·207 Fig. make sure the jack is set at the correct position on the flange of side sill. Tread wear indicator 4. Wheel Balancing A16-045 II . so check rims periodically.~ ~ . NOTE: a. replace it with a specified new one. b. . OM-58l Fig. 4) Install a snap-in valve into the valve hole of wheel rim properly not to leak air. 2) Take stone. 2) If the bead section of tire is damaged. 3) As scratched bead of tire may also cause the air leak from tire. as illustrated below. At 60 km/h (37 MPH) and over. 3.. 9-125 Jack-up points Unbalanced wheel (including disc wheel and tire) can result from improper wheel alignment. Always apply the parking brake before jacking up the vehicle. When jacking the car up. Removal On a level and solid place. be sure to check static and dynamic balancing of wheels. ~: 9-38 .. After tire exchange or wheel repair work has been performed. I) Be sure not to damage wheel rim and tire. and then proceed to remove wheel and tire by removing wheel nuts completely.~. off the tread groove. nail etc.••.9-126 Tread wear indicator '- . NOTE: a. 2. use a rubber hammer. Assembly Pay attention to the following.

76 oz) (0. 3) Handle the disc wheel fitting section of balance weight carefully because it is easily damaged. This rise amounts to an increase of up to 20% at times. steering instability is likely. along with insufficient braking.SUSPENSION. as shown. . Do not use air impact tool to tighten the wheel nuts. 9-129 8. as air pressure increases as tire temperature rises during vehicle operation. a. do not apply oil to wheel nuts th read section of bolts nor tapered seats of wheels.F' Amount of unbalance Centrifugal force resulting from unbalance A16·043 Fig. 723141010 723141020 723141030 723141040 723141050 723141070 723141080 723141090 723141100 723141 I 10 10 g 20 g 30g 40 g 50 g 5g 15 g 25 g 35 g 45 g (0.71 oz) (1. WHEELS AND AXLES There are various ways to correct wheel unbalance. air pressure must be adjusted to the prescribed value when tires are cool. uneven wear results. b. fur steel rim --'~'-------'-- OM-534 Weight Fig.35 oz) (0. or before starting vehicle. Tire Rotation If tires are maintained at the same positions for a long period of time.42 oz) at rim flange 78-98N·m (8. various forms of damage may result. NOTE: When replacing or reinstalling wheel.59 oz) c.w' F. abnormal wear is promoted. On the other hand. various forms of damage. and at such a high pressure the ride is uncomfortable. use wheel balancer. ~---~------ Parts No. 2) Firmly seat wheel on arbor. retighten wheel nuts to the specified torque after first 1.23 oz) (1.060z) (1. loss of drive power. increased fuel consumption.72 ft-Ib) A16-210 Fig.53 oz) (0.0 .180z) (0. As shown in table on page 9-4. 9-130 Order of tire rotation 9-39 . When tightening wheel nuts.0 kg-m. exceSSively low air pressure in tires may result in abnormal wear. etc. they should be periodically rotated. 2) Lower vehicle slowly by turning the jack handle.41 oz) (J . be careful of the handling. 4) After installing balance weight. NOTE: When operating a wheel balancer.000 km (600 miles) running. The balancer shaft must be aligned with the center of wheel to be corrected. w. Installation F' A 16·042 Fig. Allowable dynamic unbalance Torque 12 g (0. position it in the groove of disc wheel.10.9-128 Installing balance weight 7.88 oz) (1. Therefore. This lengthens service life of tires. Tire air pressure must be adjusted in accordance with these conditions. Tighten the wheel nuts in the order .9-127 Wheel unbalance I) Fit wheel over drum bolts. Wheel should be statically and dynamically balanced. 3) Sufficiently tighten wheel nuts in the above-mentioned sequence. and thread on four wheel nuts with a wheel nut wrench. Adjusting Air Pressure 6. etc. I) Correctly install hub nut. To correct precisely wheel unbalance. 5) Use genuine balance weights. 58 .

When rotating tires. "T -type" Tire "T-type" tire for temporary use is prepared for 4WD vehicles as a spare tire.~ kg/cm 2 • 60 psi). a. replace it with the standard tire as soon as possible.. When wear indicator appears on the tread surface.SUSPENSION. b. WHEELS AND AXLES NOTE: a. replace tire with new one without fail. replace uneven worn and damaged tires by new ones. -. Drive it as slowly as possible to prevent running over bump and/or hump on off-road. ~) Notes for maintenance of "Ttype" ti re. c Do not drive it with 4WD engaged. a. l t fPliiPIl . A1S-211 A1S-209 Fig. d. tire rotation is as follows.9-132 T-type tire I) Precaution when driving with "T-type" tire fitted. Do not drive it in a speed more than 80 km/h (50 MPH) on highway. b. 9. Ensure to keep the int1ation pressure always at 41 ~ kPa (4. 9-40 F T . b. Since this "T-type" tire is only for temporary use. 9-131 Fig. In case "l·type" tire for temporary use is prepared as a spare tire.

. 31 . Possible causes Countemleasures" (1) (2) (3) (4) (5) (6) (7) (8) Breakage of torsion bar Large deformation or loss of helper Over inflation pressure oftire Wrong vehicle posture Fault in operation of shock absorber Damage or deformation of shock absorber lower end bushing Unsuitability of maximum and/or minimum length of shock absorber Deformation or loss of bushing Replace Replace Adjust Adjust Replace Replace Replace with proper parts Replace ..----~ (3....-..._.-•..... ..........-----------------------------~ Possible causes f .. _ _ _ _ _ _ _ _ _. _ .'_ _ _ _ _ _ _ _.. Suspension 1) Wrong Vehicle Posture Possible causes Countermeasures (1) Permanent distorsion or breakage of torsion bar Replace (2) Unsmooth operation of shock absorber Replace (3) Wrong installation of inner arm Re-install (4)_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _..4..... -_.. 23 -. Fig.retightening lock bolt CD to the specified torque.2 .. Deformation of inner arm Replace L ...._ _ _..0 kg-m.. add lock bolt CV and tighten it to the specified torque.' 3) Noise -----------. .._.. Large shock in bumping .SUSPENSION..-_ 2) Bad Comfortability 1) 2) 3) Large rebound shock Rocking of vehicle continues too long after running over bump and/or hump. _ . Replace with proper parts Install new one Replace Retighten to the specified torque 9-41 .. 9-133 1LCV Lock bolt ... WHEELS AND AXLES • TROUBLESHOOTING 1. -CD Lock bolt (equipped) A15-170 -._.... Countermeasures Replace Replace Retighten to the specified torque......._------.. When noise does not stop after .-.39 N·m (I) (2) (3) Wear or damage of shock absorber component parts Damage or deformation of shock absorber lower end bushing Loosening of outer bushing lock bolt }-' --/1{ ~0fJ' Torque \ ...29 ft-lb) (4) (5) (6) (7) (8) (9) Deformation or loss of bushings Loosening of inner arm bracket Unsuitability of maximum and/or minimum length of shock absorber Loss of helper Breakage of torsion bar Loosening of each bolts and/or nuts Replace Retighten to the specified torque.

9-142 A16-046 ~ QJ? Fig.0. 9-141 '0 A16-047 925140000 Installer Housing Bearing 925220000 Installer Brake Drum Bearing (Inner) 925530000 Installer Oil Seal (4WD) 925550000 Wrench Rear Axle Ring Nut (4WD) ~ Fig. Boot .1 (~l. 9-134 0U 0 A 15·135 I A 15-134 ~ I A15-133 Hc:==:(dl Fig.~ ~'f) Plate (2) ST-172 ~~ I CD ® ~ [ r-.V.-'-:-~ " rA '"'- Fig..I . 0 -0 '::~ ~~"1 . hili' 11" f l' b t' '" 1 l' . 9-138 Fig.1. ~ t . 9-136 2. Jig for band -. Wheels and Axles 921122000 Puller Housing 921130000 Installer Brake Drum Bearing (Outer) 925091000 * 925130000 Installer Housing Band Tightening Tool 0... 9-145 EJ -. 9-139 2 Shank Base .. 1 f A16-053 * Former Band Tightening Tool (925090000) is interchangeable with this 925091000. Ratchet wrench A16-052 Fig. 9-42 l' . 9-135 Fig. Suspension 921390000 Bush Installer Inner bush of inner arm 925380000 Installer Damper strut oil seal 925390000 Wrench Damper strut oil seal 925651000 Puller & Wrench Damper strut Fig. .SUSPENSION. 9-144 - A16-154 Fig. 1 " .1. WHEELS AND AXLES eSPECIAL TOOLS 1. 9-137 ST·174 Fig. 9-143 A16-151 D\ t t ~~ Fig. Boot C. 9-140 A15-171 Fig..

............. 10..... 10-27 HILL-HOLDER 1.. 10-32 6....5..................2.. 10...... 10..................4 REAR BRAKE .9..... II SPECIAL TOOLS .....................3......................... 10-29 2........... 10~ 10............... Construction and Operation .........................8................ 10-20 REPLACEMENT OF BRAKE FLUiD .............. 10.................... Troubleshootmg ......4...... 10-10....................6.............. 10-15 BRAKE BOOSTER (Master-Vac) ................... 10-24 TROUBLESHOOTING ................ 10.....1.............2 FRONT BRAKE ... 10-17 PARKING (Hand) BRAKE .... 10-31 3.................................................. 10-35 . Component Parts ..................... 10... 4........... 10-22 BRAKE LINE ............ Installation . 10.............................. 10-33 7.......... 10-12 MASTER CYLINDER ... 10-32 5... Removal ............. 10...... 10-32 BRAKES 10.. Inspection .........................CHAPTER iJ@ Page SPECIFICATIONS AND SERVICE DATA ..... 10-33 10-11........................ Adjustment•...........

77 x 3.2 x 2 sq in) 38 x 2 cm 1 (5. 10.161 in) Built-in 180 cm 3 (180 cc.9 x 2 sq in) Automatic adjustment Drum (Leading-Trailing) 180 mm e? . Type Effective diameter 152. Hatchback.82 x 0.5 mm (1.87 mm (5/8 in) 17.98 cu in) Vacuum suspended -. Specifications and Service Data ~~ ITEM Type Effective disc diameter Effective cylinder diameter Front brake Lining dimensions (Width x length x thickness) Lining surface area Clearance adjusting mechanism Type Effective drum diameter Wheel cylinder effective diameter Lining dimensions (Width x length x thickness) Lining surface area Clearance adjusting mechanism Type Master cylinder Effective diameter Maximum stroke Brake fluid level indicator Brake fluid reservoir capacity Brake booster (MasterVac) f---.09 in) 15.35 in) Inner: Outer: 40 x 2 cm 1 (6.70 x 0.8 mm (7 in) Dual circuit system Mechanical on front brake Brake line Parking brake type * Station Wagon 4WD AT & BRAT 4WD AT: Ventilated disc 10-2 .BRAKES 10-1.18 x 5.24 in) 53.20 in) 42 x 2 x 2 cm 1 (6.64 mm (13/16 in) 29.55 x 0.5 x 2 x 2 sq in) Manual adjustment Tandem 20.97 mm (2.35 in) 45 x 94 x 9 mm (1.46 mm 01/16 in} Rear brake 30 x 141 x 5 mm (1.f-.77 x 3.4 mm (6 in) 177.1248 in) Inner: Outer: 45 x 97 x 9 mm (1. Sedan and Hardtop Station Wagon and BRAT Disc (AD type)* 184 mm (7.

....) 725807000 Part Number ' .------------------------ Brake fluid pressure with engine running and vacuum at 66. c....865 kPa (70 kg/cm 2 .......550 kPa (26 kg/cm 2 .........39 in) 15.------...........610 in) O...... Use fresh 00T3 brake fluid when replacing or refilling the fluid. When brake fluid is supplemented.----------.....5 mm (0.5 ... 995 psi) 1------...- ----------.492 in) 18mm(0..-..5 mm (0.20 in) 182 mm (7.. IO mm (0...059 in) t--------------....17 in) 1.--........59 in) 12....-------..-.. DOTJ NOTE: a.......024 in) Hill-holder Thickness Adjusting shim 0 (One shim increases an angle of approx.--..-----------...............--------------------- At brake pedal force 147 N (15 kg..---------BRAKES -~------- l \ "---Fin A17-300 Fig..j 0.. 10-1 Ventilated disc rotor ITEM Front brake (Disc type) Pad thickness (including back metal) Disc thickness Solid disc Ventilated disc Disc run-out Inside diameter Lining thickness Brake fluid pressure without engine running STANDARD 15 mm (0. 116.--------.---------------.+ .......1 3 to 4 notches/245 N (25 kg......--. 0.---.---......4 mm (6 in): 5... be careful not to allow any dust into the reservoir.. 55 lb) Lever stroke Parking brake 1 ..69 inHg) 1--------+-----------------.432 kPa (35 kg/cm 2 .....09 in) 5 mm (0.. Avoid mixing brake fluid of different brands to prevent the fluid performance from degrading... 853 psi) 177.-..5 mm (0.5 mm (0......295 in) 10 mm (0.... 66 Ib): 152.. 10-3 ......8 mm (7 in): 6...------------. 57 psi) At brake pedal force 294 N (30 kg..' • Recommended Brake Fluid FMVSS No. 66 Ib): 2.... 19......... b......--........0039 in) -----1 ~-------+---------------------------+-------------~----~- Rear brake (Drum type) Brake booster (Master-Vac) 180 mm (7..7 kPa (500 mmHg. 498 psi) At brake pedal force 294 N (30 kg....71 in) SERVICE LIMIT 7. 33 Ib): 392 kPa (4 kg/em 2 .. 370 psi) At brake pedal force 147 N (15 kg.' . 33 lb): 3......884 kPa (60 kg/ cm 2 ..--------------.------------..- -------------------.6 mm (0.....

-.6.0.49 (3..12 -17) T4: 49 .2. "" f . 10-2 Component parts Guide pin boot Air bleeder screw Air bleeder cap Lever & spindle Spring pin 11 Cap ring 6 7 8 9 10 14 15 16 17 18 19 20 21 22 Return spring Connecting link Bolt ASSY Bracket Spindle O-ring Cone spring Snap ring Support 23 24 25 26 27 28 29 30 31 32 Outer pad Inner pad Lock pin boot Sleeve Lock pin Shim Outer pad clip Inner pad clip Lever cap (upper) Inner pad clip A17-301 10-4 .6 ....69 (6.6) T2: 37 . Front Brake 1.36 .1 j j •• ~~+~ ~ t i'1:*1-.0. .51) I Caliper body 12 Lever cap 13 Garter spring 2 Boot ring 3 Piston boot 4 Piston seal 5 Piston Fig.6.8 . 6. 27 .9 (0."~ili"... .BRAKES 10-2.. il ~. ft-Ib) T1 : 7 .7 .1 . i.9..36) T3: 16 . Component Parts Tightening torque N·m (kg-m.7.~ .0 .0.24 (1..4..

10-5 NOTE: 8e sure to apply Silicon Compound (125191050 or 003606010) to guide pin and lock pin without fail.. hoi.......I Icon Compound 1725191050 or oo36OB0101 NIGLUeE RX·2 gr. 1725191040 or oo36OB0001 Inne' wall of bushings on caliper body In lever cap fitting groove at the rear of c. 1725191040 or 003606000) Silicon Compound 1725191050 or 0036060101 Silicon Compound 1725191050 or 0036OB0101 Around O-ring In the groovI Ift.for. inNrting it into the hole Fig... 1725191040 or 0036OB0001 Around . pin b.. 1725191040 or 0036060001 NIGLUBE RX·2 gr... cap ring In groove of lever & spindle to be fitted to lever cap A17·302 Fig.round lever" spindle S . of cilliper body Around sleeve before fitting boot Silicon Compound 1725191050 or 0036OB010) Around luid..~---~-~--~-- -~ -----.. 10-4 Silicon Compou~ $illcor'l Compound 1725191050 or 003Il060101 1725191050 Or 0036060101 In guid. Ipindl.. 1725191040 or 003606000) Around lev.lip~r body In the space between cone SPrings and ..rOund lever so I' to fill inside of lever fitting it a.. NIGLUBe RX·:! gr. c~ .ring stctton of caliper body Sufficiently . 10-5 .. BRAKES • Grease Application NIGLUBe FlX·2 grton 1725191040 or oo36OB000) On the face of caliper body coming into contact with cone springs NIGLUBE FlX·2 groon 1725191040 or 0036060001 NIGLUBE RX·2 gr_ 1725191040 or oo36OB0001 NIGLUee RX·2 gr... 1725191040 or 0036060001 I n groove of caliper body before fitting piltOn boOt NIGLUBE RX·2 gr ••M 1725191040 or 0038060001 On the hem of Ipindle luemblV Silicon Compound 1725191050 or 0036OB010) Around pitton boot NIGLUBE RX·2 gr ..r instilling piston into caliper body Around piston seal Fig. 10-3 A 17-227 NIGLUBE RX·2 gr .ft... pin fitti. Do not use the other grease.

6) Remove pads from support.709) Fig. c. Do not touch the brake pedal after the pads have been removed.0 (0. unusual noise is produced when brakes are not applied. When wear occurs on the pad to such an extent that the clip comes into contact with the rotor. Disc rotor thickness mm (in) I-- A17-292 Fig. Solid disc Standard Usable limit Standard Usable limit 12.492) 10. 10-7 Removing lock pin 5) Spin caliper body ASSY on guide pin. 2) Disc rotor Check for wear and damage. Always return the piston to that point which allows only a minimum clearance for the pad to be inserted. A17-291 A 17-304 Fig. check piston boot for twist. Pad thickness including back metal mm (in) Standard Usable limit . replace the pad.394) 18 (0. NOTE: a. The clip incorporated with inner pad is also used as a warning device for worn pads. To prevent this. 3) Remove inner cab Ie end from lever. 10-6 Removing hand brake cable 4) Remove lock pin. and set the piston notch to the specified position. then disconnect hand brake cable from caliper body ASSY. and the gap where pads are to be inserted is narrow. 2) Return hand brake lever completely. 10-10 Pushing back piston Fig. Rotate piston clockwise with Wrench (925590000) to force in piston to caliper body. the piston should be rotated clockwise when pushed into the caliper body. 10-8 Spinning caliper body ASSY Ventilated disc 15. b.5 (0. 10-6 . Be sure to use the special tool when pushing in the piston to the caliper body. A17-103 Fig.591) 7.5 (0.BRAKES 2. the spindle (5·thread) may be buckled.610) NOTE: a. and correct or replace if abnormal. 10-9 Removing pad NOTE: a.295) '. correct twist using a strip driver. draw out outer cable clamp. 10-11 Specified position of piston notch After pushing back piston.since piston protrudes from cylinder in proportion to the amount of pad wear. Always replace the pads for both the left and right wheels at the same time. then remove front wheels. Also replace pad clips if they are twisted or worn. If the piston is pushed into the caliper body with a vice and without rotating it. Do not disconnect hose. 15. b. If twisted.0 (0. 3) Installation 1) It is necessary to push back piston into cylinder .5 (0. If such a noise is noticed.~ d A17-305 Fig. Pads Replacement 1) Removal 1) Apply wheel chocks on rear wheels and jack up the vehicle front. 2) Inspection 1) Pad Replace if it is wet with oil or worn. Do not disconnect hose. b.

b. replace rotor. 10-12 Right installation of pad NOTE: 3) Remove foreign materials from lock pin. This causes disc rotor to be pressed against lining. 3. Fig. (Refer to page 10-6) Pliers 2 Clamp A17-234 3 Union bolt Fig. Disc Brake Assembly 1) Removal and Disassembly 1) Remove union bolt and disconFig_ 10-16 Removing support A17-307 10-7 . 6) Put back tires and rotate them several times. and rotational resistance increases. the surface of disc rotor runs out in the axial direction during rotation. 2) NOTE: a. Apply PBe grease (725191060 or 003603000) to this area. 10-15 Removing caliper ASSY 4) Remove support from housing. and the stroke of hand brake lever can also be adjusted to the normal value. 55 lb). 9 Ib) at. Then. If the rotational resistance is over the specified value due to the other causes. If wheel bearing is worn or disc rotor is not exactly perpendicular to the counterpart. and confirm that tire can be rotated with a force of less than 39 N (4 kg.20 in) from the outer periphery of the rotor. 12 . Securely attach all pads to the frictional surfaces of their supports. recheck disc brake ASSY and repair or replace it if necessary. CD CV@ CD 5) No further adjustment is needed.0039 in) Fig.BRAKES Remove rust and foreign materials from the contact area of support with the sliding part of pad. 2) Remove hand brake cable and pad in accordance with the removing procedure of pad. measure the disc rotor run-out. 4) Upon completion of installing the brake system. A 17-295 NOTE: Fit the boot securely to the sleeve groove. a. and should not be removed when performing the maintenance of the caliper ASSY.24 N·m NOTE: (1. Then. Do not install shim on inner pad. wind a rope around the circumference of tire. nect brake hose from caliper body ASSY. Hand brake lever moves 3 to 4 notches when it is pulled with a force of 245 N (25 kg. Measure the disc rotor run-out at a point less than 5 mm (0. confirm that the pad dowel (rise on pad back metal) fits into the piston notch. install a new genuine SUBARU pad. I 2 3 4 5 6 Outer pad clip Outer pad Shim Inner pad dip Inner pad clip Inner pad A 17-306 Disc rotor run-out ~. When such trouble occurs. Tighten lock pin to the specified torque.17 ft-lb) ---------" The support should be removed only when the disc rotor or the support is replaced. 10-13 Measuring disc rotor run-out b.2. If this does not correct the run-out. Make sure that pad clips are in normal operating condition before installing new pad. If the runout exceeds the limit. change the tightening position of rotor on hub or the meshing position of hub to axle shaft serration. A 17-109 Fig.10 mm (0.--~----------------~ Limit I 0. since the clearance is automatically adjusted every time the brake is applied.the outside diameter of tire.4 kg-m.] ~ Torque (Lock in) p --'T(~: 16 . [The completion of the adjustment can be confirmed as follows.6 . Install clip with this longer portion facing outward. Depress brake pedal to an extent of applying the normal braking force several times. 10-14 Disconnecting hand brake cable and brake hose 3) Remove caliper ASSY by pulling it out of support. a proper amount of clearanee can be obtained. With the aforementioned procedure.

10-24 Removing lever & spindle 10-8 . A17·116 12) Press spring washer (coned disc spring) with Puller (925471000) to eliminate a load applied to lever & spindle through spring washer. A17-296 NOTE: Fig. A17·30B Fig. then remove lock pin boot. Evenly tap the dowels (two places) of boot. pull out lever & spindle.'. Lock pin boot NOTE: The lever cap may only be pulled out of the groove in the caliper body.... Fig. remove sludge and dirt from the outer part of caliper body ASSY.i Fig. Then. use a screwdriver after the tip of the screwdriver is rounded off."::: . 10-23 Removing snap ring NOTE: Replace the removed boot with a new one.\ . 10-20 Removing guide pin boot Fig. . 10-18 Removing boot ring and boot NOTE: If the strip driver is not available. then remove snap ring from lever & spindle. 10-21 Removing piston seal Do not apply an excessively high pressure. NOTE: Take special care to prevent dirt from entering through the brake fluid inlet.. 10-17 Removing sleeve and lock pin boot 7) Remove boot ring by using a strip driver with taking special care so as not to scratch piston boot. Detach Puller. since such carelessness may cause the piston to spring out of the cylinder. Sleeve 9) Removing guide pin boot. 10-19 Removing piston ~ . and burrs are thoroughly eliminated... and then remove connecting link and return spring. 11) Remove cap ring and lever cap.". 10) Remove piston seal by using a strip driver with taking special care so as not to scratch the inner wall of cylinder.". A 17·120 o~ A17·117 Fig. remove piston boot. 10-22 Removing cap ring and lever cap [3. 8) Draw out piston from cylinder by applying a compressed air or pressurized liquid gradually from the brake fluid inlet of caliper ASSY.r BRAKES 5) After removing caliper body ASSY. A 17·309 Fig. A17·11B A17·121 Fig. 6) Remove sleeve.

refer to the figure. 10-9 Fig. deterioration or coat of mineral oil. wear. correct or replace if defective. be sure to replace the D-ring with a new one_ Also. apply NIGLUBE RX-2 grease (725191040 or 003606000) into the grooves provided in cylinder and along the circumference of piston head. NOTE: Be sure to apply the specified grease or compound to the proper sections without fail. Fig. 10-30 Fitting O-ring A17-3l0 . Six cone springs are incorporated. 10-27 Fitting piston boot and boot ring 4) Apply NIGLUBE RX-2 grease (725191040 or 003606000) to the cone springs fitting section of spindle. damage or rust. wear. attach boot ring. 10-29 A17-029 b. When attaching the boot ring. 4) Pad clip Deformation. NOTE: Be sure to apply the specified grease or compound to the proper sections without fail. and onto the face of caliper body coming into contact with cone springs. After confirming that boot is not twisted. damage or rust. damage or rust. replace it with a new one. insert spindle ASSY into cylinder by turning clockwise from the opening at the bottom of caliper body. When the cone spring is replaced due to scratch. damage. 8) Other parts Deformation._- IWti WJ Fig. 10-26 Inserting piston 3) Upon completion of inserting piston into cylinder. damage or rust. 6) Lever and spindle Damage or rust. Then. Fig. 1) Caliper body Uneven wear. damage or rust. 3) Assembly and Installation 1) Clean the inner part of caliper body (cylinder) with brake fluid. A17-l26 NOTE: Pay special attention to prevent the seal from twisting. Apply a thin coat of Silicon Compound (725191050 or 003606010) to piston seal. Niglube RX-2 CD 1 Caliper body 2 Cone spring 3 Spindle @ A17-223 NOTE: NOTE: If the rubber parts are scratched or coated with mineral oil. Adapter A17-29B Fig_ 10-25 Inserting piston seal 2) Insert piston into cylinder. wear. 2) Piston Uneven wear. 10-28 Spindle ASSY and grease application NOTE: a. apply thin coat of Silicon Compound (125191050 or 003606010) to the D-ring. into the space between cone springs after fitting them. The assembling combination is as follows. 5) Spindle and cone spring Damage or rust. Do not use a vice when inserting the piston. 7) Support Wear. Fig. and insert it with Adapter (925600000) with taking care to prevent the D-ring from being damaged. After attaching cone springs. --_. Apply a thin coat of Silicon Compound (725191050 or 003606010) to the sealing section of caliper body coming into contact with O-ring of spindle ASSY. Then fit boot into the grooves. and fit the seal to the groove provided in the cylinder with hand.BRAKES 2) Inspection Inspect the disassembled parts. (925600000) NOTE: Be sure to insert the piston into the cylinder with hand. attach a new cone spring before fitting the D-ring. 3) Rubber parts Deformation.

lever cap and garter spring in ASSY body A 17-237 Fig. NOTE: When once the guide pin boot is removed. Be sure to force in the hooked portion of return spring to the groove of lever & spindle as shown. make sure that the bushing of caliper body is clean and free from any foreign matter. Then. fit connecting link into the groove at the head of spindle. 10-37 Installing cap ring NOTE: When inserting the lever & spindle. Then. Niglube RX-2 A17-129 A17-312 Caliper Fig. 10-38 Installing guide pin boot 10-10 .BRAKES 5) Apply NIGLUBE RX-2 grease (725191040 or (03606000) to the head of spindle ASSY and onto the inner wall of bushings on caliper body in which lever & spindle is to be fitted. make sure that boot is not damaged.. Apply sufficient amount of NIGLUBE RX-2 grease (725191040 or 003606000) to the space around connecting link and lever & spindle so as to fill inside of lever cap after fitting it. 10-32 Lever & spindle. After setting connecting link and return spring. 1 If -- * . Insert lever & spindle provided with lever cap and garter spring. Apply NIGLUBE RX-2 grease (725191040 or 003606000) to the groove of caliper body in which lever cap is to be fitted and to snap ring. always replace it with a new one. NOTE: Be careful not to damage the lever cap by the edge of the cap ring. 10-34 Fig.. 10-35 Grease application Fig. press a set of cone springs by Puller (92547 \000). Fe F . 7) Remove any foreign matter from the fitting hole of guide pin in caliper body. Attach cap ring onto lever cap. Fit lever cap properly into the groove at the rear of caliper body. 10-36 Fitting snap ring A 17-121 A17-198 ~. 1 Spindle 2 Connecting link 3 Lever & spindle 4 Return spring 5 Hooked portion of return spring A17-133 Fig. remove Puller (925471000). NIGLUBE RX-2 Fig. A17-224 Lever & spindle Niglube RX-2 A . Apply NIGLUBE RX-2 grease (725191040 or 003606000) to grooves of lever & spindle in which lever cap and connecting link are to be fitted. 10-31 Grease application 6) Fit snap ring into the groove of lever & spindle. ~ I A17-225 Fig. (Be careful not to scratch boot itself.) After inserting. 10-33 Inserting lever & spindle Fig. Evenly tap the metal periphery of guide pin boot to insert.

10-11 .----~- ---- A3-266 Fig.~~~~j 5.0 kg-m. ~ \ t Install clip with this longer portion facing outward. then connect brake hose and hand brake cable. 10-43 Grease application to guide pin portion I Torque ~upport bolt) 49 .24 N·m (J 6 .0 . Tighten lock pin to the specified torque. Then insert sleeve into lock pin boot. If the boot contains too much air and is expanded. Apply Silicon Compound (725IQI050 or 00360(010) to the inside of lock pin boot and around sleeve. 14) Make sure that all parts are properly attached. 10-42 Installing pad clips Fig." A17-307 Fig. 10) Install support to housing. Insert the support guide pin into the fitting hole in caliper body. and make sure that all parts are properly attached. make sure that boots are properly fitted in the grooves on the guide pin and sleeve. A3-265 Fig. Use only Silicon Compound (725191050 or 003606010) grease for the guide pin and lock pin portions. 6. 10-39 Installing lock pin boot and sleeve 12) Install outer pad and inner pad properly. 1:1) Make sure that caliper body and support are properly coated with grease.---. / ''1\ '// ~\ ~ ~L? LSleeve I Outer pad dip 2 I nner pad clip 3 Inner pad clip NOTE: Replace brake hose gaskets with new ones..51 ft-Ib) --~1-' I Torque 16. J -. ~:irrq~l~e:~r-l screw) . \ .24 k - (Lock P.Lock pi n boot A17-314 A17-313 Fig. b. 17 ft~.5 ft-lb) ------. 36 .69 N'm (5.12 . press it to purge out some air. 10-41 Installing support NOTE: a.BRAKES 8) Install lock pin boot to caliper body.0)_. 11) Install outer pad clip and inner pad clip properly. 10-40 Grease application to lock pin portion 9) Rotate piston until the notch at the head of piston comes in alignment with the center of disc. · l --. :t'= ~. IS) Bleed air from the brake system. c.7. After assembly.

6.1 .2) Fig.8 -7. 6.0. r BRAKES 10-3. Rear Brake 1.61 T2: 8 -10 (0.rts A17·311S 10-12 11 l I .nlng torque N·m (kll"m.9.9 (0. 6.7 . 10-44 Component p. Component Parts CD CD 1 Shoe hold down pin 2 Back plate ASSY 3 Upper shoe return spring 4 Brake shoe 5 Lower shoe return spring 6 Shoe hold down spring 7 Wheel cylinder body 8 Cup 9 Piston 10 Boot 11 Wheel cylinder air bleeder screw 12 Air bleeder cap 13 Spring washer 14 Nut 15 Adjuster TIght.8 -1..0. ft·lbl T1: 7 .

6) If drum bearing is abnormal or loose. upper. support it with rigid racks. Fig. middle. replace them. Take care so that spindle shaft and bearing are free from dust. Lining thickness Standard Service limit 5 mm (0. If it exceeds the limit. Standard inside diameter Service limit 180 mm (7. correct or replace it.5 mm (0. or the outside surface of brake drum is damaged. and secure both shoes with shoe hold down springs. 10-45 Removing flare nut 3) Remove brake drum.059 in) Fig. and lower position.1 BRAKES 2. 10-13 . the contacting surfaces of anchor and shoe web. referring to "WHEELS AND AXLES" in chapter 9. then to anchor. 6) Fit spacer (seal) onto spindle and install back plate. 3) If the deformation or wear of back plate. 5) If grease has leaked from brake drum. 2) Apply brake grease (003602000) to the surface of back plate where shoe touches. jack up vehicle. In this case.5.9 kg-m.08in) by turning the wedge. A17-042 1 Back plate 2 Back plate installing bolt 3 Adjuster Torque (Back plate) 46 . If it is un· evenly worn. Upper Lower Thick On anchor and back plate side. Installation 1) Assemble shoe ASSY with springs. 34 . 4) Unscrew back plate installing bolts and remove brake ASSY. Measure the shoe diameter at three positions.7 . Removal 1) Loosen wheel nuts. 3. 4) When the shoe return spring tension is excessively weakened. 7) Pull out shoe on cylinder side.20 in) I Upper return spring 2 Lower return sprin~ A17-043 1.8mm (7. and remove wheels. A17-044 Fig. center by using the outer circumference of spacer as a faucet joint. Pay attention to the shape and instal· ling position of springs. Inspection 1) If the inside surface of brake drum is streaked. 1 Back plate 2 Spacer 5) Remove shoe hold down spring with pliers. replace it.58 N'm (4. 10-47 Assembling shoes NOTE: 1 Flare nut wrench 2 Brake pipe A17-240 Replace the leading and trailing shoes on the right and left brake ASSV at the same time. and the contacting surfaces of wheel cylinder piston and shoe web. Wire diameter Thin On wheel cylinder and back plate side. replace oil seal or drum. 2) Unscrew brake pipe flare nut and disconnect brake pipe. 10-48 InstIlling back pllte Installing pOSition NOTE: 00 not allow forailn mattan to enter the brake ASSV. 3) Fit shoe ASSY first to wheel cylinder. 5) Tighten temporarily brake pipe flare nut.17 in) 2) Measure the lining thickness. replace it.09 in) 182 mm (7. are notable. shoe. taperingly streaked. correct the surface with emery cloth (#60). etc. 4) Adjust the shoe diameter to about 179. taking care to identify upper and lower springs. replace shoe ASSY.43 ft-Ib) Fig. Insert three bolts from the back plate side. 10-46 Removing back plate 4. 6) Pull out shoe on anchor side.

1 to 0. 2) Inspection Inspect each parts after washing them with brake fluid.6. c. use the special tool Adapter.. b. Applicable size 8) Install brake drum in parallel with brake ASSY.-----------------------1 925450000 925460000 15.9 N'm (0.1 Torque L -_ _ _ _ _ _ _ ~C 13-18N·m ( 1.87 mm (5/8 in) 17... 5. When replacing the repair kit. 1) Cup: Damage. make sure that the sizes of cylinder and cup are the same as those which were replaced. While assembling. 5. Use only the tool of the correct size. 2) Tighten the wedge fully until wheel ceases to rotate. 10-14 . uneven wear. b. fatigue or wear.0059 in). 4) Be sure that tire and wheel can be rotated easily by hand.... CD 3) Assembly Assembly is the reverse order of disassembly.. Wheel cylinder can be disassembled and inspected with it mounted on the back plate. ----------Adapter ---------..7 .3 . 2) Take out piston..5 ft-Ib) Fig. Follow the undermentioned procedure... 2) Cylinder and piston frictional surfaces: damage. which is piston ASSY with cup. dust or dirt from entering the wheel cylinder. -. Therefore it should not be removed except replacing the wheel cylinder ASSV etc. When installing the cup. NOTE: a.. and the shoe clearance will be 0. be careful to prevent any metal chip. Wheel Cylinder 1) Disassembly I) Remove boot from cylinder.. Adjustment of Rear Brake Lining Clearance The adjusting mechanism for the brake lining clearance is of a manual type.46 mm (11/16 in) 7 .. Screwing up the wedge forces anchor to expand on either side by the wedge action and consequently shoes stick to drum.004 to 0. and replace if the following defects are found.1 ..BRAKES 7) Tighten brake pipe flare nut to the specified torque.0. When removing the cup from piston.1.... Torque (Air bleeder screw) .. d.8 kg-m. apply brake fluid to the frictional surface for smooth installation and pay at· tention to cup direction. 10-50 Adjusting shoe clearance 6.13 ft-lb) ______ Part No.15 mm (0. corrosion or rust. Special tools (Adapters) are avail· able in different sizes. 1) Jack up vehicle body to release wheel from the ground. be careful not to damage piston. And be sure to use the new cup.. NOTE: Do not use any cleaning solvent other than brake fluid. 9 . 0 3) Turn back the wedge for 180 . NOTE: A17-316 1 2 3 4 5 Wedge Anchor Brake shoe Adjuster Back plate Fig_ 1049 Adjusting mechanism a. 9) Bleed air from the brake system.9 kg-m.

Component Parts 1 Cylinder body 2 Primary piston ASSY 3 Secondary piston ASSY 4 Piston stopper washer 5 Stopper ring 6 Stopper screw 7 Gasket 8 Bolt 9 Brake fluid reservoir 10 Brake fluid level indicator assembly 11 Check valve spring 12 Check valve 13 Tube seat 14 Check valve cap 15 Filter 16 Reservoir seal A17-241 Fig. 10-54 Removing stopper screw Fig. 3) Remove stopper ring while pressing piston into cylinder with a screwdriver etc. NOTE: Remove stopper screw at the position where secondary piston does not contact stopper screw by pushing primary piston using screwdriver. I) Disconnect connector for brake fluid level indicator. to prevent the brake fluid from spilling onto the painted surface and then perform the work. Removal NOTE: Put cloth etc. 3. 10-51 Cross section of tandem master cylinder 2. A17-243 Fig. Disassembly I) Remove level indicator assemblies and filters. Master Cylinder 1.BRAKES 10-4. 2) Remove nuts connecting brake pipes to master cylinder. 10-52 Removing nuts 3) Remove nuts connecting master cylinder to brake booster. 10-15 . A17-242 Fig. 2) Remove stopper screw while pushing piston fully into cylinder. then drain out brake fluid. 10-53 Removing nuts 4) Pull master cylinder out forward.

2.34 N·m (2. 3) Return spring and check valve spring: Fatigue or defonnation.9N·m (0.5 .3 kg·m.9 N'm (0. Do not disassemble primary and secondary piston ASSY. Inspection Inspect all parts after wa~hing them with brake fluid.9 kg·m. ae caraful not to damage cylinder and piston cup etc. b.16 N·m (1. new one.2 ft·lb) Do not ule any cleaning lolvent other than braka fluid. 1. Installation 1) Install master cylinder to brake booster.Rear left 1 2 3 4 5 6 7 8 9 10 Master cylinder Check valve spring Check valve Tube seat Check valve cap Stopper screw Secondary piston ASSY Primary piston ASSY Stopper washer Stopper ring Front left .1 . b.2. and return spring.5 kg·m.. primary and secondary piston ASSY.18 N'm (1.0 .8 kg·m. replace as a piston ASSY.1 . Torque (Brake pipe flare nut) 13 . L 10-16 .lb) 4. s. NOTE: a. Install stopper screw while pulhing primary pilton 10 that IIcondary pilton il fully pushed.BRAKES 4) Remove stopper washer.0. Torque (Air bleeder screw) 7 . 10-56 Disassembling master cylinder 4) 3) Connect connector.25 ft. b. 18 . corrosion or rust.6. check valve: damage. Never remove and/or disassemble reservoir unless reservoir seal is damaged. Torque (Master cylinder nut) 10 . 9 .3. 1) Cylinder and piston frictional sur· faces: damage.5 ft·lb) NOTE: a.1. uneven wear. Torque (Check valve cap) Torque (Stopper screw) 25 .15 . 6.7 . 2) Primary and secondary cups. NOTE: Replace galket with.3 .Rear right Fig.5 . When replacing piston cup etc. Replace it with new one if necessary. Assembly Assembly is the reverse order of dis· assembly. c.6 kg·m.1. 5. 5) Check valve can be disassembled easily by removing check valve cap. Bleed air from brake system. NOTE: 1.13 ft·lb) "\ CD <~1\ @ (J) A 17-246 NOTE: Make sure that the piping is correct Primary system Secondary system Front right . and replace if the following defects are found. Applying the brake fluid to frictional portion facilitates the work. wear or fatigue. 7-12ft·lb) 2) Connect brake pipes with master cylinder. d. installation is clockwise.0. Level indicator is removed by turn· ing it counterclockwise.

k. booster 8 9 10 11 12 13 14 Puah rod ReacUon diIc aeulna Valve body .Vac) Operatlnl rod ASSY Power pilton Diaphr.3 .uard Retainer C1evia Front lbeU Nut Plate" leal ASSY 20 Return .m Key Retliner Filter Silencer Fig.0 -1. to-58 Croll IIICtion of br.13) T2: 10 -16 (1.BRAKES 10-5. Brake Booster (Master-Vac) 1.1. ft-Ib) T1: 13 .6. 7 -12) 1 Vacuum hose joint bolt 2 Clip 3 Vacuum hose 4 Clamp 5 Check valve 6 Master cylinder ASSY 7 Brake booster (Master-Vac) 8 Seal 9 Spacer 10 Clevis pin 11 Snap pin A17-317 Fig_ 10-57 Brake booster (Master.8.18 (1.9 . Construction Tightening torque N-m (kg-m..prlq Retliner Rear Iben Valve body leal 15 16 17 18 19 .'7-2'" 10-17 .

Four brake booster installing nuts.----. 2) Remove the following parts from the pedal bracket. 2) Checking with Gauges Connect gauges as shown in figure. if the pedal height increases.-I·-~ -.' . A16-251 :-j Fig.3 . Remove nuts connecting brake pipes to master cylinder. 13 -. Installation I) Mount brake booster in position.-- I Torque (Air bleeder screw) N·m (0.' ~.--- Connect operating rod to brake pedal with clevis pin and snap pin. Operation Check NOTE: When checking operation. then tighten lock nut. (2) With brake pedal depressed.8 kg-m. 5. proceed to each check. the nature of the failure if checking is conducted in accordance with the following procedure. 9 .9 kg-m.16N-m 4. If brake pedal is not contacted stopper.1. 10-60 3. brake booster is faulty.----.6. depress brake --.0.. Nut ~ . 7) Tightening lock nut on operating rod ASSY. Fig. tnT H Ii . Torque (Brake pipe [ flare nut) 13 . 10-59 8) Connect vacuum hose to brake booster./. brake booster is functioning normally. then turn it off. d.~~. (3) As engine starts. ~ I '---"'-~ ~I I.3. Torque (Brake booster to toe board) 2) I JI NOTE: The brake pedal should contact stopper without being depressed. 3) -- Bleed air from brake system.-~ 7. b. Air tightness check Master cylinder 2 Vacuum hose A17~250 Fig. check precisely with gauges. I--~-- ----------. Connect electric connector for brake fluid level indicator. Keep the pedal depressed for 30 seconds. 1) Checking without Using Gauges This method cannot determine the exact portion which has failed. b. Snap pin and clevis pin. inspect the condition of the check valve and vacuum hose. Loaded air tightness check I---_. Disconnect connector for brake fluid level indicator. __ L2 :. \. 10-61 A17~318 Tightening lock nut on operating rod ASSY pedal several times applying the same pedal force and make sure that the pedal height does not vary with each depression of the pedal.-~. If no change occurs in the pedal height. Depress brake pedal several times applying the same pedal force as that used in ordinary braking operations. brake pedal should move slightly toward the floor.7. Remove master cylinder installing nuts. if no change occurs in the pedal height. Operation check (I) With engine off.1~ Torque 5) -------~-. NOTE: In the event of defective operation. be sure to securely apply the hand brake.1 . 3) Remove brake booster while shunning brake pipes. brake booster is faulty.~.---~-~-~--~-~] 10. it is faulty.. The pedal stroke should be greatest on the 1st depreSSion.BRAKES 2. 6) Start engine. check precisely with gauges. c. After bleeding air from pressure gauges. ------------- l_(NU~ .l) NOTE: If faulty. If no improvement is observed. c. b. Disconnect vacuum hose from brake booster. start engine. a. adjust clevis to contact stopper. f '4 f "f . and run it for I to 2 minutes.I I It t' .17 ft-Ib) . but it can provide a rough understanding of 10-·18 Depress brake pedal while engine is running. and it should become smaller with each successive depression. a. Connect brake pipes to master cylinder. check precisely with gauges.2. a.-. . Replace them if faulty and conduct the test again.23 N'm ( 1.5 ft-Ib) .18 N'm (1. Removal I) Remove the following parts at engine compartment. 4) Mount master cylinder onto brake booster. 9-13ft-Ib) -1 1 - . and turn off engine while the pedal is still depressed. --~ -~.3 kg-m. If no change occurs in the pedal height while in a depressed state. NOTE: If faulty.!~.' ~j »~/.

I f protector is fitted correctly. • Check valve malfunction • Leak from vacuum hose • Leak from the shell jointed portion or stud bolt welded portion • Damaged diaphragm • Leak from valve body seal and bearing portion • Leak from plate & seal ASSY portion • Leak from poppet valve ASSY portion gauge.5 mm (0.432 (35. 66) -----. psi) A 17·253 Fig. 0.69 inHg) is indicated on vacuum gauge while the pedal is still depressed. Keep engine run· ning until a vacuum of 66.-.865 (70. sufficient to cause a change in the angle in excess of ±3°.--------- 47(115'33) 2. 33) Fluid pressure kPa (kgl cm 2 .----+----------1 294 (30. refer to a. Brake booster should be discarded if it has been dropped..217 in) c. The pressure must be greater than the standard value listed below.550 (26. Then. ~~~I-force ! I N (kg. and set the vacuum gauge reading at "0".3 kPa (25 mmHg. and reaction disc may drop into brake booster. 19. 2) Be careful not to drop brake booster. 19. The projected amount "Q" of pushrod should be as follows: Standard (Correct): Incorrect: Q: Q: A17·252 Fig.lb) 147 (15.66) ~ Adapter hose 5. the cause may be one of those listed below. 44 Ib). 4) Use care when placing brake booster on the floor. I f the vacuum drop range is less than 3.7 kPa (500 mmHg. If defective.. brake booster is functioning properly. I I' th e vacu urn drop range is less than 3. Whether or not reaction disc has dropped can be determined by measuring the dimension "Q". 57) . described above. b.8 mm (7 in) booster: 6. 10 mm (0. (2) Stop engine and watch vacuum Set the vacuum gauge reading at 66.3 kPa (25 mmHg. Do not depress b rake pedal. 10-19 .69 inHg) by running engine. (2) Stop engine and watch the gauge. The pressure must be greater than the standard value listed below. 392 ( 4.69 inllg) is indicated on vacuum gauge. 370) b. it may result in damage to the power piston cylinder. reaction disc will not fall out.39 in) 5. If excessive force is applied to operating rod. 498) For 152.995) Pedal force gauge Adaper hose 294(30. 19.BRAKES Pressure gauge Pressure gauge Pedal force N(kg. brake booster is functioning properly. Handling Precautions I) After protector has been removed from push·rod. Loaded air tightness check Boosting action check (I) Start engine and depress brake pedal with pedal force of 196 N (20 kg. do not turn the master cylinder side of brake booster downwards. Lack of boosting action check Turn off engine. c.98 inHg) within 15 seconds after stopping engine.7 kPa (500 mmHg.884 (60. 0. check the fluid pressure when brake pedal is depressed.9i1 inHg) within 15 seconds after stopping engine. If the master cylinder side is turned downwards. If defective. push-rod may come loose by virtue of its own weight. 3) Use special care when handling operating rod.4 mm (6 in) booster: 5. check the fluid pressure when brake pedal is depressed.. 10-63 Push rod projection ~ d. Ib) TFIUid pressure kPa (kg/cm 2 . 853) For 177.7 kPa (500 mmHg. 10-62 Connection of gauges a. Air tightness check (l) Start engine and keep it running until a vacuum of 66. Then. psi) 3. a.

4.7-10) T2: 4 . A17-254 Fig. ft-Ib) T1: 10-14(1.6.65 . 10-64 Handling precaution 10-6.4 .0.95.9.0-1.3) T3: 6.6 (0. 2. Parking (Hand) Brake 1. 10-65 Component parts of Hand brake 10-20 '-- . the resin portion as indicated by "P". may be damaged.6.9) Al7·319 Fig. Component Parts ~@ r® &--@ Detail "C" 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Hand brake lever ASSY Hand brake lever button Hand brake lever grip Hand brake lever spring Hand brake switch Flange tapping screw Bolt & washer Hand brake rod CP Clevis pin Cotter pin Equalizer Hand brake pin Washer Hand brake spring Hand brake adjuster Nut Clamp Hand brake clamp Hand brake clamp Bolt & washer Flange nut Hand brake cover Flange bolt Hand brake cable ASSY Tightening torque N·m (kg-m.9 .3 (0.0.4 .4. P {J.BRAKES Force If external force is applied from above when brake booster is placed in this position. 4.7 .

10 ft-lb) Remove bolt and bracket from transverse link. 11) Install (new) parking brake ASSY in the reverse order of removal.0. then remove inner cable end from equalizer.) 4.9. Parking (Hand) Brake Lever • Replacement 1) Remove parking brake cover. Make sure that the distance above is as specified [more than 80 mm (3. 10-67 Removing clamp Fig. 10-68 Removing hand brake cable end A17·146 10) Remove cable ASSY from cabin by forcibly pulling it forward. 4.1. Adjustment of 3. (See "Adjustment of parking brake". 10-66 Removing hand brake lever 7) 5) Install parking brake lever in the reverse order of removal.4 kg-m. Bleed air completely from the brake system before attempting the following operations.65 . NOTE: a. 4) Remove parking brake cover. Parking (Hand) Brake Cable • Replacement Loosen front wheel nuts. 9) Detach parking brake cable from cable guide at rear crossmember.14 N·m (1. Torque (Rear crossmember cable clamp) Torque (Bracket to transverse link) 6.15 in)] . 3) Loosen parking brake adjuster.3 N·m (0. Torque (Lever installing bolt) 10 . A4·129 Fig.BRAKES 2. 10-71 A17·148 Fig. 10-70 10-21 .6. and disconnect cable end. After adjusting the rear brake shoe clearances.95 kg-m. b. 4) Remove parking brake lever. 1) Clamps Parking (Hand) Brake Fig.5 mm (0 to 0. then perform the following operations. 10-69 A17-186 8) Remove bolt and clamp from rear crossmember bracket. then lock adjuster. 2) Adjust hand brake lever by turning adjuster until the play at the A portion is set at 0 to 0. and support it with safety stands (rigid racks). depress brake pedal several times. 3) Remove front tires and wheels.4 . 1) Forcibly pull hand brake lever 3 to 5 times. 6) Pull out parking brake cable clamp from caliper.020 in). 2) Jack up vehicle. 7 . A17·304 Fig. Confirm that parking brake lever of caliper returns fully after slackening parking brake cable. NOTE: Be sure to pass cable through cable guide inside the tunnel. 5) Loosen parking brake adjuster. and detach clamps. and check the depressed height (floor to the upper surface of brake pedal pad).7 .0 . 2) Disconnect electric connector for parking brake switch. and remove inner cable end from equalizer. Fig.9 ft·lb) 6) Adjust parking brake.

4 . Instruct your co-worker to depress brake pedal slowly 2 or 3 times and then hold it depressed. 6) Always start with the primary side and then work on the secondary side. d. Install one end of a vinyl tube onto air bleeder screw and put the other end into container. To refill reservoir. A17·151 Fig. Add brake fluid as necessary while performing the air bleed operation. Loosen bleeder screw approximately 1/4 turn until a small amount of brake fluid drains into container. 5) Use the same procedure as the one described above to change brake fluid of front wheel cylinder. 2) I nstall one end of a vinyl tube onto air bleeder of wheel cylinder located farthest from master cylinder and put the other end of the tube into container for receiving brake fluid. b.. and the piping on secondary side connects the front left brake and rear right brake. Repeat steps c) and d) above until there are no air bubbles in the drained brake fluid. and then quickly tighten the screw. Replacement of Brake Fluid NOTE: a.6 N'm (0. DOTJ. and confirm that the hand brake becomes effective with a lever stroke of 3 to 4 notches when pulled with a force of245 N (25 kg.:::--~---=--::---- ~ - 3) Repeat depressing brake pedal slightly. Replacement Procedure 1) Remove filler cap from brake fluid reservoir. open air bleeder and repeatedly depress and release brake pedal until a small amount of fluid remains in reservoir. in order to prevent reservoir from running short of brake fluid. 10-72 10-7. 116. a.:..~~-~~--=-~-~. 10-22 . 10-74 Air bleeding order NOTE: Front left Rear left A17-150 Fig. 2. 1 Cable 2 Equalizer A 17 ·149 Fig. 4) Open air bleeder. replace the brake fluid according to maintenance schedule or earlier than that when used in severe condition. e. 55Ib). Then securely tighten air bleeder of master cylinder.BRAKES A :): -p ~-~ ~ ..:-.." ~---- Torque (Adjuster lock nut) II ~--I 4·. 10-73 Always begin replacing the brake fluid on the primary side and subsequently work on secondary side. b.0.3 ft-Ib) ~::::::. cross design_ The piping on primary side connects the front right brake and the rear left brake. The brake piping consists of a dual system. / . Front right Rear right Primary tube into a container to collect brake fluid. 4) Forcibly pull hand brake lever 3 to 5 times and rotate tire and wheel several times by hand. 2) Refill reservoir with recommended brake fluid.4. and con firm that tire and wheel can be rotated with a force of less than 39 N (4 kg.6 kg-m. Install one end of a vinyl tube onto air bleeder of master cylinder and insert the other end of NOTE: Add brake fluid as necessary while performing the air bleed operation. Attach a wrench to bleeder screw. Recommended brake fluid FMVSS No. c. slowly and repeatedly depress and release brake pedal completely until a solid stream of brake fluid (containing no air bubbles) runs through vinyl tube. 7) Reconfirmation Bleed air from the brake lines as follows in the order shown below in figure. 9 Ib). Then wind a rope around the circum ference of tire.9 .::.:. To drain the fluid into container. and depress and release brake pedal until old brake fluid is drained out and new fluid flows through vinyl tube. Then close the bleeder.::-::--::===. To always maintain the brake fluid characteristics.--. 1. c. in order to prevent reservoir from running short of brake fluid. but do not loosen it at this point.

After completing the bleeding operation. 2.1 .5 ft-lb) 1) Air Bleeding Procedure Replenish b rake fluid reservoir with new recommended brake fluid.6. be sure to bleed air from the brake system. Always use new brake fluid. hold brake pedal depressed and tighten the screw and install bleeder cap. Bleed air according to 1. NOTE: a. Torque (Air bleeder screw) 7 . be careful to protect the brake fluid from contact with air during storage. At this time check the pedal to see if it shows any unusual movement. and start bleeding air from wheel cylinder located farthest from master cylinder. and also make the pedal stroke longer. Upon completion of the disassembly and assembly of the brake. The boiling point of the brake fluid lowers as it absorbs moisture from the air..7 . 5.9 kg-m. 10-23 . b. 3) Fluid level in reservoir Fill reservoir with brake fluid up to the "MAX" level. visually inspect bleeder screws and brake pipe joints to make sure that there is no fluid leakage. or after brake hose replacement etc. Air Bleeding Air in wheel cylinder will cause brake pedal to feel spongy. c. which can lead to an accident. 2) Check after Bleeding Air 1) Brake fluid leakage Depress brake pedal strongly and hold it there for approximately 20 seconds. 7) Reconfirmation.9 N'm (0. Use recommended brake fluid.0. 2) Proper air bleeding Depress brake pedal to determine if its operation and stroke length are correct.BRAKES f. 4) Drive car in low speed and depress brake pedal a little strongly several times to make sure that the brakes are operating properly.

.) Brake pipe cover (L.5-2..) Brake hose clamp Brake pipe (Rear R..H.~ . 11'.R. R. t''''' .H..) Brake pipe (CTR. ... I..) Brake pipe (Secondary) Brake pipe (Primary) Brake pipe (Front L._ -_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ q .. L.J'~" J>'. R.'-+'-tl_' ' ' ' ' .H.....H..) 2-way connector Clamp 7-15 Pipe ASSY (CTR. F.H.. . 10-24 1."~" " "~" ' ' '~. L.R... UTI. F..~1"~".H. Component Parts • Non-BRAT 1 3 4 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Brake pipe (Secondary) Brake pipe (Primary) Brake pipe (Rear L.H. ft-Ib) T: 15-21 (1. Brake Line 1..) Clamp 5-7-8-6 Brake pipe cover (R.BRAKES 10-8....) Clamp 5 Clamp 5-5-5 Brake pipe (CTR.11-15) A17-320 Fig.) Brake hose (Rear) Grommet (Fuel pipe) Brake hose (Front) Union bolt Gasket Brake pipe (Front R.) Brake pipe (CTR.) 2-3 way connector Bolt ASSY Brake pipe (Front L.) @ Tightening torque N·m (kg-m.H.. 1 ~ ._ _ _ _ _ _ _ _ _ _.... .....H. 10-75 Component parts of brake line (Non-BRA T) .1.. "~II' II J -I .

10-76 Component parts of brake line (BRA T) 10-25 .) Clamp 7-15 8 Brake pipe (CTR R 11 Brak.::. . R. L H Brake pipe (CTR F· .m T: 15 _ 21 (15 (kg-m. R. -2. R.H. wary) 2pIpe (Secondary) way connector Brake hose (Rear) :rake p~pe (Rear R.Ipe (F ront R.. Brake. Brake pipe (Secondary) Brake p~pe (Front L. ay connector mon bolt Gasket Bolt ASSY Brak e pIpe (Front L H ) .H. . L.) rake pIpe (Rear L. B Brake pipe (Primary) .H.) e pIpe (CTR 13 Clamp 5-7-8-6 .H.) rake pIpe (Pr.) ~~ P~pe ASSY (CTR-R) 2 21 22 o 23 24 25 26 27 28 29 30 31 32 3 3.. Brake pipe (CTR F . PIpe ASSY (CTR.H.11-15) ~ 3 4 5 6 7 Brake hose (Front) Brake hose clam Clamp 5 p Brake p.H.H.1.) A 17-321 Fig.H ) CI amp 5-5-5 .BRAKES • BRAT @ @ Tightening torq.u:e~~N·.: : . .. ..) 2-3 w .) U . ft·lb) .

In the engine compartment Fig. 10-79 Tightening flare nut NOTE: a. d) Fix brake hose with clamp at wheel apron bracket. Do not damage the brake pipe by screwdriver etc.BRAKES 2. b.3 . replace with a new clamp.1. (Always use flare nut wrench and be careful not to deform flare nut. 11 . and lightly Fig.) tighten flare nut to connect brake pipe. 10-80 Removing clamp 2) Installation 1) Press the clamp claw into body hole until it snaps. 10-81 Brake pipe clamps 10-26 . a) Pass brake hose through the hole of bracket. c. and tighten union bolt. tighten flare nut to the specified torque.18 N'm (1. c) Pass brake hose through the hole of wheel apron bracket.l3 ft-lb) 1) Removal 1) Remove brake pipe from clamp. Brake Pipe Clamp There are different kinds of clamps according to the installing positions. 2) Press brake pipe onto clamp. 10-78 Removing front brake hose 2) Installation Front brake hose a) Pass the union bolt side of brake hose through the hole of damper strut bracket. replace with a new one. Torque (Union bolt) IS-21N·m (1. c) Perform the same procedures as beforementioned in steps e) and f). 2) Push clamp claw portion (shown with arrow) by screwdriver tip and take out clamp from hole. e) While holding hexagonal part of brake hose fitting with a wrench. 9 . Fig. b) Insert clamp upward to fix brake hose. f) Bleed air from the brake system. When removing and installing the brake pipe. @ Rear brake hose A17-159 1 Brake pipe 2 Camp 3 Brake hose A17-155 Fig.5 . If bent excessively. A17-157 Fig. remove union bolt and pass the union bolt side of brake hose through the hole of damper strut bracket.1 kg-m. and lightly tighten flare nut to connect brake pipe. correct before installing. 10-77 Separating brake pipe 2) Pull out clamp to remove brake hose.15 ft-Ib) On the side sill b) Fix brake hose with clamp at damper strut bracket. Torque (Brake pipe flare nut) 13 .8 kg-m.2. be careful not to bend it If it is bent a little. A17-322 3. Brake Hose 1) Removal 1) Separate brake pipe from brake hose. 3) In case of front disc brake. If the clamp claw is damaged.

(3) (4) (5) 4. Correct by grinding. Adjust the clearance. Clean or replace the cylinder. (2) Entry of air into the hydraulic mechanism (3) (4) Excessively wide shoe clearance Wear. or wear (5) Deformed back plate (6) Improper tire inflation (7) Disordered front alignment (8) Loosened back plate or the support installing bolts (9) Loosened rear wheel bearing (10) Trouble in the hydraulic system (11) Uneven effect of the hand brake 3. Replace. Unstable or uneven braking (1) Oil on the lining. Correct or replace the drum or rotor. deteriorated surface material. improper inferior material. Correct or replace. Adjust. pipe or hose). Repair or replace (cup. grind or clean. Check. or replace. pipe or hose). Retighten to normal tightening torque. drum or rotor (2) Drum or rotor eccentricity Eliminate cause of oil leakage. or replace. or damage to the drum caused by sand Improper lining contact. Insufficient braking (1) Oil leakage from the hydraulic mechanism Repair or replace (cup.BRAKES 10-9. Troubleshooting Trouble and possible cause Corrective action I. cylinder. disc caliper. Replace the cylinder. Bleed the air. deteriorated surface material. adhering water or oil on the lining cylinder. piston. or replace. brake pipe or hose. Retighten. (3) (4) Worn brake drum. cylinder. Correct or replace. Excessive pedal stroke (1) Entry of air into the hydraulic mechanism (2) Excessive play in the master cylinder push rod Bleed the air. Adjust alignment. wheel 2. Correct or adjust (2) Improper master cylinder return (3) (4) Clogged hydraulic system Improper return or adjustment of hand brake 10-27 . Correct by grinding. Replace. piston. and replace the front brake and cable system. clean. brake booster or check valve (5) Improper operation of master cylinder. Oil leakage from the hydraulic mechanism Improperly adjusted shoe clearance Improper lining contact or worn liming Brake dragging or improper brake return (1) Insufficient pedal play Adjust play. Adjust. Inflate to correct pressure. adjust. Correct or replace.

(3) Loose or bent drum or rotor. (5) Weakened spring tension or breakage of shoe return spring (6) Excessively narrow clearance between pad and disc rotor (7) Excessively narrow shoe clearance (8) Improper wheel cylinder operation (9) Improperly adjusted rear wheel bearing 5.BRAKES Trouble and possible cause Corrective action Replace the spring. Replace the shoe assembly or pad. Adjust or replace. Correct or replace the shoe assembly or pad. Retighten to normal tightening torque. Brake noise (1) (creak sound) (1) Hardened or deteriorated lining (2) Worn lining Replace the shoe assembly or pad. Adjust the clearance. Replace the shoe assembly or pad. Brake noise (3) (click sound) In the case ofthe front brake. (1) Excessively worn shoe ridge (2) Excessively worn wheel cylinder piston (3) Lack of oil on the shoe ridge surface and anchor Replace the back plate Replace the wheel cylinder assembly Add more grease 10-28 . Retighten. Clean the drum or rotor. Adjust the clearance by rotating the piston clockwise. Correct or replace. Retighten or replace. Brake noise (2) (hissing sound) (1) Worn lining (2) Improperly installed shoe or pad. Replace the pad or the support. 7. (3) Loosened back plate or the support installing bolts (4) Loose rear wheel bearing (5) Dirty drum or rotor 6. (1) Excessively worn pad or the support In the case of the rear brake. or clean and replace the brake assembly.

1 Body 2 Ctmahaft 3 Ball 4 BallJUide 5 Seal 6 Plate apriq 7 Cap 8 Push rod 9 SPrina 10 Boot 11 Collar 12 Lever 13 O-rina 14 O-rina A17-283 Fig. Hill-Holder 1. the hydraulic pressure is maintained so far as the clutch pedal is kept depressed..) When stopping the vehicle on an uphill road by depressing both brake and clutch pedals. the pushrod retracts to close the valve. In this status. 10-82 Outline of hill-holder 2) Pressure Hold Valve (PHV) PHV (Pressure Hold Valve) is connected to one of the service brake pipes and pushrod (8) is pushed in and/or pulled out by cam shaft (2) interlinked with the clutch pedal to change the clearance between ball (3) and seal (5).BRAKES 10-10. the ball roIls toward the rear and. Normally. so that hydraulic pressure is maintained. smooth starting is enabled by usual engagement of the clutch while depressing the accelerator pedal. the maintained hydraulic pressure is released simultaneously with the generation of driving force to permit smooth starting. when engaging the clutch ordinarily while depressing the accelerator pedal.. Even when takins your foot off the brake pedal. Therefore. on a flat road. Construction and Operation 1) Outline Hill-holder is a device to make starting on an uphill road easy and permits even a driver not yet familiarized with starting by use of parking brake to start the vehicle smoothly. (ntis status is the same as on a downhill road. this device holds the brake temporarily upon taking your foot off the brake pedal (until the clutch pedal is released). When pressing down the clutch pedal with the brake pedal depressed in order to start the vehicle on an uphill road. Fork (clutch release) (Front) Clutch pedal (Rear! PHV cable A17-262 Fig.. at the same time. To front LH brake Front To rurRH brake .83 Pressure hold vllive 10-29 . ball (3) is located at the front and the valve is kept opened regardless of the position of the pushrod. thereby opening and/or closms the hydraulic circuit. 1().

when interrupting starting operation or shifting gear from other than WW because of misoperation) 5. If the brake is not held sufficiently upon releasing the brake pedal with the clutch pedal depressed. Fig. which does not constitute abnormality. A slight shock is given to the vehicle when starting the vehicle after stopping the reverse movement. These phenomena are caused by the activation of the hill holder. When stopping A17-267 • Inactive status This accessory is not activated in any status other than the above. In this case. In this status. depress the brake pedal again. During acceleration or usual driving 3. 10-87 While driving Even when stopping on an uphill road. A17-215 Fig. Hill-holder may not be activated on a slope of an extremely small inclination. A17-266 Fig. When reversing the vehicle on a flat road. 10-86 A17-264 Fig. 10-84 Even when depressing the clutch pedal. b. except for reversing. 10-85 Since the clutch pedal is not depressed. you must keep the brake pedal depressed or pull the parking brake. the pushrod is located outside the port. 10-88 10-30 . therefore. 4. Brake effect remains even after releasing the brake pedal if depressing the clutch and brake pedals when reversing the vehicle. Hill-holder is a device used to facilitate starting on an uphill road. hydraulic pressure is not maintained unless the clutch pedal is depressed. hydraulic pressure is not maintained. For stoppage on the uphill road. When stopping the vehicle on an uphill road. a. (Because the brake is released when returning the clutch pedal halfway) (For example. the ball rolls toward the rear to seal the port and therefore the hydraulic pressure is maintained even by releasing the brake pedaL 2.BRAKES • Activating condition This device is activated only when depressing the clu tch and b rake pedals with the vehicle stopped on an uphill road. hydraulic pressure cannot be maintained. 3) Operational Precautions 1. 2. the following phenomena may be felt. Before you leave the driver's seat. On a flat road A17-265 Fig. 6. b. If depressing the clutch pedal again in the course of starting operation. In this status. 3. the brake may be released. the ball is kept at the front by decelerating force. be sure to pull the parking lever and confirm that the vehicle is kept stopped upon releasing the clutch pedal. 1. press down the brake pedal a little strongly once again. a. During deceleration This device is not designed to operate on a flat road.

10-89 Component parts of hill-holder Master cylinder Connector (J-wav) 1 2 3 4 5 6 Brake Brake Brake Brake Brake Brake pipe (primary) pipe (secondary) pipe (Front LH) pipe (Cenier front LH) pipe (Center front RH) pipe (Front RH) : : : : : : Master cylinder (primary) .Rear LH PHV .Front LH Connector .Front RH A17-269 Fig.BRAKES 2.PHV Master cylinder (secondary) .Rear RH Connector .Connector PHV . 10-90 Piping of hill-holder 10-31 . Component Parts Fork (clutch releasell \ 8 ® Clutch cable Hose 1 PHV (Pressure hold valve) 2 Support 3 Hook (spring) 4 Stay (PHV) 5 Return spring 6 Bracket 7 Connector 8 PHV cable 9 Adjusting nut 10 Bracket (cable) 11 Clamp 12 Clip 13 Clip Side frame A17-268 Fig.

3 kg-m. 1) Check if boots of PHV cable are damaged or degraded. Fig. s. operate clutch pedal about 30 times as a running-in operation prior to adjustment.1.3 . 3) Detach PHV cable from clips. 5) Connect PHV cable with clips_ 5) Separate connector bracket from support ofPHV. NOTE: Avoid sharp bending of PHV cable as it may cause breakage. replace it with a new one. and disconnect PHV cable from cable bracket on engine. 9-13ft-lb) A16·273 4.3 kg-m. Pay attention not to drop brake fluid onto body painting since it may dissolve paint b.8 kg-m.4 ft-lb) 2) Install PHV onto side frame.18 N'm Torque Fig. 5. Pay attention not to damage hexagonal head of flare nut by using pipe wrench without fail. Replace them with new ones if necessary. 4) Install PHV cable to PHV stay. and replace defective ones. 13 . 10-32 . (1. 4) Remove cable clamp.13 N·m (0. 10-94 NOTE: Exercise utmost care to prevent foreign matter from entering into PHV when removing it. and disconnect PHV cable from PHV stay. 6) Install PHV cable onto cable bracket on engine_ NOTE: a.13 N'm (0. 10-91 A17·270 7) Detach PHV along with support from side frame. 5.9. 2) Remove adjusting nut and cable clamp. 2) Check if return spring is worn out. 3) Connect brake pipes to PHV. 10·93 A16-272 NOTE: Carefully protect boots and inner cable from damage when disconnecting PHV cable. Fig. NOTE: After replacing PHV cable or clutch cable with new one. Torque 7 . 6) Disconnect brake pipes from PHV.4 ft-lb) NOTE: If cable clamp (and clips) is damaged.7 . damaged or corroded. • Hook portion of return spring • Cable end portion of lever • Cable end portion of clutch release fork Grease used Idemitsu Auto Lex A A16·271 Fig.1.1 . ( \ \ \ \ Torque 7 . Installation 1) Assemble bracket with support of PHV. Replace entire PHV ASSY if necessary.7 . Inspection Check up removed parts as follows. 7) Apply grease to the following points.1 .1.BRAKES 3. 3) Confirm that rolling sound of ball is heard with PHV inclined and lever rotates smoothly.9. and if inner cable is damaged or corroded. NOTE: Confirm that brake pipes are not deformed and/or damaged. Removal 1) Drain brake fluid from reservoir on primary side of master cylinder. 10-92 CAUTION: Never disassemble P!'IV. 8) Be sure to bleed air from the system.

55 .3.8 .4.95 kg-m.9 ft-Ib) 2. Tighten adjust nut of PHV cable.0 .0.3 ft-lb) A3-234 A. Shock is felt when starting (1) Poor adjustment of starting performance (2) When depressing the brake pedal strongly: (3) When starting on flat road after stopping reverse movement: Adjust (The stronger brake pedal depressing force.25 . Repair or replace Replace entire PHV ASSY Refer to "Clutch and pedal cable system" Machine does not stop on uphill road of 3° or higher inclination (l) Front side of machine is lowered (2) PHV cable is broken (3) Play of clutch is excessive Refer to "Suspension" Replace Adjust Adjust Replace entire PHV ASSY (4) PHV cable is elongated (5) Sealing of PHV is poor 3.6.79 in) At center of cable 2-3mm on clutch release (0. Standard of free play At clutch pedal 13-20mm (0.51 . • Case B . If it is out of the specified value.0. Torque Adjusting nut of clutch cable 5.0.0.4 N'm (0. If vehicle does not start properly. a.5 . Then make adjustment the same as in Case CAUTION: Whenever turning adjust nut. the later hill holder releasing) (Because hill holder is activated) 10-33 .3 N'm (0. 10-95 Turning adjust nut for PHV cable Adjusting nut of PH V cable 7. b.45 kg-m.): Loosen adjust nut gradually until smooth starting is enabled. • Case A .9. prevent PHV cable from revolving as shown in following figure. Adjustments 1) Inspect free play of clutch pedal by depressing the pedal by hand.BRAKES 6.4 .08 . If vehicle does not stop. Counterforce of clutch pedal is too strong (1) PHV cable is damaged or does not operate properly (2) Lever of PHV is defective (3) Clutch system is anomalous 2. Troubleshooting Trouble and possible cause Corrective action 1.12 in) fork 2) Confirm stopping and starting performances by activating hill-holder on an uphill road of 3° or higher inclination.): Tighten adjust nut so that hillholder is released later than engagement of clutch pedal (status in Case A). Fig.When hill-holder is released later than engagement of clutch pedal (Engine tends to stall. 4.When hill-holder is released earlier than engagement of clutch pedal (Vehicle slips down slightly. adjust it by turning adjusting nut on engine side end of clutch cable at release fork. 1.

"'.... Machine slips down when starting Corrective action (l) PHV cable is elongated (2) Clutch facing is worn out (3) Bracket (cable) or stay (PHV) is deformed 5...5°.... which does not constitute abnormality. insert a shim in between the side frame and support..... Description in parentheses is a characteristic of hill-holder and does not indicate abnormality... When vehicle cannot travel (brake cannot be released) because return spring is broken. ..BRAKES Trouble and possible cause 4... Machine cannot start after stoppage (1) Return spring is fatigued or broken (2) PHV lever won't return Adjust Adjust or replace Repair or replace Replace Replace entire PHV ASSY [When the brake pedal is depressed by a force of 1... Abnormal sound is generated when operating clutch pedal (1) Grease is inadequate for the hook of return spring and sliding portion of PHV cable end (2) When releasing after maintaining high fluid pressure: (3) Clu tch system is anomalous Apply grease (Flowing sound of fluid when releasing high fluid pressure) Refer to "Clutch and pedal cable system" CAUTION: a.._. Part Number 725807000 Part Name Shim Shim [Thickness of shim is 0.. 265 Ib) or more] (3) When intentionally depressing brake pedal strongly: 6. .. '..... *)_ _a_. It is recommendable to avoid raising front of PHV excessively. 10-96 Inserting shim ·"t'·"" 'j ...+... and then return PHV lever to release the brake._. l l t ' ...•.-----__ 1"'f------_-_____n_.. ' _ _I " ' ' I-...... I'I t*t ... and one shim increases an angle of 0... drum and lining matched with each other due to inadequate depressing force to brake pedal (Abnormal sound is not generated when depressing brake pedal a little stronger) 7. k .6 mm (0.... 4 to 7 Ib) larger than the conventional specifications. The hill-holder may not be activated on a slope of an extremely small inclination. remove adjust nut. When inserting a shim. disconnect clutch and PHV.... Depressing force required for clutch pedal equipped to hill-holder specifications is 20 to 29 N (2 to 3 kg. c>... thereby raising the front of PHV. c. Abnormal sound is generated upon releasing brake pedal when stopping Rotor and pad. be sure to confirm stopping status on a slope whenever inserting a single shim._....... Never insert 2 or more shims at a time. b.. If you want to correct it._..177 N (120 kg..~II. .~..] A17·274 Fig.024 in).. '.I~ .___ 10-34 .

_- - --- _D e A17-161 C-==-O Fig. 10-101 . 10-99 ~ ~ . 10-100 A 17-162 925600000 ADAPTER. 10-97 Fig. r\ [1 '~ ~ t . DISC BRAKE CYLINDER Pressing cone spring 925590000 WRENCH. BRAKE PISTON Rotating brake piston c -- ~- -- -_. Special Tools 925450000 ADAPTER.BRAKES 10-11. WHEEL CYLINDER 11/16" Installing cap 925471000 PULLER. O-RING Installing spindle O-ring C Fig. WHEEL CYLINDER 5/8'" Installing cap 925460000 ADAPTER.. ) A17-160 10-35 .--FST-148 Fig. 10-98 e A17-163 Fig.

I.! i...: .~ ..'. I . I ".:.

.. 11-37 BELT LINE (Power Steering System) ..... 11. ... . ...8.8 TILT STEERING WHEEL . 11.. ......5.. .. . 11-46 TROUBLESHOOTING.. .. ..... ...... 11-10............ .... . . ... . 11-50 SPECIAL TOOLS .....4.. 11... . ........ .2 COMPONENT PARTS . .1.... .... .7. .. ....... 11.. ..3..... ......... ... 11-11... ..... . .. 11-18 STEERING GEARBOX (Power Steering System) .. ........5 OPERATING PRINCIPLE (Power Steering System) .. .. .... 11.. ... .. 11......7 STEERING SHAFT ..... 11....... 11-63 STEERING SYSTEM 11.. SlIBARU . ... ......... 11... ...9..... 11-11 STEERING GEARBOX (Manual Steering System) ....... .. .. . . 11. .6. . 11. .. .... . .2.... . 11-42 FLUID LINE (Power Steering System) .. 11-27 OIL PUMP (Power Steering System) .. ..... ... 11...CHAPTER 1] 1] Page SPECIFICATIONS AND SERVICE DATA.......... ..... ...... 11-12..... . 11.

Specifications r--------. Integral 00 Type Gearbox Gear ratio Backlash Manual steering Power steering o(Automatically adjustable) Rotary valve Vane pump Integrated to pump 10 cm 3 (10 cc.04 in) Rack and pinion Rack and pinion.8 US qt.2 Imp qt)/min.7.7 m (15.8 Litter (0.5 US qt.8 m (15.7 3. lock to lock Toe-in (in empty) Non-4WD 4WD 18.7 Imp qt) Valve (Power steering system) Type Reservoir Output Pump (Power steering system) Relief pressure Hydraulic flux control.394 kPa (55 kg/cm 2 . 3 Litter (3. Specifications and Service Data 1.61 cu in)/rev.4 Imp qt) 0.04 in) OUT 5 ± I mm (0.04 ± 0. 0. 0.------------------------. Hydraulic flux 700 rpm 3. 6. 600 .STEER ING SYSTEM 11-1. 11-2 Overall gear ratio Turns.6 Imp qt)/min. 2. 0.000 rpm Range of revolution Revoluting direction Working Fluid (Power steering system) Name Capacity 11-2 .-----------------------------------------------------Minimum turning radius Inside Outside (STD and DL models) 2-spoke type 4.20 ± 0. 5.4 US qt.45 Litter (0. 11-1 Fig.4 ft) (Hatchback) 4.7 ft) (Except Hatchback) Steering angle (GL model) 2·spoke soft type ~?ITl~J~?~ 16Jn~ I ! I Whole System Steering wheel diameter I I I I A18-336 A18-337 Fig.2 US qt. 782 psi) Drooping in response to engine revolution 7 Litter (7.8 I ± I mm (0.000 rpm Clockwise ATFDEXRON Reservoir Total 0.

0059 in) or less 0.039 in) Less than 32.0059 in) or less 0.6 N·m (0.283 in) Less than 0. 668 to 853 psi) Input shaft play In radial direction In axial direction Turning resistance Oil pump (Power steering system) Pulley shaft Pulley Radial play Axial play Ditch deflection Resistance to rotation Fluid capacity Regular pressure Relief pressure and working pressure 11-3 . 1.884 kPa (47 to 60 kgJcm 2 .1 ft-lb) 245 N (25 kg. 0.98 in) 35°30' to 37°30' 34° to 36° 857.18 in) from rack center at straight-ahead position: Less than 1.0059 in) or less Horizontal movement: 0.43 N (0.15 kg-m.18 in) from rack center at straight-ahead position: Less than 6.047 in) I to 3 mm (0.004 in) 0.012 in) Within 30 mm (1.6 mm (0.89 in) from rack center at straight-ahead position: 8.56 kg. 1.0.3 mm (0.3 mm (0.15 mm (0.STEERING SYSTEM 2. 1.7 Imp qt) 981 kPa (10 kg/cm 2 .49 N (0. 2.4 ft-lb) 5.3 mm (0.0 mm (0.901b) 0.78 ± 0.071b) or less 0.012 in) or less Vertical movement: 0.5 N·m (0.004 in) or less Within 30 mm (1.008 in) or less 0. 142 psi) or less 4.18 N (0.11 kg-m.12 in) Zero mm (in) 0.2 mm (0. 55 lb) or less 1 SERVICE LIMIT Steering shaft Steering gearbox (Power steering system) Sliding resistance Rack shaft play in radial direction Right-turn steering Left-turn steering 0. 0. Service Data ITEM Steering wheel Turning angle Free play Inner tire & wheel Outer tire & wheel Overall length Outer diameter of elliptical portion when rotating Run-out Collar portion Shaft end portion Clearance between steering wheel and column cover Universal joint Looseness Maximum yawing torque Folding torque (only for power steering system) Steering gearbox (Manual steering system) Rack shaft Pinion Bend limit Free play limit Rotating torque STANDARD o to 25 mm (0 to 0.0 mm (33.04 to 0.1 N·m(O.15 mm (0. l.8 Liter (0.94 kg.06 kg-m.039 in) or less 9.024 in) Less than 1.6 mm (1.1 mm (0.8 US qt.22 N (0.8 ft-lb) Maximum allowable value within 175 mm (6.1 mm (0.231b) or less 0.9 ± 1.39 lb) Maximum allowable value within 175 mm (6.63 kg.89 in) from rack center at straight-ahead position: 1.2 mm (0.15 mm (0.012 in) or less 1.609 to 5.86 kg.

3 mm (1. _'_'''''..91b) or less Idler pulley Dust seal Steering wheel efforts (Power steering system) In standstill with engine idling on concrete road In standstill with engine stalled on concrete road • Recommended Power Steering Fluid B.. .760 to 0..909 in) 19.902 in) 47.5 mm (1..._'_'1 t"1" " ' .~~_I.3 to 19. .... 5.0 mm (0...6 to 48.. .""" - .+-<11""' 1>""" 11.STEERING SYSTEM ITEM Belt line (Power steering system) Belt tension STANDARD 1 SERVICE LIMIT IS to 20 mm (0. .5 kg.. . Autran DX Texamatic Fluid 6673 Dexron CASTROL TQ Dexron Mobil ATF220 Shell ATF Dexron Texamatic Fluid 6673 Dexron 11-4 * . _ . _ _ _ _ _ _ _' _ _ _ _ _ _ _ __ . . CALTEX CASTROL MOBIL SHELL TEXACO B.780 in) 24.8 mm (0.6 to 48..P.5 kg.5 N (2..-_ _ _ _ _...5 lb) or less 93.. _rr.2 N (9.874 to 1. "·"·~~~~·~. . 20.:.874 to 1. 221b) Ditch deflection Outer diameter Outer diameter (Bearing side) Inner diameter 1.79 in)/ 98 N (10 kg. . . .039 in) or less 47.59 to 0.P..

5.5 .5.31 (2'.2.88 (8 .19) T4: 25 .10 -14) T3: 22 .40) 1 Bushing 2 Spring washer 3 Bolt Universal joint Torque rod Rubber coupling Washer Self-locking nut 9 Coupling cover 10 Tapping screw 11 Castle nut 12 Cotter pin 13 CIampB 14 CIampA 15 Flange bolt 16 Protector 17 Steering gearbox 18 Steering shaft ASSY @ 4 5 6 7 8 A18-338 Fig_ 11-3 Component parts of manual steering system 11-5 . ft-Ib) T1: 20 .6.20 (1.54 (4.65) T6: 44 .STEERING SYSTEM 11·2.25 (2.4 .22) T5: 78 .29 (2.2.2. Manual Steering System Tightening torque N·m (kg-m. 33 .0.18 .5 . Component Parts 1.2 . 16 .0 .0.14 .3.23) T2: 14 .9. 58 .3.

0 .5.0.5. Power Steering System Tightening torque N·m (kg-m.6.2 .STEERING SYSTEM 2.23) T2: 22 .25 (2. 11-4 Component parts of power steering system 11-6 . 14 .3. 33 .31 (2.2.3.22) T4: 44 .16 .54 (4.5 .5 .19) T3: 25 .29 (2.40) @ (j) ® (j) ® 00' @ i ([D ® 1 Bushing 2 Spring washer 3 Bolt 4 Universal joint 5 Joint 6 Rubber coupling 7 Washer 8 Self-locking nut 9 Grommet 10 Castle nut 11 Cotter pin 12 Flange nut 13 Clamp 14 15 16 17 18 19 20 21 22 23 24 25 26 Flange bolt Protector Steering gearbox ASSY Steering shaft ASSY Cap Idler pulley Ball bearing Snap ring Dust seal Shaft Bracket V belt Clip 27 28 29 30 31 32 33 34 35 36 37 38 39 Supporter Oil pump ASSY Connector bolt Pipe B Pipe A PipeC Pipe D Clamp A Clamp B Connector Pressure hose Return hose Hose clip A18-339 Fig.2. 18 . ft-Ib) T1 : 20 .

Relief valve (12) incorporated in the hydraulic pump ASSY limits the maximum hydraulic pressure and reliaves pressure if an excassive pressure works on the valve. the above·mentioned control valve (4) coupled to the pinion shaft works to form working fluid line according to the steering direction. Operating Principle (Power Steering System) 1) The engine drives vane pump (I) through belt to deliver working fluid. 11-7 .STEERING SYSTEM 11-3. and is fed to control valve (4) through pressure hose (3). working fluid in the other working chamber is forced out and returned to oil reservoir (11) via pipe (5) or (6). 5) When rack piston (8) is shifted. working fluid passes through pipe (5) or (6) and enters working chamber A or B of power cylinder (7). 3) When turning the steering wheel. 2) The delivered working fluid is controlled to appropriate volume ac· cording to engine speed by flow con· trol valve (2) in the hydraulic pump ASSY. b. If a trouble occurs on the hydraulic system. That is. control valve (4) and return hose (10). the steering shaft is me· chanically coupled with the pinion shaft via control valve (4) and operates the rack and pinion the same as in the manual steering system. 4) The working fluid entering either of the working chambers acts on rack piston (8) and generates rightward or leftward force on rack shaft (9). 11·5 NOTE: a. Working chamber A Pinion axle Working chamber B ® ® 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Vane pump Flow control valve Pressure hose Control valve Pipe A Pipe B Hydraulic cylinder Rack piston Rack axle Return hose Oil reservoir Relief valve Connector PipeC Pipe D @ @ Oil pump assembly Steering shaft Steering wheel A18-340 Engine Fig. thereby assisting and reducing the steering effort.

a. 6) Remove the steering shaft installing bolts under instrument panel. remov~. While lifting up lower ends of pad with taking care of bosses not to interfere with horn plate spring. 3. 7) Pull out the steering shaft assembly from the hole on the toe board. Hook Sectional view A-A A18-084 A18-373 Removing horn pad (2-spoke type steering wheel) Fig.a screw at center of back side of steering wheel and slide horn pad downward while pressing it. 11-7 Removing horn pad (2-spoke soft type steering whee/) 11-8 . In 2-spoke soft type steering wheel.STEERING SYSTEM 11·4. 3) Remove trim panel of driver's side. Construction 2-spoke soft type 3 @ @ be 1 CD (j) CD 2-spoke type 1 Steering wheel 2 Horn pad 3 Column cover 4 Steering column 5 Steering shaft 6 Nut 7 Tapping screw 8 Upper bearing 9 Combination switch 10 Hazard knob Fig. 2) Separate steering shaft and gear box by removing universal joint connecting bolt at steering shaft side. Removal 1) Open the front hood and disconnect the minus terminal of the battery. 11-6 Construction of steering shaft A18-341 2. 4) Remove ECM from steering column. b. slide pad upwards. 5) Disconnect connector for ignitionstarter switch and combination switch wiring harness under instrument panel. Disassembly 1) Removing horn pad In 2-spoke type steering wheel. Steering Shaft 1. Pull up lower areas a & b of pad to unclip bosses from lower cover.

upper bearing and horn brush). Then. if it is defective. fit a new upper column bearing so as to correspond end surfaces of column and bearing by the same manner of removal.047 in) 4. NOTE: -kEEIIS! I· If it is necessary to replace upper column bearing.024 in) Less than 1. 4) Remove horn brush by loosening a screw.9±1. 5) Remove th~ lower bearing installing screws and pull out the steering shaft with the bearing downward. Then remove upper and lower column covers.6N·m (0. Replace the bearing and/or O-ring if any trouble is found.78±0. and two combination switch installing screws.:C-~'~Support (Upper bearing portion) A18-095 Notch on bearing housing Fig.6 mm (0. CD Check yawing torque Maximum yawing torque 0. replace it with a new one. Looseness A18·344 5) Steering Shaft and Lower Bearing Check for looseness between them along the shaft and vertically toward the shaft.9 mm (33:78 in) --I ~ A18-009 NOTE: Be careful not to deform the snap ring.283 in) Less than 0. Standard steering shaft length s.98 to 1.06 kg-m.10 in)) to the bearing and tap it with a hammer. Tighten the lower bearing installing screws. Check that lower bearing is installed with no free play in all directions. O-ring and bearing with housing from steering shaft.STEERING SYSTEM 2) Remove the steering wheel installing nut and pull out the steering wheel from the steering shaft. 0. 11-8 Cross section of steering shaft 8S7. 11-12 A18-066 11-9 . 3) Check the shaft for damage.2 mm (0. 11-11 Measuring steering shaft runout Fig. 3) Remove five screws fitting lower column cover to upper column cover. Install the bearing. Inspection 1) Universal Joint 1) Check looseness along the axis and the rotation. Looseness 2) Zero mm (in) ® Collar portion (runout) @ Shaft end portion (runout) a. O-ring. 6) Remove snap ring and then remove washer. when rotated) Less than 32. 'Staked portion Fig.4 ft-lb) Support (Lower beari ng portion) ® @ ~EE:E·~iEE~P~e. Fig. washer and snap ring to the steering shaft. (Power steering) 4) Snap ring Check and replace if deformed.039 in) 1) Apply grease on the sliding portion of steering shaft (at lower bearing. and combination switch. A18·l24 @ @ (i) ® 1 Snap ring 2 Washer 3 O-ring 4 Screw 5 Shaft 2) Steering Shaft Assembly 1) Check the steering shaft for its length and straightness. S 857. b. 11-10 Steering shaft length NOTE: Straigh tness CD Elliptical portion (outer dia. 3) Steering Column Bearing (Upper and lower) Check for wear and damage. 2) Insert the steering shaft into the steering column from the lower side. 11-9 Inspection of universal joint 3) Check the seal ring for damage or the serration for wear.0 mm (33.6 mm (1. apply a wooden piece [outer diameter: 25 to 28 mm (0. Replace it with a new one. Assembly 6 Steering column 7 Lock washer 8 Housing 9 Bearing Fig. Align the cut of bearing housing and electro-united portion of steering column pipe when inserting steering shaft. (Manual steering) 2) Check the press calked part for looseness. If any trouble is found.

0 .. t .. 5) Install the steering wheel to the steering shaft..... 11-7) of pad so as to clip into lower cover.. pull (-. a... - ~ - " " · " 4 ~ ' _ ' ~ _ " ' " . Torque (Universal joint bolt) 22 ...3. ... Check brush for deformation.23 ft-lb) Torque (Steering wheel) 29 . 2) Tighten the steering shaft installing bolts under instrument pannel. 11-16 Tightening universal joint bolt .25 N'm (2.OJ... ... Align fin part of pad with lower cover front end._ _ _... then depressing (-. Install brush without fail because it is ground connection for horn circuit.. 4) Install the combination switch and column covers (upper & lower) to the steering column.-.04 . depress boss parts (a & b in Fig. 11-10 Fig.12 in) (Manual steering) Clearance If the clearance is not in the specified range. 11-13 Checking clearance 7) In 2-spoke type steering wheel.12 in) A1S-096 A1S-345 Fig. Aligning pad and lower cover laterally..0 ..31 N·m (2. ~:~]Y Lower cover Hook A18-374 6.....29 ft-lb) CD 6) Check clearance between the steering wheel and the column cover.. . .6 kg-m.. 1.2 kg-m._ . 1· .374 in) Universal joint tightening bolt Torque rod Pinion Gearbox D.2.. ® 1 2 3 4 5 6 7 * Clearance 9. ... ..3mm (0.1_ ' . .. 4) Tighten the universal joint bolt._ _ _ _ _ _ _ _""'_ _ _ _ _ _ _ _ _ _. b. a... Toe board Steering shaft installing bolts (Manual transmission vehicle) 16.. ....39 N·m (3.4. Confirm that the bolt is aligned with the notch on the steering shaft serration.5 mm (0...2) pad so that hook meets with insert.5 mm (0. _ _ _ _ _ ... 3) Connect connector for ignitionstarter switch and combination switch wiring harness under instrument panne!. b. In 2-spoke soft type steering wheel. 14 ... b..3 mm (0.0. .... install horn pad to steering wheel and tighten screw securely from the back side of steering wheel. 22 .STEERING SYSTEM 3) Install the horn brush.... Fig. loosen column cover installing screws and adjust column cover.....2 .. 16-19ft-Ib) NOTE: A1S-055 NOTE: After installation of pad.1) slightly... .0.... Fin part of pad Pad assy NOTE: a.. 11-14 Installing pad (2-spoke soft type steering wheel) (Power steering) Torque 20 .. 11-15 Installation of steering shaft Fig.0 kg-m... Make sure to insert bolt and washer from the recession of universal joint.650 in) (Automatic transmission vehicle) Clearance: 1 . check horn by depressing horn mark of pad... Installation 1) Insert the end of the steering shaft assembly into the universal joint through the grommet of the toe board.. .04 .

1 Roller 2 Lock gear 3 Return spring 4 Sector gear S Pin 6 Guide groove 7 Tilt lever A18·3l0 Lock gear disengaged Fig. The upper end of the upper shaft is attached to the steering wheel ® and the lower end is connected to the lower shaft @ by means of the universal joint @ . so that the lock gear is engaged with the sector gear. releasing the tilt lever will return the lever to the original position by return spring tension. and the lower shaft @ is incorporated in this one-piece structure. The shock absorbing unit is of an elliptic. Construction The upper shaft ® is attached to the steering lock (j) by a bearing. locking the engagement of the lock gear with the sector gear without any clearance.STEERING SYSTEM 11-5. Into the groove is inserted a pin that is unitized with the lock 2) The tilt lever is equipped with a roller that pushes the rear face of the lock gear by the lever spring. the roller on the tilt lever moves away from the rear face of the lock gear and the pin that is unitized with the lock gear moves along the guide groove. with the bolt and pin used as pivot. General The tilt steering wheel is designed to adjust up or down in seven steps from the neutral position: four steps upward (9°48') and three steps downward (7°21'). 3) When the tilt lever is pushed down. expanding pipe design while the column bracket is a collapsible column design. 4) With the steering wheel positioned at any desired angle. The force of the roller against the rear face of the lock gear is added by the "wedging" effect. as shown in the figure. This causes the roller (unitized with the tilt lever) to push the rear face of the lock gear. along with the steering lock (j). Two "arc" shaped gears are used to engage and disengage all of the tilt positions and are operated by the tilt lever. 11-17 A18-346 Fig. moves up or down. This then causes the lock gear to release the sector gear. Tilting of the steering wheel is accomplished by means of a universal joint (utilized as a pivot). 11-18 Fitted to tilt brackat aligning canter of rotation A18·309 2. The column pipe CD and column bracket ® are welded into a one-piece construction. Tilt Steering Wheel 1. which is attached to the steering shaft located beneath the instrument panel. The tilt bracket ®. Center of rotation 1 Column pipe 2 Column bracket 3 Roller 4 Sector gear S Bolt 1 Column bracket 6 7 8 9 10 Tilt lever rotation Steering lock Steering wheel Upper shaft Tilt bracket Fitted II 12 13 14 Pin Universal joint Balance spring Lower shaft A18·307 to column bracket 2 Universal joint 3 Tilt bracket 4 Upper shaft S Lower shaft CD ® @ Roller Pin Lock gear Tilt lever Sector gear Guide groove A1B·308 Fig. 11-19 11-11 A18·3ll . 3. Operation 1) The tilt lever is provided with a guide groove of gourd design. which is attached to the column bracket ® by the bolt @ and pin @. The balance springs @ are placed between the column bracket ® and tilt bracket ® to hold the steering wheel in the upward direction by their tension.

Component Parts '\---CD I 2 3 4 5 6 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 Spring washer Coating clip Steering column Stopper Lock washer Tapping screw Rod Nut Shaft (D) Lock gear Spacer Shaft (B) Tilt lever Plate Washer Self-locking nut Lever spring Vinyl tube Ground lead wire Spring washer Tapping screw Balance spring Tension cord Steering shaft ~" Lower bearing I O-ring : Washer Snap ring Tapping screw Washer Spring washer Tapping screw Coating plate Vinyl tube Washer 1. n I ® 'J A18-347 Fig.STEERING SYSTEM 4. 11-20 .

STEERING SYSTEM 5. Remedial action Replace bearing and O-ring. remove stop ring (8).2 mm (0. such as wear. Check for any abnormalities. NOTE: Be careful not to lose wave washer. 8) a. 11-21 A18-313 • Shaft runout Elliptic. Remove bolt (A). 1 Remove spring (A) using a sharp-end tool. then detach switch and universal joint shaft from tilt bracket. 644. then remove the cords and balance springs together. race. 3) Remove snap ring. c. then detach shafts (8). 7) Remove lock gear and lever assembly as a unit while sliding them. then withdraw needle (A) and race (A). Inspection Completely clean all disassembled parts. set up one end of column bracket vertically. damage. needle (8) and race (8). 5) Remove lever spring.283 in) or less 1. Repair or replace any faulty part. Part to check Lower column bearing • Wear or damage Check both axial and radial play with bearing installed on steering shaft. d.9 ± 1 mm (25. To facilitate removal. etc. as required. loosen lower bearing screws. removing grease and dust using a clean cloth. as required. then detach washer. Similarly.047 in) or less CDC? c:::r 11: ®_Cf E=L B -tL~ommin) (0.6 mm (1. then withdraw shaft and bearing as a unit downward. Remove tilt bracket.39 ± 0. then detach bushing (A). bearing and housing as a unit from the shaft. If it should be removed. • Length Specs. then remove spring (8) using a sharpend tool. 11-22 A Lower bearing location B Staked portion C Upper support location • Staked portion • Damage 11-13 . NOTE: Be careful not to scratch bearing.39 © A18-314 ® Fig. Remove snap ring. Loosen two nuts. b. as required. then withdraw shaft (E). Fig. 6) Remove two nuts and self-locking nut. and mating surface of ignition-starter switch to bearing. then detach plate. Remove stop ring (A) from the switch using a sharp-end tool. O-ring.04 in) 2 Steering shaft (collapsible shaft) Replace shaft. when rotated) Tip end of shaft (runout) CD ® 32. (D). it is good practice to set steering wheel at the extreme upward tilt position in advance. No. detach washer. 9) Do not remove rod unless it is worn or otherwise damaged. 2) Remove universal joint retaining bolt. Removal 1) Disconnect tension cords. detach washer. 4) Remove ignition-starter switch retaining bolts. Inspection 6. pressed portion (outer dia.

_ _--~+I\' 1 . .. (B) and needles (A).....> .. 0..... (B) as a unit. .. 12 13 Tilt bracket • Dents. as reqUired. ... Replace tilt bracket and lock gear as a unit. . __ .. wear or cracks on gear teeth Replace Replace lock gear and tilt bracket as a unit.STEERING SYSTEM No. ...03 kg-m.. .. Replace 6 • Deformity....._ .. Replace needles (A)..... t v..j'~1h.-url_I. Part to check Snap ring Universal joint shaft Inspection • Deformity or fatigue • Looseness • Yawing torque Looseness Maximum yawing torque Omm (0 in) Replace Remedial action 3 4 Replace shaft.OJJZ': ~ ::::::::::. "4k·... ________. (B) and races (A)..-?- .~ ·.~~ I" " .-. 11-23 .3 N·m (0.. scratches or damage 7 • Deformity or fatigue 8 • Deformity or breakage Replace 9 • Fatigue Replace 10 11 Lever spring Tension cord Lock gear • Wear._______-_- ..2 ft-Ib) VON.  '~'-I-. . .. breakage.. ... . wear or cracks on tooth faces • Wear of pin portion • Damage • Roller jamming • Deformity or cracks 14 15 Tilt lever Coating plate Replace Replace 11-14 ~-. 0.. . (B) as a unit.~' IFig. .. ./ ~ Looseness A18·315 • Damage to shaft and key lock collar at needle bearing location • Damaged or cracked key lock collar 5 Race (A) Race (B) Needle (A) Needle (B) Spring (A) Spring (B) Stop ring (A) Stop ring (B) Balance spring • Deformity or scratches Replace races (A). or poor connection • Dents...

J I 5 Wave washer 6 Shaft (E) 7 Steering column A18-319 I NOTE: NOTE: Be careful not to deform snap ring. (B) face in direction in which races (A). 11-25 NOTE: a. 0 1 Column bracket 2 Tilt bracket 3 Wave washer A18-320 b 1 Race (A) 2 Needle (A) 3 Spring (A) A18-316 6) Install universal joint shaft to ignition-starter switch. 3) Attach needle (A) to race (A). washer. After installation. turn the shaft to ensure that it operates properly without binds. Grease brand Auto Lex A or its equivalent NOTE: b ~~ Be careful not to drop or strike ignition-starter switch wh ile handling it. then insert them into ignition-starter switch. O-ring. insert bushing (A) and shaft (E). n oz) of grease to the inner walls of needles (A).28 -0·004. then install snap ring to shaft with washer in place.STEERING SYSTEM 7. 11-24 7) Apply a coat of grease to the frictional surface of steering column against tilt bracket. 11-27 11-15 . Apply a coat of grease to the frictional surface of the shaft (at the lower bearing location). (B) to the grooves in ignition-starter switch. as shown in the figure. 1 Stop ring (A) 2 Needle (A) 3 Race (A) 4 Spring (A) 5 Race (B) 6 Washer 7 Stop ring (B) 8 Spring (8) A18-317 Fig. 4) Install stop ring (A). washer and snap ring onto steering shaft. b. Grease brand Auto Lex A or its equivalent Ensure that the mating surface of ignition-starter switch is clean and free of foreign matter. then install tilt bracket. as shown in the figure. Ensure that stop rings are fitted properly in the grooves. 1 Washer 2 Snap ring 3 Shaft (E) 4 Tilt bracket 5 Wave washer 6 Bushing (A) A18-321 Fig. J (j) I Bushing (A) CD I~II . (B) are inserted as indicated by the arrows in the figure. and stop ring (B). Fig. Apply a coat of grease to the inner and outer walls of bushing as well as to the outer wall of shaft. Fig. and needle (B) to race (B). 2) Attach springs (A). NOTE: SUNLIGHT 2. 5) Apply about 3 grams (0.In ) -0. 2 Tilt bracket 3 Snap ring 4 Washer NOTE: Ensure that springs (A). to get their relative positions. SUNLIGHT 2. NOTE: Be careful not to drop wave washer. (B). NOTE: 58-0·1 mm -0.020 A18·318 Ensure that snap ring fits properly in the groove on shaft (E). Installation 1) Install bearing. Be canful not to strike or apply shocks to the joint shaft and switch during installation. 11-26 8) Align steering column and tilt bracket at the holes.5 (2 . position wave washer.

22 N·m (1. NOTE: This adjustment is important for proper function of the tilt steering and should always be made pr:iiJerly. NOTE: Ensure that the brazed portions of shafts (B). the holes in plate. then insert lock gear guide pin into the groove on tilt lever. 17) Install and tighten the ignitionstarter switch on the tilt bracket with the four bolts. .2 kg-m. 11-16 " . Return spring NOTE: Be sure to move the lever up and down several times while applying grease. until grease is applied evenly.4 ft-Ib) Fig. 5. 11-30 Self-locking nut 12) Attach spacer to shaft (0). Tightening torque Nut (4 places) A18-324 NOTE: Ensure that the brazed portions of the two shafts are inserted into the steering column's holes. then install a vinyl tube onto spring.3 kg-m. With guide pin held in that position.31 in) A18-327 10) Apply a coat of grease to shafts (8).16 ft-Ib) 9 .2 kg-m. Install plate while aligning it with bolt (A) and shafts (0).8_7 ft-Ib) II) Apply a coat of grease to the outer periphery of roller and teeth surfaces of both lock and sector gears. 18) Insert the steering shaft into the lower side of the steering column until it reaches the serration of the universal joint.16 to O.5 . then tighten all nuts securely. (0) are aligned with.9.2 . and attach spring to hook of tilt lever and plate_ A18-323 1 Lever assembly 2 Lockgear 3 Guide pin Fig.2.STEERING SYSTEM 9) Attach shafts (8). 15) Move tilt lever up and down several times until the clearance between the cutout portion of plate and tilt lever is 4 t08 mm (0. and bolt (A) with washer and self-locking nut.9 . (0). The lower two bolts should be tightened together with the coating clip. 16) Guide the universal joint through the hole in the tilt bracket. (0) and bolt (A) to the steering column. 9 . 11-29 Tightening torque 8-12N·m (0. install tilt lever on shaft (8) and lock gear on shaft (0).16 to 0. Sector gear 2 Lock gear 3 Roller 12 . Tighten nuts temporarily I Shaft (B) 2 Shaft (D) 3 Bolt (A) A18-322 Fig. 2 Plate 3 Lever assembly A18-326 Fig.1. then install the ignition-starter switch. then temporarily tighten the two shafts with spring washers and nuts.8 .8 . 14) Apply a thin coat of grease to the surface of return spring. 11-32 NOTE: Ensure that the universal joint fits into the cutout in the steering shaft's serration at the bolt hole location.1. 11-31 A18-325 Fig_ 11-33 13) Temporarily tighten shafts (8). (0) with spring washers and nuts.31in). (8) at holes. 11-28 Adjust so that the clearance is 4 to 8 mm (0.13 N·m (0. 6. Fig.

Ensure that the tip end of universal joint does not show any looseness in both vertical and horizontal directions. and install vinyl tubes onto springs. Tightening torque 20.22 ft-Ib) Body Bearing NOTE: Do not twist column covers while installing. Tightening torque 1. 11-38 1 Harness 2 Bracket 3 Column cover fixture A18-329 A18-330 Fig.18 .29 N'm (2 .8 . 11-17 . then tighten the lock washer and tapping screw.2. CD ® @ @ 1 Column 2 Ground lead wire 3 Washer 4 Coating plate A18-332 Fig. 11-36 NOTE: Ensure that the right side of the column is tightened together with the ground terminal and that coating plates are not dislocated. 24) Attach coating plates to steering column.25 N·m (2.2.0.3 kg-m.0 ft-Ib) 22 . 23) Install column cover fixture. e. 11·35 Fig. 16-19ft-Ib) Fig.2 . NOTE: Ensure that both ignition-starter switch and combination switch harnesses are arranged between the column cover fixture and mounting bracket.6 kg-m.2.3 . b. then tighten combination switch and column covers. 21) Properly insert combination switch into universal joint shaft. Tighten the universal joint with the bolt. Ensure that tilt lever is locked at each position when lever is oper· ated. 22) Install upper and lower column covers while aligning them with the bosses in ignition-starter switch. Fig_ 11-34 19) Align the holes in the steering shaft's bearing and the steering column.28 kg-m.7 N·m (0.STEERING SYSTEM 1 Universal joint 2 Bolt 3 Steering shaft A18-328 NOTE: a. Universal joint 20) Apply a thin coat of grease to the surfaces of balance springs. 11-37 A 18-331 NOTE: The cutout portion makes it easier to attach coating plates securely. 14 . Ensure that the eyes of tension cords are properly inserted into the concaves in the tilt bracket. 1. Then attach springs to the hooks of steering column and the eyes of tension cords to the concave portions of tilt bracket. 25) Install steering column on vehicle body. then clamp ignition-starter switch harness and combination switch harness with two coating clips each.

Steering Gearbox (Manual Steering System) 1.88 (8 .58 . Construction CD @-e. ft-Ib) T1: 29 .STEERING SYSTEM 11-6.36) T2: 78 (8. @-o 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Tightening torque N'm (kg-m.49 (3 . 58) T3: 78 . 11-39 Construction of steering gearbox 11-18 .5.9.65) 18 19 20 21 22 23 24 25 26 Tie-rod end assembly (LH) Tie-rod end assembly (RH) Dust seal Snap ring Nut Clip Boot Clip Tie-rod complete Lock washer Rack Pinion assembly Oil seal Snap ring Ball bearing Snap ring Gearbox unit Adapter B Adapter A Bushing A Clip Sleeve Spring O-ring Adjusting screw Lock nut A18-125 Fig. 22 .

insert aluminum plates between the vise and gearbox for preventing damage to the gearbox. Aluminum plates A18-018 Fig. NOTE: Be careful not to damage the housing inner face by snap ring and pliers.STEERING SYSTEM 2. place safety stands (rigid racks) under both front lifting points. 11-41 2) Remove tie rod end and lock nut from the tie rod. 3. 7) Remove spring and sleeve. SUBARU GUARD etc.) to the tie-rod end. 8) Detach the oil seal of pinion from the gearbox unit with a slot screwdriver. loosen the castle nut and remove the tie-rod end from the knuckle arm of the housing by using a puller etc. 3) Pull out the cotter pin. 7) Remove bolts fitting the gearbox bracket to the crossmember. 9) Remove the snap ring (larger one) with snap ring pliers. 6) Remove a boot protector. NOTE: When vising the gearbox. Disassembly 1) Vise the gearbox. Clip (large) ~ /8A Fig. and then remove boot from steering gearbox. 1143 Removing ball joint 6) Loosen the lock nut on the gearbox adjusting screw and unscrew fully the adjusting screw. 4) Remove the rubber coupling connecting nuts and disconnect the pinion with gearbox from the rubber coupling. 5) Unscrew the ball joint and remove the tie rod from the rack. 8) Pull down the steering gearbox until pinion flange is pulled out of the hole of crossmember. In order to remove the tie-rod end from the housing easily. LOOSEN. Turn gearbox backward and pull it out toward the left side. NOTE: Be careful not to damage boot with a driver or the like when removing clips (smaller and larger ones). 1142 NOTE: A18-126 Replace the oil seal with a new one every disassembly. 1140 Removing rubber coupling Fig. A18·060 1 Adjusting screw 2 Lock nut A18-304 Fig. to prevent it from turning. A18-085 Fig. NOTE: Take care not to damage the gearbox boot. 11-19 . Removal 1) Disconnect ground cable from battery. 4) Unbend the lock washer on ball joint with slot screwdriver or chisel etc. and then remove both front wheels. apply a penetrating oil (CRC. NOTE: Hold the rack with a adjustable wrench etc. 2) Jack up vehicle. 3) Remove clips (smaller and larger ones) on outside end of boot. 1144 5) Loosen nuts connecting the exhaust manifold with engine and pull down the exhaust manifold.

'--. Aluminum bar NOTE: Support the depressing force with inner race of bearing.. . ._._ _ _ _ _ __ _ _ . Fig._'. .1"""-·. _ . 11-20 "'Ir"'-~'''''''H ... . NOTE: Be careful not to damage inside of gearbox unit... 11-48 10) Pull out the pinion... . A·18·305 Bushing A A18·127 Fig..._ _ _ _ _ _ __ ....._.._."1------...... 15) Remove clip from gearbox unit with a slot screwdriver. .. A18·091 12) Remove the snap ring (smaller one) on the pinion with snap ring pliers.._ . 16) Remove bushing A from the end of gearbox unit by using a aluminum bar and a hummer.. NOTE: Be careful not to damage the bushing placed inside. .._[1-'. 11-46 Removing snap ring (smaller one) 14) Remove the oil seal and snap ring (larger one) from pinion.. ... .STEERING SYSTEM 13) Remove the ball bearing from pinion with a press... __ . . It ._.. 11-47 Removing ball bearing A18·090 Fig.... 11·45 Removing snap ring (larger one) Press Fig.. u_... 11) Pull out the rack from the pinion side of the gearbox unit.

004 in) ~ ~~ Fig. 3 Rack [ Bend limit I 0.w one" combin.STEERING SYSTEM 4.ce g". Replace. 7 8 9 Damage or deterioration on dust seal Deterioration Deterioration Crack or deterioration Damage 10 11 11-21 . If necessary. Be sure to use SUBARU genuine parts. Replace. it with n. damage or deterioration I) 2) Looseness of baIl joint Bend of tie rod i Replace.1 mm (0. Replace. deformation or bend on the tube portion 3) Wear or damage on bushing A 4) Disconnection of needle on needle bearing 5) Wear or deterioration on adapter A and B !} R'pl. 11-49 7J ~ A18-068 4 Gear box unit I) Crack on the die casted aluminum case. Replace. Replace. Replace. 2) Crack. Replace it every disassembly. inspect all removed parts for wear and damage. I Item Rubber coupling Possible cause Crack or damage I) Damage on pinion teeth such as indentation. No. cracked boot or defective sealing of the adjusting screw O-ring. 2) If a water infiltration is found in the steering gearbox when disassembling it may be caused by a defective oil seal on the pinion. 2 Pinion assembly 2) Smoothness of rotation or looseness of ball bearing 3) Snap ring deformation Oil seal Damage on rack teeth such as indentation. wear or crack. replace each parts with a new one. Replace. 5 6 Boot Tie rod complete Tie rod end Spring (Adjusting screw) Boot and clips O-ring of adjusting screw Sleeve Crack. Replace it with new one as combination of pinion and rack. if necessary make repair or replacement. wear or crack Corrective action If wear or crack is notable. Bend of rack shaft 4) I) 2) 1 I R'pl". Inspection I) In accordance with the following table.box unit. Replace. Replace.tion of pinion and rack. Replace gearbox unit. replace it with new one.

snap ring may be improperly installed.5kg(l. ®~ Snap ring A18-073 A18-070 00 ~:= 3 Adjusting screw 4 O-ring Fig. So remove oil seal and then check snap ring installation. 11-51 Assembling rack 4) Apply grease on the teeth and specified portion of the pinion assembly. netO.020 in) from the end of the gearbox unit.9 mm (0. 3) Set the rack end to be located at 76. 11-53 Grease application A18-072 Fig.012 in) I Specified grease for gearbox VALIANT GREASE M2 [Parts No.1lb)] 1) Apply grease on the bushing A after fitting in bushing A and clip with a press.7 mm (3. 11-50 Install the oil seal.9 mm (0. NOTE: Fill up grease.STEERING SYSTEM s. 11-56 5) Install large size snap ring in to groove to fix ball bearing. 8) Install CD sleeve and ® spring in turn and then screw in @ adjusting screw. NOTE: 76. in the straight-ahead drive condition. Limit 10 .3 mm (0.035 in). When the clearance between the flange of oil seal and gearbox is more than 0. 1 Ball bearing 2 Snap ring 3 Oil seal A18-071 Fig. NOTE: Insert rack from pinion side surely to prevent bushing A from damage.7 mm (3. A18-093 Fig. 36° clockwise from the center line of the hole where the sleeve is to be set. Clearance 0. confirm that snap ring turns smoothly for checking of proper installation. Use only SUBARU genuine grease for gearbox. 11-57 11-22 . 11-52 Direction of pinion ASSY A18·094 Fig.020 in) A18-092 After inserting snap ring. 11-54 Fig. 11-55 Bushing A A18'069 Fig.035 in) 7) 2) Apply grease on the teeth portion and sliding portion of the rack and insert it into the gearbox unit. 003608001. and insert it into the gearbox unit to mesh with the rack in a position where the direction of the pinion flange is inclined. @ ~ Fig. Assembly NOTE: Pinion flange position in straight-ahead drive condition 6) Measure the clearance in the direction parallel to pinion shaft.

0025 in) between the screw tip and sleeve. 76. screw in and tighten ball joint assembly. 11-58 Adjusting screw Torque (Ball joint) 78 N·m (8. 12) Bend the lock washer toward the plain surface of the ball joint.063 mm (0.m. 11-23 . When bending the lock washer. Put the rack and pinion in straight·ahead drive position.0 kg. 11-62 Bending lock washer 10) Check the engaging condition of rack and pinion by turning the pinion with hand.020 in) Torque (Lock nut) 29 -49 N·m (3. Do not leave sharp edge on bent lock washer. Turn adjusting screw until the turning torque increase steeply. confirm that the whole of boot turns smoothly. and then turn back it 1/24 turn (ISO).020 in) 76. I-----@ Marking of straight ahead drive condition 2 Oil seal 3 Pinion shaft NOTE: A18-076 Fig.7mm (3.0 kg·m. readjust backlash. 22 .STEERING SYSTEM 9) Adjust backlash between rack and pinion as follows. always put the ball joint on the plane block. If turning is unusually heavy or harsh. 58 ft·lb) A18-128 Fig.0 . This adjustment leaves a clearance of 0. 11-59 Straight-ahead drive condition NOTE: Hold the adjusting screw with a wrench to prevent it from turning while tightening the lock nut. Lock the adjusting screw by lock nut. Fig. Apply grease A18-0l8 Fig.36 ft·lb) A18-075 Fig. paint marking on the pinion shaft and oil seal.7mm (3. Aligning the cut portion of rack and the nail of washer. After installing. NOTE: Hold the rack with a wrench to prevent it from turning while tighten· ing the ball joint.5. 11-60 A18-074 1 Sleeve 2 Spring 3 O·ring 4 5 Lock nut Adjusting screw 6 Apply grease 11) Fit the lock washer on the screwed portion of the rack end. 11-61 Tightening ball joint 13) Apply grease to the specified portions of the boot and then install it to gearbox.

Clip (smaller 15) Screw in the lock nut and tierod end to the screwed portion of tierod and tighten the lock nut temporally in a position shown in figure.1 ft-lb) Fig_ 11-66 Installing gearbox NOTE: Use screwdriver with blunted tip to prevent boot from damage.5 kg-m. . b.. .. Straight-ahead position within ±30 mm (1... The groove on ball joint. 1. _ .. '-. " I 6. Installation A18·348 Fig..5 .. 6l: e:g=:q. +\1 +'..~ r Reverse after installing Apply grease Apply grease NOTE: If boot deflates when pinion is turning..«~~_ .. 2) Align the gearbox with the crossmember brackets and tighten the clamp installing bolts.·"'.11 kg-m. _ . .54 N·m (4.40 ft-lb) NOTE: a. t .:..... refill air. After installing. A18-06l ·1-<-.1 N'm (0. Torque (clamp bolt) ¢ Fig..... Right one RH Identification mark Left one LH 1 2 3 4 Crossmember Screw Cover Torque rod 5 6 7 8 Rubbercoupling Bolt Clamp Gearbox Install boot in grooves firmly. 11-24 _ _ _ _. 0. Be careful to avoid damaging the gearbox boots.. Pinion rotating torque 14) Fix clips (smaller and larger ones) at the specified position of boots. _ '.to the following portions in both sides of assembled steering gearbox.. 11-63 1) Insert the gearbox ASSY into the crossmember from the left side. c.. The groove on gearbox or the groove on adaptor.·. 11-65 NOTE: 23 mm 109'. * ... . 33 . The groove on tie-rod.. 11-64 16) Confirm the operation of the pinion by turning round it.STEERING SYSTEM I .. check boot end is positioned into the groove on tie-rod. . when installing...5. draw out rack until maximum turning position and then apply grease again to the teeth and the sliding portion of rack for both sides._ . 2.0' +FE.1 _ .. .8 ft-lb) 1..18 in) from rack center Maximum allowable torque Less than 1.. 1.._"'... 3.... Check boot is installed without unusual inflation or deflation. NOTE: Pay attention to the difference between the right and left tie-rod ends.5 N'm (0. .15 kg-m.~"l< . A18·079 Fig. A18-080 Tighten the left clamp (pinion side) first. Install the fitting portions of boots .""'.. ' 1 .r._ _ _ _ _ _ __ . Before installation of boots... 44 . -_ _ _ _ _ _ _. .

0 . loosen the lock nuts of the tie-rod ends and.2. Then insert a new cotter pin and bend it around the castle nut.9. 7) Install the front wheels and lower the vehicle.88 N'm (8.04 in) OUT 5 ± 1 mm (0. 11-67 Adjusting clearance 6) Connect tie-rod end to knuckle arm and tighten it by using castle nut.22 ft-lb) NOTE: 7. b. 1) Adjust the road clearance to the standard value. Install the exhaust manifold.04 ± 0. 8) Tighten wheel nuts. 19 . 11-71 Toe-in adjustment 11-25 .STEERING SYSTEM 3) 4) Install a boot protector. a. Use new self-locking nut.0 kg-m. Torque (Self-locking nut) 14 . tighten additionalv in one-sixth (1/6) turn until both holes of bolt and castle nut align each other.3. Do not strike the cap on the bottom of tie-rod end with hammer or the like. 11-69 Tightening lock nut When adjustment is necessary.0 kg-m. then turn the 'tie-rods as shown in figure. Torque (Nut) 5) Connect the rubber coupling with the self-locking nuts. 58 .29 N'm (2.4 . Fig.5 . A18-063 Fig. b.6 . correct the steering wheel setting position to the straight.20N·m (1.3. If the clearance between coupling and cover is not uniform. adjust the cover position bV loosening the screws. 9) Tighten the lock nuts of tie-rod ends. After tightening the castle nut to the specified torque. Torque (Lock nut) 78 . Adjustment Adjust the toe-in of front tires. 2) In order to put the rack to the center of gearbox. Check the steering wheel setting position.0 kg-m.22 ft-lb) When the steering wheel is turned more than 9° [30 mm (1.04 in) 1 Rubbercoupling 2 Cover 3 Screw 4 Self-locking nut Fig. 11-70 Steering wheel setting position 3) Check the toe-in.14 ft-lb) A15·078 Fig. 10 . 18 . 25 . @ Toe-in (when empty) Except 4WD 4WD A18·064 Adjust the clearance all round uniformly A18·08l 1 ± 1 mm (0. 11-68 Connecting tie-rod end with knuckle arm NOTE: a.65 ft-lb) Fig.18 in) round] from the straight. Torque 25 .29N'm (2. after adjusting toe-in and turning angles. match the white paint marks on the gearbox and the pinion.20 ± 0.0 kg-m.

. . if tie-rod is found to be abnormally loose. . Do not allow clip on the small end of boot to come off. Tie rod one-fourth (1/4) turn adjusts steering wheel round distance 10 mm (O. 11-73 NOTE: After removing boot.4mm (0. . A18·350 Fig. 11-74 Large end Small end A18·349 Fig. .. inspect ball joint.. Measuring Axial Displacement of Ball Joint of Tie-rod Complete (On car) Upon inspection. Remove the boot's small end from the tie-rod groove first and then the large end.. replace tie-rod CP with a new one. coat ball joint with specified grease (VALIANT M2) and properly reinstall boot as before.STEERING SYSTEM 4) Inspect the turning angle. 1) Boot must be moved aside. One operator reads the dial gauge indicator under vehicle while the other turns steering wheel 15° to 20° right and left several times.... Move boot to tie-rod end and hold it stationary with adhesive tape._ .-· ' . ' . measure its axial displacement in the following manner.. 11-72 Adjusting tie-rod A18·083 8. . 3) Set a dial gauge as shown. Clean all mud off tie-rod... Axial displacement limit O.016 in) 5) After the above work..~-.36° NOTE: If the adjustment of steering angle is necessary after adjusting toe-in.. adjust the right and left tie rods by turning to the same direction and same turns at a time. Next move boot aside.. 11-26 ..jU. If the displacement is not within the limit. If the reading exceeds the limit.37°30' Outer wheel: 34° .. NOTE: Be sure that boot is properly fitted in the grooves of gearbox and tie-rod CP with clips attached in place. Rack Fix magnet on tie·rod.--. and move it toward tie-rod end as far as it will go. Fig.39 in). Put vehicle on the ground. If it is extremely soiled with mud or rusty due to the entering of muddy water. replace both tie-rod CP and boot. 4) This measurement requires two operators.. " ! . Place push rod end on socket end face. 2) Remove boot from gearbox.. '''11-'--------------------_--_______ I . Inner wheel: Turning angle (in empty) 35°30' . replace tie-rod. 41.

Construction 1 Tie-rod end ASSY LH 2 Tie-rod end ASSY RH 3 Dust seal @ \ 4 Snap ring 5 Nut 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Clip Boot Clip Tie-rod CP Lock washer Dust seal Clip Air vent pipe Sleeve Spring O-ring Adjusting screw Lock nut Gearbox unit Adapter Valve ASSY .36) T3: 78 . ft-Ib) T1 : 78 (8. .I nput shaft Torsion bar Rack piston Valve housing Rack axle A 18-137 Fig.65) A18-351 Fig. 22 . 58) T2: 29 .9. 11-76 11-27 .5. Steering Gearbox (Power Steering System) 1. 11-75 Steering gearbox Control valve Power cylinder I .49 (3 . 58 .88 (8 . ' CW@@@@ Tightening torque N·m (kg-m.STEERING SYSTEM 11-7.

"'-". . . In order to remove tie-rod end from housing easily. LOOSEN.. NOTE: Be careful not to damage boot with a 11) After taking out piping...STEERING SYSTEM 2. and pull up joint ASSY.. Removal 1) Disconnect ground cable from battery. Fig. otherwise oil leakage might be caused.'. b. install vinyl tubes onto gearbox and piping to prevent the fluid from splashing. . 6) Remove boot protector. and drain the working fluid while turning steering wheel clockwise and counterclockwise.._._______ . 925670000 and Handle. 2) Pull out air vent pipe from boot. A18·352 Fig.. "'41-~. 1 -_4. 11·79 NOTE: a.. A18·152 Fig. 4) Take out boot with clip (large) and clip (middle). A18-159 NOTE: Remove a flare nut of which width across flats is 14 mm (0. .) to tie-rod end.-_. wrap waste cloth around flare nuts. 4) Detach jack-up plate.-____. and take out spare tire. c..... After removing flare nuts. 925680000)... screwdriver or the like when removing clip.1'.-'. apply a penetrating oil (CRC. . 11-80 Fig. . and remove front exhaust pipe._. 11-78 Removing flare nuts 10) Remove the bolt to fix both piping and gearbox to crossmember.. ._. 11-28 5) Unbend lock washer on ball joint with slot screwdriver or chisel etc.·...•. Take care to prevent dust and foreign matter from adhering andl or entering onto joint portions of hydraulic piping as well as gearbox.. Pay attention not to damage gearbox boot..55 in) by using special tools (Socket..._. 11·81 A18-157 NOTE: Be sure to vise gearbox by using special tool. . NOTE: a. SUBARU GUARD etc...... between vise and gearbox. loosen castle nut and remove tie-rod end from knuckle arm of housing by using a puller etc.... 3. When removing flare nuts. 7) After removing flare nuts at center of power steering gearbox.. detach power steering gearbox... Be careful not to damage flange portion of gearbox by excessive load when removing bolts. Fig.. 5) Disconnect cap from O 2 sensor. NOTE: Pay attention to prevent rack surface on the right side from being damaged by a tool or the like.__________. 925690000).... 3) Pull out cotter pin. 11·77 Draining fluid A18·156 Fig. 9) Remove flare nuts of control valve above crossmember. 11·82 8) Remove bolts on bottom and top sides of joint ASSY. b. Remove tie-rod end on another side housing in the same manner. Disassembly 1) Vise gearbox by using special tool (Stand. 2) Jack up vehicle and place safety stands under both of front lifting points and then remove both of front tires and wheels. Never vise gearbox with inserting aluminum plates etc. 3) Remove clip (small) on outside end of boot.

replace each parts with a new one. 925700000) to prevent it from revolving. b. 11-85 Loosening lock nut If a water infiltration is found in the steering gearbox when disassembling it may be caused by a defective dust seal on the input shaft. NOTE: a. 2 Input shaft (1) Bend of input shaft (2) Damage on serration 3 Dust seal (1) Crack or damage (2) Wear 11-29 . Inspection • In accordance with the following table. cracked boot or defective sealing of the adjusting screw O-ring. If necessary. replace entire gearbox . inspect all removed parts for wear and damage. lip is worn out or damage is found. I Parts Rubber coupling Inspection Crack or damage Corrective action If wear or crack is notable. If bend or damage is excessive.ASSY. hold rack with a wrench or special tool (Wrench. 4. replace it with new one. 8) Take out spring and sleeve. If outer wall slips. While removing right-hand ball joint with tie rod. No. 925700000) to prevent it from revolving. 9) Remove dust seal by using a screwdriver. hold rack with special tool (Wrench. 11-83 Removing left-hand ball joint Fig. 11·84 Removing right-hand ball joint 7) Loosen lock nut on gearbox adjusting screw. NOTE: A 18-160 Fig. and make repair or replacement if necessary. While removing left-hand ball joint with tie rod. Fig. carefully prevent housing from being damaged and foreign matter from entering the inside. replace it with new one. and unscrew fully adjusting screw. NOTE: When removing dust seal.STEERING SYSTEM 6) Unscrew ball joint and remove it with tie rod from rack.

(Refer to "Service limit". Parts Rack and pinion Inspection Poor mating of rack with pinion Corrective action 4 (1) Adjust backlash properly. replace gearbox ASSY with new one. (Refer to "Service limit". check if rack and pinion engage uniformly and smoothly with each other. damage or deterioration Replace Replace Replace 7 8 (1) Looseness of ball joint (2) Bend of tie rod 9 10 Tie rod end Adjusting screw spring Boot clip O-ring of adjusting screw Sleeve Damage or deterioration on dust seal Deterioration Replace Replace 11 Deterioration Crack. damage or deterioration Crack.STEERING SYSTEM No. replace gearbox ASSY with new one.) 6 Boot Air vent pipe Tie rod complete Crack. 5 Gearbox unit (1) Bend of rack shaft (2) Bend of cylinder portion (3) Crack or damage on cast iron portion Replace gearbox ASSY with new one. (4) Damage on coupled portion (5) Wear or damage on rack bushing If free play of rack shaft in radial direction is out of the specified range.) (2) Keeping rack pulled out all the way so that all teeth emerge. Even if abnormality is found in either (1) or (2). damage or deterioration Replace Replace 12 13 Damage Replace 11-30 . (Refer to "Service limit" . replace entire gearbox ASSY. By measuring turning torque of gearbox and sliding resistance of rack.) (6) Wear on input shaft bearing If free plays of input shaft in radial and axial directions are out of the specified ranges. check teeth for damage.

0059 in) or less Direction (Left-tum steering) A18-172 Fig. 55 lb) or less U 98N (10 kg. vise gearbox by using special tool (Stand. Never vise gearbox with inserting aluminum plates etc. 11-89 (Right-turn steering) (Left-turn steering) A18-171 -l 1. Rack shaft play in radial direction (Right-turn steering) Service limit 0.. replace gearbox with a new one.15 mm (0. Fig. ~ Service limit 0.0059 in) or less NOTE: When making a measurement./" ~/ ! Direction ~ ..15 mm (0. 11-87 A18-165 .15 mm (0. 221b) A18-168 Fig.0059 in) or less Fig. between vise and gearbox. (In axial direction) Service limit 0./ :\r(D~ Fig. 11-88 A18-166 A18-169 11-31 .3 mm (0. If it exceeds the specified service limit.1 mm (0_004 in) or less 22 Ib) Fig. 11-86 Sliding resistance of rack shaft Service limit 245 N (25 kg.012 in) or less 0. 925690000).STEERING SYSTEM • Service limit Make a measurement as follows. 11-90 A18-170 Input shaft play (In radial direction) Service limit A18-164 0. 11-91 98 N (10 kg.

..._ ~ . Torque (Lock nut) 29 . 4) Press-fit dust seal while tapping it via a spanner or the like so that stepping between gearbox and dust seal is nonnally 2 mm (0. 2) Apply grease to sleeve insertion hole..'1 """ it" ...391b) 8... Move rack shaft to stroke end two (2) or three (3) times to squeeze grease which accumulates on both ends.. 11-93 6) Adjust backlash of rack and pinion in the following manner...... 11-94 Fitting dust seal 11-32 ... Turn adjusting screw until turning torque increase steeply. Lock adjusting screw by lock ..nut... oil seal at the inside might be damaged..49 N·m (3 ... When moving rack to stroke end without tie-rod attached.. prevent shocks from being applied at the end.. . tighten adjust screw to 5 N·m (0..08 in) Hold adjusting screw with a wrench to prevent it from turning while tightening lock nut. 3) Apply grease to dust seal insertion hole..' -.... 11-95 (Maximum allowable resistance) Apply clean grease with clean hands..0050 in) between screw tip and sleeve. net 0. into input shaft that rack shaft completely. NOTE: or less Use only SUBARU genuine grease for gearbox. 22 ..08 in). Specified grease for gearbox VALIANT GREASE M2 [Parts No..-n . c.. 5) Install sleeve and spring in turn and then screw in adjusting screw. Assembly Depth 2 mm (0. and then turn back it 1/12 turn (30°)..126 mm (0..18 in) from rack center Maximum allowable resistance Less than 6. 3. ·~"Hh'_~'~"-""""'·. If material having a sharp edge is used for applying grease.5 kg-m.63 kg..r .STEERING SYSTEM 1) Apply grease to teeth of rack so that grease applied is about as high as teeth. rack shaft play in put steering wheel and turn it fully so is out of gearbox NOTE: s.. NOTE: Never directly hit dust seal when pressfitting it. I "'11 ' .6 ft-lb) and return it about half a rotation........ ....5 kg-m.5 kg (1. NOTE: Apply grease to O-ring set groove and spring set space. 1.1Ib)) Fill up grease A 18-177 Fig... ' ... and also apply a thin mm of grease to sliding portion of rack shaft. NOTE: A18-173 Fig. ...... portion at end of rack shaft. This adjustment leaves a clearance of 0..901b) a. 1..... ®~ m~ ~ ~ I 00 ~ Slom 2 Spring 3 Adjusting screw 4 O-ring A18-073 Service limit NOTE: Fig. A18-353 Fig...86 kg.. Do not apply grease to threaded . . To make sure that sleeve is in contact with rack.36 ft-lb) NOTE: When measuring radial direction.. 003608001. Remove grease to prevent it from choking air vent line..43 N (0.....18 N (0. 11-92 Turning resistance of gearbox Straight-ahead position within 30 mm (1.. b.

Torque (Ball joint) 78 N·m (8. /. The groove on gearbox 2. 11-101 Fig.~IiP (middle) Reverse after installing Apply grease and install boot in groove firmly A18-372 Fig. 11-96 7) Check for service limit as per article of "4. when installi ng. Service limit". otherwise oil leakage might be caused. The groove on tie rod c. 11-102 Inserting air vent pipe NOTE: a. 1. after removing gearbox assembly from stand. 925700000) to prevent it from revolving. Do not leave sharp edge on bent lock washer. align stopper projection with notch in gearbox groove. 8) Fit new lock washer on screwed portion of rack end. Make sure that boot is installed without unusual inflation or deflation. 11-99 Bending lock washer 10) Fit clips (large and middle) to boot. 11-98 Tightening right-hand ball joint Fig. b. always put ball joint on plain block. 12) Insert air vent pipe into the specified hole in boot. Do not apply grease to air vent pipe. While tightening left-hand ball joint. Install fitting portions of boots to the following portions in both sides of assembled steering gearbox. Fig. Clip (small) NOTE: When bending lock washer.-1 (0. A18-181 Clip (middle) Fig.0 kg-m. While tightening right-hand ball joint.STEERING SYSTEM H~~~ 10. 9) Bend lock washer toward plain surface of ball joint. Make replacement and adjustment if necessary. The groove on ball joint 3. NOTE: a.0050 in) 1 Sleeve 2 Spring 3 O-ring 4 Lock nut 5 Adjusting screw A18-179 b. After installing. By rotating boot. b. 11-97 Tightening left-hand ball joint A18-159 Install boot in Apply grease and install boot in groove firmly EfBf==:::::1~rt=3 A18-182 Fig. Use screwdriver with blunted tip to prevent boot from damage. A 18-160 Fig. 11-33 . Inspection. Aligning cut portion of rack and nail of washer. c. screw in and tighten ball joint and tie rod. 11-100 NOTE: a. 58 ft-Ib) NOTE: a. Pay attention to prevent rack surface on the right side from being damaged by a tool or the like. check boot end is positioned into groove on tie-rod. otherwise air connection might be shut off Or pipe might be pulled out easily. 925700000) to prevent it from revolving. 11) Fix boot end with clip (small). hold rack with special tool (Wrench. and then install boot to gearbox while holding boot flange.126 mm . hold rack with a wrench or special tool (Wrench.

.40 ft-Ib) NOTE: Install boot protector.-·~l-~_""'~. t.. 12 . 11-34 j~ "$I' 1 ··'"'1t-··J.3. t-k. If it is inserted with an excessive force.......34 N·m (2. f' ... 925680000)..0 . Torque (Flare nuts) Pipe A and B 16 ..36 ft-lb) Pipe C 6. adversely affecting air connection. 33 ... NOTE: Torque (Bolt) Screw the front left bolt halfway.. 925670000......91 in) Torque (Bolts) 44 ... 33 .._ _..5 ...... and tighten lock nut temporally in a position as shown in a illustration......5 kg-m*.... A18-183 Fig. 29 ... and connect cap of O2 sensor. its tip exceeds stopper and comes in contact with wall of boot. Proper insertion distance up to the end is 13 mm (0. Be careful to avoid damaging gearbox boots. 23 mm (0.I -.5 kg-m.5..14 ft-lb) 25 .. and Handle. Right one Identification mark RH Fig.. Holding tie-rod end. B.40 ft-lb) 4) Wind pipes A and B with clamp and tighten a bolt to flx both gearbox and the piping to crossmember. it is liable to slip off. turn assembly slowly at a radius one (1) or two (2) times as large as possible.... C and D. PipeD * Recommended value for the flare nut at control valve. 3) Connect pipes A..2_0 kg-m.5 kg-m. Fig.. Installation 1) Insert gearbox assembly into crossmember....i . 18 ..51 in).54 N'm (4..' .25 ft-lb) 39 ..5 .0 kg-m.... If pipe is inserted less than the value. After all..5 . ' .' ...49 N'm (4. repeat lock to lock two (2) or three (3) times as quickly as possible...6 .. 11-106 6) Install exhaust manifold.5.54 N·m (4.. A18-354 Fig.. 11-104 Inspecting gearbox ASSY A. 11-105 Tigh tening bolts A 18-156 14) Inspect gearbox assembly as follows. make sure that boot is installed in the specified position without deflation. 2) Align gearbox with crossmember brackets and tighten bolts to install both clamp and gearbox.20 N·m (1... Flare nut of pipe C at control valve can easily be tightened with special tool (Socket. t _.. 11-108 A18-184 Fig. B. 11-107 Tightening a bolt A18-352 Left one LH Fig.. 5) 44 .. Holding tie-rod end. Insert pipe until it reaches stopper. that air vent pipe without being disconnected and that grease is not sucked into air vent pipe.5..... 13) Screw in lock nut and tie-rod end to screwed portion of tie-rod. 11-103 A18-080 NOTE: Pay attention to difference between right and left tie rod ends....-...STEERING SYSTEM b..

A15-078 Fig.38 ft-lb) 25 .9.0 kg-m.3. Torque (Nuts) 78 . Then insert a new cotter pin and bend it around the castle nut.5 . b.6 kg-m. otherwise vane pump might be seized up.29N'm (2. tighten additionally in one-sixth (1/6) turn until both holes of bolt and castle nut align each other.25 N·m (2.2. 18 . 1.6 . dirt and grease from around the steering gearbox prior to removal of the unit from the vehicle. (For more details. 14) Tighten bolts to fix both jackup plate and clamps for piping.25 ft-lb) NOTE: a.2 . Care must be taken to avoid getting any dirt into the gearbox ASSY when servicing. 31 .65 ft-lb) 7) Install steering joint assembly as follows. 13) Check the fluid leakage at flare nuts after turning steering wheel from lock to lock with engine running. Replacement of Valve Assembly NOTE: a. Steam and/or a degreasing agent is suitable for this procedure. 16-19ft-lb) 9) Install front wheels by tightening wheel nuts. Fig.3. 15) Adjust the fluid level in the reservoir. Do not strike cap on bottom of tie-rod end with hammer or the like.3 kg-m. 11-110 Connecting tie-rod end with knuckle arm Torque 22 .29 N'm (2. 11-109 8) Connect tie-rod end to knuckle arm and tighten it by using castle nut.3. 3.5 kg-m. (For details. NOTE: Never start the engine before feeding the fluid.0 kg-m.22 ft-lb) Fig. 58 . Insert joint to steering shaft fully. and fit spare tire. 11-112 NOTE: At adjusting toe-in.5 .) 9. Tighten bolt for yoke and then tighten bolt for joint. Pull up joint after installing bolt through yoke.88 N·m (8.22 ft-lb) 42 .) 8. 11-111 Torque 11-35 .52 N'm (4. A18-153 7. Measuring Axial Displacement of Ball Joint of Tie-rod Complete (On-car) (See page 1] -26. refer to the section regarding fluid line. 11) Feed the specified fluid and discharge air.) Fig.) 16) Tighten lock nuts of tie-rod ends after adjusting toe-in and turning angles. 10) Connect minus terminal of battery. 18 . and confirm bolt to be aligned with notch on serration. 19 .5. Push down yoke fully towards gearbox side. refer to the section regarding fluid line. NOTE: Make sure to hold piping properly by the clamps. b. 12) Jack up vehicle again and take out safety stands. 4. 2.0 .0 kg-m. Adjustment (See page 11-25. Clean all fittings carefully before removal. and then lower vehicle. 25 .STEERING SYSTEM Torque Nuts at engine Bolts and nuts at exhaust pipe Bolt at hanger 25 . clasp boots to keep boots from rotating and twisting.3 . After tightening castle nut to the specified torque. Clean all debris.34 N·m (2.

. 1 Adjusting screw 2 Spanner (925640000) A18-359 Fig_ 11-117 A18·162 NOTE: Fig.. b. 11-36 . )~'.. 11-116 Fig..I · . *.. 11-115 1 I 1 .. ~. 7) Tighten two housing bolts in alternating sequence so as to draw the components together evenly without distortion. 3) Remove two bolts securing the valve ASSY..STEERING SYSTEM 1) Removal Remove gearbox.r ~ Fig. 14 . (See page 11-28. 6) Insert valve ASSY into gearbox with the notch of input shaft facing the adjusting screw on gearbox.. . .'-. PIN. ....) 2) Disassembly 1) Mount gearbox in Stand (Special tool 925690000).29 N·m (2 . . 4) Separate valve ASSY from gearbox by pulling input shaft and valve housing as a unit. . Unscrew adjusting screw completely. 2) Apply SUBARU genuine steering grease (VALIANT M2. Do not remove 4 plugs until gearbox has been reinstalled into vehicle.._1'_ . NOTE: NOTE: Never attempt to vise gearbox alone as this will damage the gearbox.._'___________________ .. A18·357 Fig.._ _ .+.d .. 4) While holding pinion into valve housing. _ ... 00360800 I) to ball bearing and pinion gear portion. 3) Set the rack to the extreme right hand turn position.. . . . 11-114 Do not allow the cleaner to enter the Valve ASSV.r_'. 20 .. Do not allow pinion to slip out of housing as this will damage "V" packing.. k1" I I 5) Install a new gasket on the gearbox.22 ft-lb) Torque A1Q·358 A18-360 Fig. 11-118 " j~ ".. 11-113 }- /) A18·356 5) Inspect needle bearing which is pressed in gearbox for wear or deformation. cut the shipping band... Notch portion of input shaft \ CD 3) Assembly 1) Prepare new ASSY for installation by cleaning rust preventive grease from pinion gear and bearing with clean kerosene or degreaser.3 kg-m. . _ .k.... nl"'tl-'--------'.. Replace as necessary.. Secure Stand in a vise.. Stand (925690000 ) a. 2) Loosen locknut on gearbox adjust· ing screw..

Measurement of steering effort.54 (4.40) Spring washer Bolt Spring washer Bolt Flange nut Stay Supporter Spring washer Bolt Hose clamp Fig. c.5 kg-m.5. Steering condition.49 N·m (3 .13) T2: 44 . a.5 kg-m. 10 . If excessive tightness. Noise and vibration.5 .6 ft-lb) torque] . binding or looseness is felt. Tighten adjusting screw until it gets tight. 22 . tighten lock nut. 1. b. f. Back it out 30° (1/12 turn). 11·119 A18-361 11-37 . g. ft-Ib) T1: 14 . c. Back the adjuster out 1/2 turn. d. 33 . h. Clearance. NOTE: It is recommended to recheck the above after several days. Installation of gearbox.36 ft-lb) 9) Check the adjustment by turning the input shaft in both directions by hand. 4) Installation As for the following service procedures and checkings.5. e. Torque 11-8. Piping of fluid line. 29 . b. Fluid leakage. Oil level. refer to the power steering section in this chapter. Oil Pump (Power Steering System) 1. Construction r--@ CD ® I ® I I (j) I Tightening torque N·m (kg-m. 3.4 . While holding the adjuster.8.18 (1. Tighten adjusting screw until sleeve contacts rack [5 N·m (0.STEERING SYSTEM 8) Adjust the backlash of rack and pinion as follows: a. repeat the adjustment procedure.

Disassembly and Assembly 1) To take out oil pump pulley. loosen lock bolt by giving it about two more turns. 3. 5) Pinch brim of idler cap by pliers with waste cloth around it. two ways with two spanners or combination of a spanner and a screwdriver. After removing flare nuts. 9) Take out electric wirings and hoses that extend beyond oil pump to permit the removal of oil pump ASSY. 11-122 . install vinyl tube onto gearbox for drainning fluid. wrap waste cloth around flare nuts to prevent fluid from splashing.STEERING SYSTEM 2. 11-121 A18-192 NOTE: a. When removing flare nuts. 8) Disconnect hoses from air cleaner and take out air cleaner by removing bolts. and the belt will become ready for easy removal. 12) Remove bolts and a nut installing oil pump ASSY onto brackets. and take it out.13 ft-lb) NOTE: In case pulley turns idly. 10) Remove hoses at the back side of oil pump ASSY after taking out engine oil level gauge. otherwise the cap might be damaged. tighten bolts halfway with belt slackened. A18-193 NOTE: After adjust bolt is loosened by turning counterclockwise. idler pulley will normally be slid upward by the tension of oil pump belt. 10 . 7) Turn adjust bolt counterclockwise. remove bolts fixing the pulley to oil pump ASSY in advance of removal of oil pump with belt tightened. 4) Adjust belt and then tighten bolts completely. 2) Take out pulley with belt slackened. the remedy NOTE: required can be effected in either of Wrap clean waste cloth or the like around the ends of hoses to keep dust or the like out. 3) To fix pulley in position. and gently hit the head of adjust bolt by plastic hammer until the idler pulley slides. A 18-187 Fig. Fig. In case idler pulley fails to slide upward with adjust bolt loosened. 3) J)etach jack-up plate. 2) Jack up vehicle and place safety stands under both of front lifting points. 11-38 A18-194 Fig. 11) Take out stay by removing its fixing bolt. Removal 1) Remove ground cable from battery. 11-120 NOTE: Do not pinch idler cap directly by pliers without cushioning waste cloth around it nor remove it by using a minus-head screwdriver. NOTE: After taking out air cleaner. and take out oil pump ASSY. and take out spare tire and carburetor shield. NOTE: Take care not to allow dust or the like to collect on the junction with hoses.1.4 . and take out oil pump belt. b. seal carburetor to prevent dust and foreign matter from entering. 6) Loosen lock bolt by giving it about two (2) turns. 4) Drain the working fluid by removing flare nuts at center of power steering gearbox while turning steering wheel clockwise and counterclockwise.8 kg-m. Torque (Bolts) 14-18N·m (1.

STEERING SYSTEM 4. damage or oil leakage (2) Play of pulley shaft 2 Pulley (1) Damage (2) Bend 3 4 Cap Strainer Crack or damage (1) Clogging with dirt (2) Breakage S Oil pump (Interior) (1) Defect or burning of vane pump (2) Bend in the shaft or damage to bearing 6 Stay Supporter Hose clamp Deformation Crack. Inspection • In accordance with the following table. Replace it with a new one. Replace it with a new one. inspect all removed parts for wear and damage. and make repair or replacement if necessary. Measure radial play and axial play. If it is past the service limit.) Replace it with a new one. deterioration or damage 7 8 11-39 . (Refer to "Service limit". replace oil pump assembly with a new one. replace oil pump assembly with a new one. Replace it with a new one. Modify or replace it. Parts Oil pump (Outside) Inspection Corrective action Replace oil pump assembly with a new one. replace oil pump assembly with a new one. Check resistance to rotation of pulley. I (1) Crack. Measure V ditch deflection. Wash it. No. If it exceeds the service limit. (Refer to "Service limit". (Refer to "Service limit". deterioration or damage Crack. If any of these exceeds the service limit.) Replace it with a new one.) Oil pump emits a noise that is markedly different in tone and loudness from a sound of a new oil pump when turning with a string put around its pulley. replace pulley with a new one.

29 .2 .4 .. 11 Ib) Fig..1' >. .. 11-123 A18·195 b.5. (Axial play) NOTE: A rather higher value may be indicated when pulley starts turning.....STEERING SYSTEM • Service limit Make a measurement as follows. 11-128 A18-191 NOTE: 0.. At this time..94 kg.. Resistance to rotation of pulley To tighten easily bolts at the front side. otherwise flange or pulley might be deformed.40 ft-lb) Service limit 1..07 Ib) or less Torque Joint nut 2 .TI-'_'.22 N (0...5 kg-m.36 ft-lb) A 18-199 A18-189 Fig. "._____"""""___________________ t .2 mm or less ( Direction) (0. 33 . replace oil pump assembly with a nt. . Installation I) Fix oil pump assembly in position by tightening flange nut and bolts.0 mm or less (0.... Torque (Nut and bolts) 49 N (5 kg. •• .008 in or less) I I Service limit Axial play 0.3 mm or less (0.. .2.. 2) Interconnect the hoses.. If it exceeds the specified service limit. Select properly sized wood pieces...012 in or less) Radial play NOTE: (~n) Read the value for one surface of V ditch.1.3 N'm (0.49 N·m (4._*'_ _* _. 2. 11-129 11-40 ".039 in or less) Fig. 11-125 A18-197 Ditch deflection of pulley 44 .0.. 1.0 .3 kg-m._'_'. S. Clip Service limit (Radial play) Maximum load.0 kg-m.._ .+- ··. .-.. Measure the load during rotation and make a judgement. Do not set flange of reservoir or pulley on a vise. .''"'I+-''''''"'<''"''_. NOTE: a. 11-124 Fig. . f " t - .w one.. align the screw holes using flange nut tightened halfway at the rear end as a support. Play of pulley shaft Fig.5. Fix oil pump assembly on a vise to make a measurement.5 .2 ft-lb) 39 .54 N·m (4. 11-127 Fig._. securely hold oil pump assembly between two wood pieces. and then the value for another off the dial. . 9. 11-126 A18-198 Fig..

10) Feed the specified fluid and discharge air. 4) Install stay by tightening bolt. 12 . 7) Set oil pump belt and adjust its tension.STEERING SYSTEM NOTE: If a hose is twisted at this step. 6) Connect electric wirings and hoses to air cleaner and hold them by connectors or clips. and then lower vehicle. otherwise vane pump might be seized up. NOTE: Make sure to hold piping properly by the clamps. oj Fig.) 11-41 . 11-131 NOTE: Make sure to fit idler cap properly by turning it. 11-130 Torque (Flare nuts) 16 .6 . 9) Connect minus terminal of battery. . Fig. the hose may come into contact with some other parts.151 Fig. and then fit idler cap.0 kg-m. (For m. refer to the section regarding fluid line.20 N·m (1. refer to the section regarding fluid line.) . A18·362 Fig. 22 Ib) A18·200 NOTE: Never start the engine before feeding the fluid. 8) Tighten flare nuts of piping to the specified torque. refer to the section regarding fluid line. 13) Tighten bolts to fix both jackup plate and clamps for piping.2. (For more details. and fix spare tire and carburetor shield in position.:>re details. A 18.) 3) Insert engine oil level gauge into its hole.14 ft-lb) NOTE: The side surface of stay and that of tank shell should contact with each other when installing. (For details. 98N (10 kg. 11) Jack up vehicle again and take out safety stands. 11-132 14) Adjust the fluid level in the reservoir. 12) Check the fluid leakage at flare nuts after turning steering wheel from lock to lock with engine running. 11-133 A18·355 5) Fix air cleaner in position.

.... . Lifting to an excessive extent would result in disconnection of pipes from air cleaner. ft-Ib) T1: 25 . Construction In case idler pulley fails to slide upward with adjust bolt loosened.. _. connect them propErly.... and take out oil pump belt... turn adjust bolt counterclockwise..3._ ..... 11-42 3.......... 11-135 Tightening torque N·m (kg-m. NOTE: NOTE: Do not pinch idler cap directly by pliers without cushioning waste cloth around it nor remove it by using a minus-head screwdriver. Disassembly 1) Remove adjust bolt and lock bolt of pulley. ...3. 2) Loosen lock bolt by giving it about two (2) turns.. 6) Take out bracket with idler pulley by removing bolts.".... Belt Line (Power Steering System) 1..STEERING SYSTEM 11-9. .*_ . Removal 1) Pinch brim of idler cap by pliers with waste cloth around it...29 (2 ...- . and the belt will become ready for easy removal.. and gently hit the head of adjust bolt by plastic hammer until the idler pulley slides. 11-134 A18-202 2.._ .18 . 14 . '· Ht' _'1_'.5 .. idler pulley will normally be slid upward by the tension of oil pump belt. .._______. . 5) Remove bolts for the front of oil pump assembly while lifting up air horn portion of air cleaner slightly... . Oil pump pulley / icrank pulley A18-203 Fig..5. '_ _ _ _ _ _ __ P .~.. ... b.. .. ~~.. '... . After adjust bolt is loosened by turning counterclockwise..+.... Do not put an excessive load on oil pump assembly since it is supported by flange nut at rear end of it alone. a_ It is sufficient to lift air horn by about 25 mm (1 in).. and take it out...j..'_....22) NOTE: 7 Snap ring 8 Dust seal 9 Shaft 10 Adjust bolt 11 Spring washer 12 Spring washer 1 2 3 4 5 6 Front bracket assy Lock bolt Spring washer Plain washer Idler pulley Ball bearing 13 14 15 16 Bolt V belt Idler cap Bracket Fig.!_ .. ''''''_11... In case they are disconnected.......25) T2: 20 . loosen lock bolt by giving it about two more turns. .. 2) Draw out pulley... 4) Disconnect air duct and hose connecting to right-hand side rocker cover from air cleaner and remove bolts fixing air cleaner onto brackets and loose a wing nut onto carburetor... ..... ...... otherwise the cap might be damaged....'_'....34 (2. ... 3) After taking out carburetor shield.

and then shaft can be removed by pressing it hard again with hand. No. otherwise damage might be caused to area of bracket into which the lip of dust seal comes into contact. 11-136 4. b. Do not force pulley out with a minus-head screwdriver inserted between pulley and bracket.STEERING SYSTEM NOTE: NOTE: a. Measure the diameter of the lip. Measure V ditch deflection. and replace them if necessary. • Inspect all removed parts for wear and damage. Replace it with a new one. 3) Draw out dust seal and shaft. 2 Idler cap Idler pulley Crack. If it is past service limit. damage or deterioration Replace it with a new one. (Refer to "Service limit". A1S·20S Fig. If it is past service limit. Usually. pulley can be dislodged by pressing it hard with hand. In case it cannot be dislodged. 1 (1) Crack or damage to thread portion (2) Deformation Measure the deformation. replace dust seal with a new one. replace bracket with a new one. 8 11-43 .) Replace it with a new one. If it cannot be easily removed.) (2) Wear of the lip 6 7 Shaft Adjust bolt Lock bolt Damage to thread portion Replace it with a new one. Inspection 4) Remove snap ring of pulley. replace it with a new one. and then remove lock bolt and pulley. give lock bolt four to five turns again and gently hit the head of the bolt with a plastic hammer.) Replace ball bearing with a new one. The shaft can normally be removed by pressing it hard with hand. 5) Remove ball bearing by using Remover (925720000) and press. If it is past service limit. damage or deterioration 3 (1) Damage (2) Deformation 4 Ball bearing (1) Burn or damage (2) Broken rubber seal 5 Dust seal (1) Crack. gently hit the end of shaft with a plastic hammer. Parts Bracket Inspection Corrective action Replace it with a new one. (Refer to "Service limit". (Refer to "Service limit".

760 . Assembly NOTE: Read the value for one surface of V ditch and then the value for another off the dial.909 in) 19._____. .. 11-141 11-44 "...5 mm (1..780 in) l B C A18-213 Fig. b.3 .48.1.1.5 mm (1.._'''''''1t.08 in) 95.. Bring the processed surface of bracket into contact with V block and hold bracket on it while measuring.-'.. Service B&C limit D s.. Wear of dust seal 1) Fit ball bearing in position by using Remover (925720000) and press. 11-140 Fig...25 ± 2 mm (3....__....-~*.3 mm (1. • Service limit Deformation of bracket NOTE: A 32 ± 1... (2) Wear of a side surface or carbonization (3) Stretch If belt is stretched to suc h an extent that it cannot be adjusted wit h idler pulley.0.26 ± 0. .7500 ± 0. 11-138 Measurement anywhere on the circumference should be within the appropriate range in the above table.48. ' ef' ' ...059 in) 35 ± 2 mm (1. .. scale-off or crack Replace it with a new on e.38 ± 0.. 9 Belt Parts Inspection Corrective'action - (1) Fraying. 11-137 2) Fix snap ring in position..6 .08 in) Fig.902 in) 47. ) \-~ t__ 1 Surface A 2 Surface B 3 Surface D 4 Surface C 3 Service limit A18·209 A 47.STEERII\lG SYSTEM ------ No... NOTE: a..-~.-.0 mm or less (0..8 mm (0. Measure the levels of surfaces from the top surface of V block.___________ -.~.._______--. 11-139 A18-212 A18-207 Fig..874 .-'1"""""'_..I~'~'--"'''''''-'''''''' ..874 ..19..039 in or less) Fig.6 .*. Ditch deflection of pulley Service limit 1......'-"'. replace belt with a new 0 ne .

Idler cap can be fixed easily in position if a thin grease coat is given to the contact areas of idler pulley and cap. 4) Tighten bolts and a wing nut for air cleaner. Do not apply grease to any area near V ditch. b. 5) Set belt with hand in the sequence indicated below. otherwise V ditch might be deformed. 25 ft~lb) NOTE: At this time. do not run engine at speed more than 3000 rpm and for more than one minute.3 kg-m. b. If it fails to turn smoothly. tighten adjust bolt until the washer comes into close contact with the bolt.2_2_f_t-_Ib_)__~ __ ____ L _ _ _ 11-45 ----' . NOTE: Do not tighten them excessively. 4) Fit dust seal to shaft together. NOTE: If spring washer for adjust bolt is not in close contact with the bolt. I_4_. 11~ 142 ::-_ L 7) Torque Tighten lock bolt. with resultant slip of not only oil pump belt but also alternator belt. Do not drive pulley in position with a hammer or the like. Installation 1) Tighten bolts for bracket and oil pump assembly halfway. 5) Apply grease to the inner circumference of pulley. Use of anything other than the bolts specially provided for the purpose will result in damage to cylinder head. A18-188 Fig. 6) Tighten lock bolt halfway. ball bearing is not fully set in position. otherwise grease will be splashed about possibly. ~ 34 N·m 3. otherwise dust seal in idler pulley might have a short life due to overheating. A 18-200 Fig. (I) Crank pulley (2) Oil pump pulley (3) Idler pulley 6) Adjust the belt tension by turning adjust bolt. NOTE: a. Turn the cap to see if it is securely in position. 11~143 8) Fix idler cap in position. 7) Loosen lock bolt by giving it about two turns and give adjust bolt five to six turns to set it into shaft. Wipe away grease completely. 3) Tighten bolts and a nut for oil pump properly. 20-29N'm (2 . 11~144 A 18~204 Fig. and fix it in position. 6. 9) Fit carburetor shield in position. 11~ 145 NOTE: Completely wipe away surplus grease between bracket and pulley. and connect duct and hose to it. 2) Tighten bolts for bracket properly. A18-191 Fig. 3) Apply grease to both outer and inner circumferences of dust seal.5 kg-m. NOTE: a. 10) Confirm that idler cap is not removed and belt does not strike other parts while engine is running at idling speed.STEERING SYSTEM NOTE: Turn snap ring to see if it is securely in position.

2) T3: 16 .25) T5: 44 .3.6 .49 (4 . 33 .0.0.3.40) A18·363 Fig.5 .5.5 . Fluid Line (Power Steering System) 1.2.STEERING SYSTEM 11-10. ft-Ib) T1 : 18-31 (1.13-23) T2: 39 .5.54 (4.5 . Construction • Hoses and piping 1 Pipe B 2 Pipe A 3 Grommet 4 Clamp A 5 Hose A 6 Has.5.34 (2.49 (4 .18 .2.5.8-3.! clip 7 Hose B Tightening torque N·m (kg-m.20 (1.34 (2. 29 .2 .5.3 (0. 11-147 11-46 it! "'f I I I r . 11-146 ® • Connector and piping CD Tightening torque N·m (kg-m.12 ·14) T4: 25 . ft-Ib) ~' ~ T1 : 39 .36) T3: 25 .4 .36) T2: 2 .2. 1.5.3. 29 .25) 0 1 PipeC 2 Pipe D 3 Clamp B 4 Connector 5 Washer (small) 6 Grommet 7 Washer (large) 8 Spring washer 9 Connector bolt A18·364 Fig.18 .

NOTE: a.55 in) by using Socket (925670000) and Handle (925680000). Flare nuts can be easily removed if top one is removed first and the others are removed one by one in the downward sequence since the rotation angle of the wrench will be increased. NOTE: Pay attention to keep flare portions of pipes. A18-152 Fig. 11-149 A 18-154 7) Remove flare nuts of control valve above crossmember. Removal 1) Disconnect minus terminal of battery. After removing flare nuts. b. 6) After removing flare nuts at center of power steering gearbox. wrap waste cloth around flare nuts. Then tighten the bolts halfway. 11-47 . flare nuts and screw holes of connector clean from dirt or the like.STEERING SYSTEM 2. 2) Jack up vehicle and place safety stands under both of front lifting points. and slide the connector forward so easily as to remove flare nuts at the connector. take out exhaust manifold by removing nuts and bolts fixing it with engine and body. 4) After disconnecting cap of O 2 sensor. 14) Draw out grommets from each pipe. b. 8) Remove a bolt to fix both piping and gearbox to crossmember. otherwise flare nuts are damaged. A18-184 10) Loosen bolts fixing connector to crossmember. Remove a flare nut of which width across flats is 14 mm (0. 3) Take out jack-up plate by removing bolts. When removing flare nuts. NOTE: Pay attention to keep flare portions of pipes. install vinyl tubes onto gearbox and piping to prevent the fluid from splashing. 9) Take out pipes from crossmember without bending them. 00 not use wrench with its flats deformed. 12) Remove nuts joined hoses to connector. 13) Take out connector by removing bolts. 11-150 A18-216 NOTE: a. Fig. and take out pipes without bending them. 11) Remove flare nuts at connector. drain the working fluid while turning steering wheel clockwise and counterclockwise. flare nuts and couplings of gearbox clean from dirt or the like. c. 11-148 Fig. 5) Remove boot protector.

. 11-151 * Recommended value for the flare nut at control valve.....STEERING SYSTEM 3. 11-48 ...... 3 4 Grommet Clamp Wear or deterioration Replace it with a new one.6 .23 ft-Ib) NOTE: Set grommets for connector in position that the side with a step will be outside crossmember.2. 3) Set and fix pipes in the specified positions between control valve and gearbox or connector by tightening flare nuts as following order..'''""''. 29 . (5) Wear of hose surface (6) Damage to hose clip Replace it with a new one.5. 13 . Replace the clamp with a new one. Torque (Flare nuts) For pipe A and B 16 . .... 4.""'-. Inspection Inspect all removed parts for wear and damage.36 ft-Ib) (1) Pipe A to control valve and gearbox (2) Pipe B to control valve (3) Pipe C to control valve and connector (4) Pipe D to control valve and connector (5) Pipe B to gearbox Torque (Bolts) For pipe C For pipe D A1S-151 A1S-220 Fig.5 .20 N·m (1. i• .0 kg-m. . .0 .________.31 N·m (1..3.... 2) Set grommets for connector and fix the connector in position by tightening bolts.<-''''''~~.8 . 1 Pipes Parts Inspection (1) Damage to flared surface (2) Damage to fare nut (3) Crush Corrective action Replace the pipe with a new one. ..._ . 2 Connector (1 ) Damage to tapered seat (2) Damage to internal thread Replace the connector with a new one. .-. 18 ...3... 12-14ft-Ib) 25 ... replace them if necessary. Installation 1) Set grommets for each pipe in position so that the large-diameter side will be outside crossmember.. ""'.25 ft-Ib) 39 ...34 N·m (2.49 N'm (4. 18 .2 kg-m... No. .-_______ .'''''-f~k.. . (1) Scale-off of the coat (2) Deterioration of the hold on pipe 5 Hoses (I) Damage to flared surface (2) Damage to flare nut (3) Crack on hose surface (4) Swollen hose Replace the hose with a new one.5 kg-m*.0 kg-m..''_'''''''I' __ '"*''''_''''.. '''''Tr"'''''''''-'-----...

59 in) or more.0 to 2.2 ft-Ib) 9) Connect minus terminal of battery.5 kg-m.3.0. 7) Install boot protector. 10) Feed the specified fluid and discharge air as follows. 18 . Tighten flare nuts to prevent a hose from twisting as well as hose B. Recommended fluid (ATF Dexron) A18-184 B. Tighten a flare nut at connector prior to one at oil pump so as to keep the hose at a right angle with crossmember as well as hose B.36 ft-lb) 25 . (3) Start.2 . 11-153 . (2) Continue to turn steering wheel slowly from lock to lock until bubbles stop appearing in the tank while keeping the fluid at that level.5 . b. 31 . Flare nut 39 . 19 .40 ft-Ib) Torque (Flare nut) At oil pump At connector Torque (Bolt) (1) Feed the specified fluid with its level being about 5 to 6 cm (2. 6) Set clamp to piping and tighten a bolt to fix gearbox and the clamp to crossmember.52 N·m (4.5. Make sure to hold piping properly by the clamp. leave it about half an hour and then do the step (2) all over again.0 . 44 .3. 11-49 In case air is absorbed to deliver bubbles into piping because the fluid level is lower.4 .29 N·m (2.3 .5 .54 N'm (4. A18-221 Fig. Set clamp so as to see a marking "lH" on it. and idle the engine. 11-152 NOTE: Fix pipe C to control valve by tightening a flare nut with Socket (925670000) and Handle (925680000).0 kg-m. nector 29 . 33 . c.0 kg-m.22 ft-lb) 42 . 8) Fix exhaust manifold in position by tightening nuts and bolts to the specified torques. -"\ NOTE: NOTE: a. CALTEX B.2.STEERING SYSTEM NOTE: .3 kg-m. and connect cap of O2 sensor.5. 29 .6 .38 ft-lb) 25 .4 in) lower than the mouth of tank.25 ft-lb) 5) Fix hose B to connector and oil pump.5 . 11-154 4) Fix hose A to connector and oil pump by tightening flare nuts to the specified torques.25 ft-lb) SHELL TEXACO NOTE: Set hose B inside of hose A as shown in the above illustration.3 N'm (0.3 kg-m.34 N'm (2.3.34N·m (2. Keep the hose apart from washer tank by 15 mm (0.5 kg-m. 18 .P.P.49 N·m (4.36 ft-Ib) Torque Clip at oil pump 2 .--- a. (4) Continue to turn steering wheel slowly from lock to lock again until bubbles stop appearing in the tank while keeping the fluid at that level. 1.0 .49 N·m at con(4. b. A3-199 CASTROL MOBIL Fig.5. A18-365 Torque Nuts at engine Bolts and nuts at exhaust pipe Bolt at hanger 25 .0 kg-m.5 kg-m. 39 . Autran DX Texamatic fluid 6673 Dexron CASTROL TQ Dexron MOBIL ATF 220 SHELL ATF Dexron Texamatic fluid 6673 Dexron Fig.5.

If flare or tapered seat is damaged... . tighten again it to the specified torque after cleaning flare and tapered seat..' ' -. • .. The fluid level changes over 3 mm (0..8 US qt. I... NOTE: In case bubbles do not stop appearing in the tank.._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ ' "I . b. OM·751 Fig.8 liter (0. wipe off any fluid on flare nuts and piping. Troubleshooting 1.. c. b... tt . leave it about half an hour and then do the step (4) all over again... it is caused by dust (or the like) and/or damage between flare and tapered seat in piping.. and idle the engine. Bubbles remain on the upper surface of the fluid.. 11) Check the fluid leakage at flare nuts after turning steering wheel from lock to lock with engine running. and take out safety stands after jacking up vehicle again. In case the fluid leaks from flare nut. Grinding noise is generated from oil pump.7 Imp qt) (1) Check at temperature 21°C (70°F) on reservoir surface of oil pump NOTE: In case the following happens. Before checking.STEERING SYSTEM It is normal that bubbles stop appearing after three times turning of steering wheel.. 11·157 Indicator of filler cap I 11-11... t ..~"'Ihl' I....... a. Steering wheel operation is heavy Jack up and when the left and right front wheels are clear the ground. •' 11-50 tt'''''11-'-'_ •. If at upper point or above.. 13) Inspect fluid level on flat and level surface with engine "OFF" by indicator of fIller cap.. 12) Install jack-up plate and clamps by tightening bolts.12 in). 0.. If the level is at lower point or below. separate the gearbox from steering shaft at the universal joint and operate the steering wheel.. leave it about half an hour and then do step (6) again. remove the tie-rod ends from the housings and operate the steering wheel." • *' --"~~'''4+''~'''''~'''''''''_1 . (6) Continue to turn steering wheel from lock to lock until bubbles stop appearing and change of the fluid level is within 3 mm (0. drain fluid by using a syringe or the like. A) When easy B) When heavy Tire pressure and suspension Steering system trouble I Corrective action When heavy.. NOTE: a."". Fluid capacity 0. (5) Stop the engine... A) When easy B) When heavy Trouble in connection with gearbox Trouble in connection with steering shaft . .. Then lower the vehicle.. Manual Steering Trouble and possible cause 1. replace it with a new one. add fluid to keep the level in the specified range of the indicator. 11·156 Indicator of filler cap Fig. OM·752 Fig...12 in). So remove the flare nut. 11·155 (2) Check at temperature 60°C (140°F) on reservoir surface of oil pump NOTE: Make sure to hold plpmg properly after installing clamps.

on rough road or when play of the steering wheel exists. I) Improper tire pressure Incorrect front wheel alignment 3) Unbalanced wheels and tires 4) Loosened wheel nuts 5) Distorted wheel 6) Damaged or worn wheel bearing 7) Worn ball joint 8) Damaged suspension mounting 2) Adjust to normal pressure Adjust toe-in Correct Tighten to correct torque Correct or replace Repair or replace Replace Inspect. and correct or replace 3.STEERING SYSTEM Trouble and possible cause Tire pressure too low Improper front wheel alignment 3) Stuck ball joint 4) Insufficient lubrication 5) Too much tightening of adjusting spring 6) Worn tires 7) No smooth operation of universal joint 2. Steering wheel vibration l) 2) Corrective action Ad just to normal pressure Adjust toe-in Replace Lubricate all parts Adjust Replace Replace This condition is manifest mostly at high speeds. correct or replace Replace Correct Rotate or Replace 3) 4) 5) 6) 7) 8) 4. The steering wheel pulls to one side This is a very dangerous vehicle condition. often attributable to abnormality in the front suspension system_ l) 2) Unbalanced tire pressure Incorrect front wheel alignment Worn or incorrectly adjusted wheel bearing Insufficient operation of shock absorber Damaged suspension or improper installing Warped crossmember Unequal left and right wheel base Special character of tire Adjust to correct pressure Correct Adjust or replace Replace Inspect. I) Worn rack and pinion 2) Worn or damaged serration of steering shaft and torque rod 3) Loose tightening of steering wheel installing nut 4) Loose universal joint bolt 5) Looseness on universal joint 6) Worn front wheel bearing 7) Loose connections and insufficient tightening Replace Tighten additionally or replace Tighten to specified torque Tighten to specified torque Replace Adjust or replace Tighten to specified torque or replace 11-51 . the distance along the circumference should be less than 25 mm (I in) until the front wheels begin to turn. Tire pressure too high Adjust toe-in Adjust to normal pressure Steering wheel free play more over 25 mm (l in) Set the steering wheel in straight ahead and when turning the wheel to both left and right. Shock felt at the steering wheel I) Incorrect front wheel alignment 2) 5.

refer to the next article 2). refer to the following article 3).. Loose connection of suspension Adjust or retighten GOOD Others 1. l..... One-sided weight l. Low fluid level 2. Improper or unbalance caster NG l Fluid 2.. After warming up engine. Aeration 3. tum steering wheel from stop t o stop several times to warm up fluid.. Excessive drop of idling speed at start with turning steering wheel 1 GOOD Measure hydraulic pressure.. there is no abnormal thing.-_ _... *3 In cold weather or with insufficient warm up of engine.. Detrioration of fluid 5.._1t""'. Poor uniformity of V belt cross section 3. it is recommended to start the car with increasing engine speed than usual. steering effort may be heavy due to increased flow resistance of cold fluid. Mix use of different rims 4. Improper or unbalance tow-in GOOD Refill. Dust mix 4. *2 In cold weather. Mix use of different tires 3....STEERING SYSTEM 2. Folded hose NG 2. Then if steering effort reduces normally..'.."" 0".... there is no abnormal thing.. bleed air. V belt touches to Pulley bottom 4. relief valve may work before maximum turning angle.. Lower idling speed 2. Accordingly.. Measure steering effort.. steering effort may be heavy. . 11-52 "'~"' ~'''''''''''''''''II-' . Improper rims out of specification 3. Unbalance of hight 2..________. Power Steering 1) Steering condition Heavy steering effort in all range ~ Heavy steering effort at stand still Steering wheel surges when turning Car leads to one side or the other Poor return of steering wheel to center V belt l. Loose or damage of V belt 2. in a condition..... In this case...._.___________.. In this case. ! GOOD *1 If tires and/or rims are wider... Tires not properly inflated NG Replace or reinflate GOOD Front alignment 1..'11-... replace or instruct customer 3. .. Poor warming up of fluid *2 NG NG Adjust or instruct customer Idling speed 1 GOOD *3 NG Adjust or instruct customer GOOD Measure steering effort. Unbalance of tire pressure Reform or replace 1 NG GOOD Fix or replace Tire and rim l. the load to power steering system is the more. Poor revolution of oil pump pulley • NG Adjust or replace Fluid line 1. When measured hydraulic pressure is normal. . of ) specification *1 2.. Flattened pipe GOOD Tire and rim 1.""".. Then if steering effort reduces normally. Abnormal wear of tire 5.. ' ... for example before fluid warms up..... refer to the following article 3). Unbalance of remained grooves 6... t here is no abnormal thing. steering effort may be heavy due to excessive drop of idling speed when turning steering wheel...' n' . Impwp" ..... Flat tire 2.. Poor revolution of idler pulley 5....

(Refer to Fig. 11·159 Fig.884 kPa (47 .STEERING SYSTEM 2) Measurement of hydraulic pressure Note: Be sure to complete all items aforementioned in article 1). 11·160 11-53 .609 . b. 668 .884 kPa (47 to 60 kg/ cm 2. 11·158 Fig.60 kg/cm 2.853 psi) A18·223 A 18·224 A18·225 Fig. 668 to 853 psi) ~ ?r - Poor work of relief valve Fluid leakage inside oil pump Assy Excessive wear of vane pump mechanism > Replace oil pump assembly Poor work of control valve Replace gear box assembly NOTE: Do not lelve the valve of pressure gauge closed or hold the steering wheel at stop end for 5 seconds or more in any case.884 kPa (47 . (Refer to Fig.60kg/cm 2. (Refer to Fig. 11·158) Result: 981 kPa(lOkg/cm2. I. 11·160) Result: 4. turning steering wheel from stop to stop.5. Otherwise. IS the oil pump may be damaged due to long keep of these conditions.609 to 5. pressure can not be measured correcdy. 142 psi) or less ~ ~ Flattened pipes or hoses Leakage of fluid line Obstacle in fluid line I 1 Replace bad parts Retighten or replace Replace fluid or com· ponent of fluid line J GOOD Measure relief pressure at idling with valve closed. Put cotton cloth waste at a place where fluid drops before pressure gauge is installed.884 kPa (47 to 60 kg/cm 2.853 psi) Working pressure 4. 668 .5. Keep engine idling during the measurement. Measure regular pressure at idling with valve opened.609 to 5. prior to measuring hydraulic pressure. 142 psi) or less Relief pressure 4. Wipe off spilt fluid thoroughly after the melsurement c. 11·159) Result: 4. Regular pressure 981 kPa (10 kg/cm 2.609 . 668 to 853 psi) GOOD Measure working pressure at idling with valve opened.

(Refer to Fig.STEERING SYSTEM 3) Measurement of steering effort..'. 11-161) Result: Maximum force is 2."..... ·*-""'''.....5 kg..-------__... replace if necessary 11-54 "it_tiLl.'1f-11-'-. 5. 1. r----_. GOOD (To be continued) NG Inspect. GOOD Measure folding torques of the universal joint.. . *4 Measure steering efforts in stand still with engine idling on concrete road. readjust. 11-162) Result: 5.23 kg. 20... readjust.~~·_. replace if necessary Measure steering wheel effort (Refer to Fig.49 N (0. '''''r_'. 11-161) Result: 24. • ....000 rpm. ' .-.5 kg. r- -1 Adjust back-lash Remove universal joint f-NG Check.26 N (0.. eResult: 93. tie-rods and ball joints of suspension for unsteady revolution or rattling. .4t--j.. steering effort may be heavy.11 kg.24Ib) or less..56 kg. 0.... (Refer to Fig. -. ' '. replace if necessary Check tie-rod ends.'''''. This is caused by flow characteristic of oil pump and is no problem. GOOD Remove tie-rod ends NG Replace with a new one NG Inspect.5 lb) or less in both direction GOOD Measure steering efforts in stand still GOOD with engine stalled on concrete road.08 N (0...9 lb) or less in both direction NG *4 When turning steering more quickly than necessary from a directi on to the other direction at an engine speed over 2. Fluctuation width is 1.-..... 0.t_H*_'_'.2 N (9..'_r _________ .5 N (2.. _..51 lb) or less in both direction...23 lb) or less in four directions GOOD Check front wheels for unsteady revolution or rattling and brake for dragging.

5 lb) or less Rotating resistance Straight-ahead Less than position within 6. 1. 11-164 11-55 .49 N (0. 55 Ib) or less A18-367 Fig.63 kg.2 . 16 .56 kg.18 N (0.5 kg. Tighten to 22 .18 in) (0. 11-164) Result: Rotating resistance is 6.86 kg.63 kg.90 Ib) or less in all position within 20% differency between clockwise and couterclockwise.19 ft-Ib) A18-227 A18-369 A18-166 Fig. Sliding resistance is 245 N (25 kg.43 N (0.STEERING SYSTEM Measure rotating and sliding resistance of gearbox ASSY. if ineffective replace gearbox ASSY Steering effort 24.23 Ib) or less A18·l65 A18-368 . 1. 11-162 Fig. NG Readjust backlash. 1.391b) or less around center position and 8.18 N 30 mm (1. (Refer to Fig.86 kg.2.5 N (2.90 Ib) Sliding resistance Right-turn steering Left-turn steering 245 N (25 kg. 11-161 Folding torques of universal joint in four directions 5. 5. l. 11-163 and Fig.39 lb) from rack center Maximum allowable torque 8.43 N (0. 1.6 kg-m. 11-163 Fig.25 N·m (2.S 5 lb) or less with 20% differency between left and right directions.

If a customer complains strongly and he is not likely to satisfy for this phenomena. fluid may bleed out from air vent hole of cap. This is not a problem. if ineffective.. numbered with CD thru @ in Fig. 11-165 Leakage from surrounding of casted Iron portlon of oil pump assembly @ and @ in Fig. @ Damaged Y shaped packing @.@ *5 Fluid level is specified at optimum position (range) for ordinary use. 11-165 *5 Damaged inside of power cylinder. @ and @ in Fig. @ and @ in Fig. 1""+'. This is because the fluid spilt during the last maintenance was not completely wiped off.1"* d tt . 11-165 Leakage from reservoir of oil pump assembly.@ Leakage from control valve of gearbox assembly. "place connector or gear· box assembly Replace with a new one Replace oil pump assembly Crack in reservoir. Be sure to wipe off spilt fluid thoroughly after maintenance. replace Retighten or replace clamp Leakage from hose @ and ® in Fig. @. @ Damaged oil seal. @ and @ in Fig. 11-165 Insufficient tightening of flare nut. lower the fluid level so extent that fluid does not bleed out at the above conditions and lead him to perform checking of fluid level and fluid deterioration more frequently_ 11-56 ~I eft • · . if ineffective. poor clamping Damage in tapered seat Loosen and retighten. Leakage from connecting portions of pipes and hoses. .@ Replace cap Replace oil pump assembly Adjust fluid level Damaged cap packing Leakage from filler neck ~ Crack in root of filler neck High fluid level Leakage from surrounding of power cylinder of gearbox assembly. catching dirt or the like.1 1 . @.. @.STEERING SYSTEM 4) Fluid leakage Note: It is likely that although one judges fluid leakage. . . Damaged O-ring.. @ Damage in control valve. damage to flare or flare nut Poor insertion of hose. @ N 1-----1001 Replace pipe or hose with new one. @ @. there is actually no leakage. 11-165 Replace gearbox assembly Damaged Y shaped packing or oil seal. 11-165 ~I Crack m damage in hose Crack or damage in hose hardware Damaged O-ring. Accordingly when the car is used in many times in hard conditions like as very rough road or mountain area.

STEERING SYSTEM @ @ I ® ® @ A18-370 Fig. 11-165 11-57 .

1 . . Cross member or Connector Retighten - Loosened installation of Oil pump pulley or Idler pulley Loosened linkage or play of steering sys. 11-58 1. or suspension. Pump bracket. l Retighten Retighten or replace - Knocking When turning steering wheel in both direction with small angle repeatedly at engine ON or OFF Excessive backlash Loosened Lock nut for adjusting backlash Adjust and retighten Loosened tightening or play of Tie-rod.STEERING SYSTEM 5) Noise and vibration *6 Hiss noise (continuous) While engine is running with maximum turning angle Relief valve sound Generates at Max. Replace oil pump assembly. *7 Grinding noise may be heard immediately after the engine start in extremely cold condition. Check clearance. turning Angle Generates without steering operation Normal (Don't keep this condition over 5 seconds. Rubber coupling or Column sys.) Defective. at any time or inner parts of the oil pump may be damaged due to rapid increase of fluid temperature. This is due to the fluid characteristic in extremely cold condition. Tie-rod end Retighten or replace *6 Don't keep the relief valve operated over 5 sec. if the noise goes off during warm up there is no abnormal function in the system. Loosened tightening of Universal joint. Gearbox Assy. In this case. [Refer to next article 6)] Correct if necessary Rattling noise (intermittent) While engine is running Interference with adjacent parts Loosened installation of Oil pump Assy.

STEERING SYSTEM *7 Grinding noise (continuous) While engine is running Vane pump aeration Inspect and retighten fluid line connection. Replace fluid and vent air Replace Damaged tapered seat in Gearbox Assy or Connector J Abnormal inside of hose or pipe. Flat hose or pipe Rectify or replace *8 Oil pump makes whine or growl noise slightly due to its mechanism. flat pipe Squeal. squeak. i.Assy Replace Oil pump Replace Adjust or replace Run out or soilage of V-groove surface of Oil pump pulley or Idler pulley Clean or replace Grease shortage for Idler pulley I Apply grease I Sizzling noise (continous) while engine is running I Fluid aeration I Fix wrong part causing aeration. power steering can be operated easily due to its light steering effort. the disk rotates slightly and makes creaking noise. Fluid temperature and braking condition. If the noise goes off when the brake is released. Refill fluid and vent air.e. Engine speed and turning speed of steering wheel. Maladjustment of V belt Damaged or chared V belt r-. Even if the noise can be heard when steering wheel is turned at standstill there is no abnormal function in the system provided that the noise eliminates when the car is running. This phenomena does not indicate there is some abnormal function in the system.. 1 Vane pump seizing Pulley bearing seizing of Oil pump Assy Folded hose. Road surface and tire surface. *9 When stopping with service brake and/or parking brake applied. The vibration can be known when steering wheel is turned repeatedly at various speeds from slow to rapid step by step with parking brake applied on concrete road and in "D" range for automatic transmission vehicle. *10 There may be a little vibration around the steering devices when turning steering wheel at standstill. Hidraulic systems are likely to generate this kind of vibration as well as working noise and fluid noise because of conbined conditions. If doing so. The noise is generated by creaking between the disk and pads. there is no abnonnal function in the system. even though the component parts are properly adjusted and have no defects. 11-59 . While engine is running.

...~.....j"... Gearbox Assy I Damaged valve in Oil pump Assy..... ""_"1"1_'.-______ ""'.________ . • 1' r_. if the noise can be heard when running as well as stand still Remove power steering V belt and confum Replace Gearbox Assy Apply grease or replace . Hose Retighten I Abnormal inside of Oil pump Assy.... Connector or abnormal inside of Hose Loosened installation of Oil pump Assy...1 Torque converter growl Creaking noise (intermittent) while engine is running with steering turned Abnormal inside of .~"I. wrong part.~. Pump bracket *8 Replace Gearbox Assy. Hose Replace Oil pump Assy..~... . ' ' ...-H • .... .... normal Vibration while engine is running with/without steerinR turned I Too low E/G speed at start : Vane pump aeration 1 I I Adjust and Instruct customers Fix. ~ t L! k·.STEERING SYSTEM Whistle (continuous) while engine is running Whine or growl (continuous or intermittent) while engine is running with/without steering turned Abnormal tapered seat in Gearbox Assy.. Suspension parts I Retighten I 11-60 .. ...... Gearbox Assy Looseness or play of Steering.Gearbox Assy Abnormal bearing for Steering shaft *9 Generates when turning steering wheel with brake (service or parking) applied *10 If the noise goes off when brake is released. Vent air Replace Oil pump Assy...-"'. Hose. >+ Q "'f ..... Connector.... "_.~.... ""1_ _ _ _ _ _ _ _ _..

around Inputshaft Rubber coupling .51) 5 (0.20) ® ® ® Boot . @ (J) ~' I i 8.20) 15 (0.Pipe Pipe .Washer tank ® V belt .Distributor (j]) DOJ .Boot protector DOJ boot .08) 10 (0.71) 15 (0.V belt .59) 13 (0.39) 18(0.04) 1 (0.04) 5 (0.Spare tire supporter ® Hose .Pipe Oil pan .Pipes ® Pump bracket .Pipes Fixed side of E/G mounting rubber .04) 1 (0.04) ® @ Rubber coupling .59) 10 (0.5 . 11-166 11-61 .20) 5 (0.59) 10 (0.STEERING SYSTEM 6) Clearance table Min.Brake pipe 1 (0.Shroud Idler cap .39) 10 (0.Pipes 10 (0.Shroud V belt .20) 5 (0.39) 1 (0.Crossmember @ Air stove .374) (0.Shroud @ Hose .20) 2 (0.04) 9.39) 5 (0. allowance mm (in) Min.Cylinder @ Connector .Crossmember (j) ATC hose . ( @ ® @ A18-371 Fig.15 (0.39) 1 (0.V belt Air horn .Valve housing @ Crossmember .Heater hose @ Pipe . allowance mm (in) Location Location CD CV Movable side of E/G mounting rubber .Pipes Boot protector .

. It is very important to keep the hoses free from before-mentioned fluids and to wipe out immediately when the hoses are adhered with the fluids. they are likely to be damaged chemically by brake fluid.... heat resistance and resistance for low temperature brittleness. tensioned Replace hose Excessive play of E/G due to deterioration of engine mounting rubber Replace defective parts Inproper stop position of pitching stopper *11 Replace defective parts Replace instruct customer Replace lcrack on hose I I Excessive holding time of relief status Excessive tightening torque for return hose clip Power steering fluid. it is necessary to perform careful inspection frequently when the car is used in hot weather areas. Since resistances for heat or low temperature brittleness are gradually declining according to time accumulation of hot or cold conditions for the hoses and their service lives are shortening accordingly.. the fluid._.j·~~_~""""'~f __ lb""''''''''''''''_·.-.t_ _'1". the oil pump assembly.-______ t . battery electrolyte.. engine oil and automatic transmission fluid and their service lives are to be very shortened.. electrolyte adhere on the hose surface Replace Pay attention on service work Too many times use in extremely cold weather Replace Instruct customers *11 Although surface layer materials of rubber hoses have excellent weathering resistance. avoid to keep this kind of condition when servicing as well as driving..__________. ~"'."~. ' .. E/G oil. cold weather areas and/or a driving condition in which many times steerings are required in short time..STEERING SYSTEM 7) Breakage of Hoses IPressure hose burst I I Excessive holding time of relief status I Malfunction of relief valve I Instruct customers Replace Oil pump Assy Replace fluid I I I I I Correct Poor cold characteristic of fluid 11Forced out Return hose I I Poor connection Poor holding of clip Poor cold characteristic of fluid J Retighten I I Replace I fluid I Fluid bleeding out or hose slightly Wrong layout. . etc. brake fluid. Particularly continuous work of relief valve over 5 seconds causes to reduce service lives of the hoses.·... '-"1'I-'--____... So.-...j... 11-62 ". due to over heat. 11-.

/ Fig. 11-169 A 18·231 ~ Fig.STEERING SYSTEM 11-12. 11-173 A18·236 Fig. 11-167 A3·167 ~. 11-171 11-63 . . 11-170 A18·232 Fig. 11-168 A18-230 925700000 WRENCH Tie-rod 925710000 PRESSURE GAUGE Oil pump 925720000 REMOVER Idler pulley bearing ( -S A18-233 ~ Fig. Special Tools 925640000 SPANNER Steering gearbox 925670000 SOCKET Flare nut of control valve 925680000 HANDLE Flare nut of control valve 925690000 STAND Steering gearbox ~ Fig. 11-172 A18-234 (» Fig.

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............ ..... ..... CABLE ...... .. . ....... ... .. 12-5 12-2. 12-6 1. .. . . Speedometer Cable .. ........ ... ........ .. Inspection ........... .... Accelerator Cable ... .. 2.. ... .. ........... 12-3 4............. .. 12-7 3. .......... . .... .......... . . On-car Services ............ .............. ...... ..... . 12-2 PEDAL AND CABLE 12-1..... 12-6 2.... Installation......... ... ....CHAPTER 11~ Page PEDAL .. ........... ................ ........... 12-4 6. ..... ...... Clutch Cable .... ....... ..... . ........... Removal and Disassembly.. ........ Com~onent Parts .. Assembly....... ...... .. . .. . 12-8 SlIBARU ........... ...... 12-3 3.. ... .. .. ...... .................... 12-2 1.... .... ... . . ... .... ..... .. 12-4 5.....

22 Clip 23 CI 24 Clutch cable clamp utch cable 25 Clamp 26 Clamp 27 Clip 28 Clutch ~wltch bracket .55 -0 9 .3-239 . 12-1 I. 30 Washer (AT I cruIse control) 31 Clip (AT on y) 32 S only) (::p & ~rake switch r crUIse control) Tightening torq T1: 5. 1.PEDAL A NO CABLE 12·1. II "~'_4~.3 (0.17) A20-093 j Fig.0 . ft-Ib) T2: 13 _23 ( . 14 Snap pin 15 Pedal pad 16 Stopper 17 Cl 18 Brake pedal spring utch pedal 19 Washer 20 Clip 21 Clevl's pm . Component P arts 1 Pedal bracket 2 Pedal shaft 3 Flange nut ~ 6 7 8 9 10 Stop light switch KIck-down switch Accelerator .6. (AT only) St spnng opper Accelerator pedal ~~~~~:ator pedal pad 11 Bushing 12 B rake pedal 13 CIeVlS pin .4 _9 ue N·m (kg-m. Pedal 1.9) . __ 1 .. 5.~~~~~~ _____ .4. (for c 29 Cl rUlse control) utch switch (for . 'k~_ffi~'~I12-~2~~..

0. 4. Grommet of toe board 4) Detach trim panel and lower steering column.0.79 in) OM-526 I Stroke at cable end 2 Pedal bracket r-~~ if( I Q) Free play 2 . adjust it by turning nut connecting accelerator cable to carburetor.18 mm (0. Removal and Disassembly I Lock nut 2 Adjusting nut 3 Release fork A20·054 A20-051 Fig.67 . 66 Ib) [' om". adjust it by turning adjusting nut on engine side end of clutch cable. If it is not in specified value.4 . 2) Clutch Pedal 1) Check clutch pedal free play by operating pedal by hand.0.6. adjust it by adjusting position of stop lamp switch.91 in) ~\~~~ (V \ \ Fig_ 12-4 Operation at accelerator pedal I 2 3 4 5 6 Stop lamp switch Free play Stroke Remaining clearance Mat Toe board 3.71 in) 3 Accelerator pedal 4 Stroke at pedal pad 5 Pin 6 Toe board 7 Accelerator cable A20-073 ® \ \ I I @\y~'\.9 ft-lb) at cable end 29 .43 in) Pedal play 13-20mm (0.5.08 .150 mm (5. 3) Disconnect/detach clutch cable from the following parts.PEDAL AND CABLE 2.@ @ \ 135. 12-2 Checking brake pedal Fig.73 . Locking nut tigh tening torq ue 5.1.55 . of abl' clutch release fork 01 Stroke 2 .12 in) Full stroke 17 .30 in) NOTE: Be careful not to rotate stop lamp switch.51 .3 N'm (0. 12-3 Adjusting clutch pedal free play 2) Apply grease to operating rod connecting pin to prevent it from wearing_ 2) Apply grease to connecting portion of clutch pedal and clutch cable and contact point of clutch release fork and clutch cable nut. Clamp on transmission case c.51 .14 . 12-3 .1.97 in) More than 80 mm (3.11 mm (0. Clutch release fork b.20 in) at pedal pad 44. a. 2) Disconnect accelerator cable from carburetor.0.20 mm (0.08 . 1) Disconnect ground cable from battery.15 in)! 294 N (30 kg. If it is not in specified value.33 mm (1.3 mm (0. adjust it by adjusting power brake unit operating rod length.95 kg-m.20 .9.0 .50mm (1.31 .0.0. If it is not in specified value. If it is not in specified value.12 in) Check free play by operating pedal by hand.3 mm (0. On-car Services 1) Brake Pedal 1) Check position of pedal pad.79 in) Free play at pedal pad 0-5mm (0 .0. 3) Accelerator Pedal Check pedal stroke and free play by operating accelerator pedal by hand. Reserve distance (Remaining clearance) Free play at clutch pedal pad 13 .0. Brake pedal free play 5 .

replace bushing and/or shaft with new one if defective. and then install pedal shaft completely to prevent it from rotating. If operation is not smooth and/or stroke is not within specified value. Circlip retaining pedal shaft f. Insert clutch cable outer end to groove of pedal bracket. 7) Detach following parts from pedal bracket assembly. 4.55 .0.130 in) I 1II"iTi11r-. Operating rod of brake booster b. 2) Clean inside of bores of clutch pedal and brake pedal. etc.. 4. Clutch cable d. and inside of bore of accelerator pedal.8. 12-8 Inspecting stop light switch (6. Electrical connectors (for stop light switch.6.55 .9 ft-lb) .4 . etc. 12-10 Adjusting brake pedal position Fig.95 kg-m. Brake pedal return spring e. Clutch pedal and brake pedal g. to pedal bracket temporarily. 4.4 -. a. Install accelerator pedal onto pedal bracket. Assembly A20-040 Fig.071 .PEDAL AND CABLE 5) Disconnect the following parts from pedal bracket. Accelerator cable 2) Accelerator Pedal Clean up all parts and inspect for wear and damage. 7) NOTE: Fig.0.89 in) A20-053 5. 3) Align bores of pedal bracket. 12-7 Inspecting accelerator pedal Fig. attach brake pedal return spring.9 ft-lb) 6) Connect clutch cable to clutch pedal by using clevis pin and clip. Torque (Lock nut) 5.. _:-T 1. 12-9 Installing pedal 4) Clean and apply grease to shaft 3) Stop Light Switch Inspect switch stroke and operation. 12-5 Inspecting play between bushing and shaft 1) Attach stop light switch. Accelerator pedal c. apply grease.3. 12-6 a. 12-4 Clamp bolt torque 5.!iiiiilr--------.9. Replace it with new one if defective. replace it with new one. a.0 . Clean up inside of bushes and apply grease before installing shaft.) c. b. Make sure of 2 washers being installed at both sides of brake pedal. Accelerator pedal return spring b. 6) Remount pedal bracket ASSY along with clutch cable while supporting brake booster in engine room. clutch pedal and brake pedal.3 mm (0.0 .9. Inspection 1) Pedal Shaft and Bushing 1) Clean off grease and dust. Push 2) Inspect play between bushing and shaft. and hold it with cable clamp.3 N·m (0. 5) Set brake pedal position by adjusting position of stop light switch. Stop light switch • A20-052 t 1 2 3 4 Pedal shaft Clutch pedal Brake pedal Brake pedal return spring A20-0B1 Fig. NOTE: Be careful not to kink accelerator cable. and inspect for wear and damage. Stop light switch Switch ON A20-009 f---- --175 mm -i Fig.95 kg-m.6.3 N·m (0.0. and set bushings into bores.

2) Insert bolts of brake booster into holes on toe board. NOTE: Never fail to cover outer cable end with boot. 6) Connect electrical connectors for . 9 . 9) Attach clutch cable grommet to toe board. and then connect clutch cable to clutch release fork. Make sure to check operation of accelerator cable by operating accelerator pedal by hand. A20-082 Fig. and set pedal bracket above steering column. and attach it to accelerator pedal. 12·11 Installing pedal ASS Y 6.3 kg-m. Tightening torque 13 .lb) stop light switch.23 N'm (1. 12-12 Connecting operating rod and brake pedal 12-5 . operating rod of brake booster should be engaged with brake pedal. 5) Pull out accelerator inner cable to its maximum stroke. tighten 4 nuts and 2 bolts at its upper surface. Pull accelerator cable from carburetor side. NOTE: Be careful not to kink accelerator cable. Be careful not to bend clutch cable too much.PEDAL AND CABLE NOTE: Make sure that outer end of clutch cable and two washers are inserted into groove of pedal bracket com· pletely. etc.2.17 ft. NOTE: NOTE: 4) Connect operating rod of brake booster to brake pedal using clevis pin and snap pin. At this time. support it from engine room. and fit holes of pedal bracket onto the bolts. 3) While pushing pedal bracket up· ward firmly. 8) Connect accelerator cable to carburetor. Installation 1) Insert clutch cable into hole on toe board. 7) Install steering column as before. A20-083 1 Clevis pin 2 Snap pin 3 Operating rod Fig.3 . A t this time.

Clutch Cable NOTE: Apply grease to contact point of adjusting nut and release fork.08 . 12-13 12-6 .9. Make sure that outer end of clutch cable and two washers are inserted into groove of pedal