
CHASSIS
Before
inspecting 
various
parts 
thoroughly 
wash
them
so 
that
damage 
and 
wear
can 
be
easily 
detected
Then
proceed 
as
follows
Check
gear 
teeth 
for
scoring 
cracking 
and
chipping
and 
make
sure 
that 
tooth
pattern 
indicates
correct
meshing 
depth
If
any 
defect 
is 
evident
replace 
parts 
as
required
Note 
Drive
pinion 
and 
drive
gear 
are 
supplied 
for
replacement 
as 
a 
set 
therefore
should 
either
part
be
damaged 
replace 
as 
a 
set
Check 
the
pinion 
gear 
shaft 
and
pinion 
gear 
mating
faces 
for
scoring 
and
signs 
of 
wear 
and
replace 
as
required
Follow 
the 
same
procedure 
for 
inner
faces 
of 
side
gear
and 
their 
seats
on 
differential 
case
3
Inspect 
all
bearing 
races
and 
rollers
for
scoring
chipping 
or 
evidence 
of 
excessive 
wear
They 
should 
be
in
tiptop 
condition 
not 
worn 
with
mirror 
like 
surfaces
Replace 
if 
there 
is 
a 
doubt 
on 
their
efficiency 
since
an
incorrect
bearing 
operation
may 
result 
in 
noisiness
and
gear 
seizure
4
Inspect 
thrust 
washer 
faces
Small 
defects 
can 
be 
corrected 
with
emery 
paper 
In
ASSEMBLY 
AND 
AD
JUSTMENT
Tightening 
torque 
of 
side
bearing
cap 
bolts
5 
to
6kg 
m 
36 
2 
to
43 
4 
ft 
lb
co
g
E
E
on
N 
case 
the 
clearance 
between 
the 
side
gear 
and 
thrust 
washer
exceeds 
0 
2
mm 
0 
0079 
in
replace 
the 
thrust 
washers
Three 
kinds
of 
thrust 
washers
are 
available
5
Measure 
run
out 
of 
the 
drive
gear 
at 
the
rear 
side
using 
a 
dial 
indicator
When 
the
run
out 
is
more 
0
05
mm 
0 
0020
in
replace
the 
drive
gear 
and
pinion 
gear 
as 
a 
set
Fig 
PD 
15
Measuring 
run
out
of 
drive
gear
6
Inspect 
carrier 
and 
differential
case 
for 
cracks 
or
distortion
Replace 
defective
parts 
as
required
Adjust
spacer 
of
adjusting 
drive
pinion
without
drive
gear 
oil 
seal 
Preload 
for
pinion
bearing 
6 
to 
8
kg 
em 
5 
2 
to 
6 
9 
in 
Ib
1
9 
to 
2 
6
kg 
4 
2 
to 
5 
7 
Ib 
at 
bolt 
hole
1
Tightening 
torque 
of 
drive
pinion 
nut
12
to 
17
kg 
m
86 
8
to 
122
9 
ft
Ibl
Fig 
PD 
16 
Carrier
section
PO 
8 

BODY
FRONT 
FENDER 
AND 
FRONT 
END
CONTENTS
FRONT 
FENDER
Removal
FRONT 
BUMPER 
BF 
17
BF 
17
BF 
18
FRONT 
FENDER
i 
RADIATOR
GRILLE
OUTSIDE 
MIRROR 
BF 
18
BF18
1 
Front 
fender
2 
Cowl
top 
sealer
3 
Front 
fender 
sealer
4 
Cowl
top 
5 
Side
dash 
board
6 
Front
pillar
7 
Front
bumper 
8 
Front
bumper 
stay
9 
Front
bumper 
side 
bracket
10
Bumper 
side 
bracket 
shim
Removal 
Fig 
BF 
27
Front
fender 
and
front 
end
components
I
Open 
the 
hood 
disconnect 
the
battery 
terrninal
for
the 
sake 
of
safety 
and 
disconnect
wirings 
for 
the
head
lamp 
and 
side 
marker
lamp 
at 
their
connecting 
terminals
2 
Remove 
the 
front
bumper 
radiator
grille 
and
radiator
grille 
surround
3 
Remove 
the
sm
moulding 
and
holding 
the 
fender
remove 
it
Fig 
BF 
28
Removing 
front 
fender 
I
BF 
17 

BODY
Fig 
BF 
29
Removing 
front 
fender 
II
FRONT 
BUMPER
Remove 
six
bolts
retaining 
bumper 
stay 
to
body 
and
remove 
the 
front
bumper 
from 
the
body 
together 
with
the
bumper 
stay
RADIATOR
GRILLE
Loosen
self
tapping 
screws 
five 
self
tapping 
screws 
for
sedan 
station
wagon 
and 
van 
and 
ten 
for
coupe 
and
remove 
the 
radiator
grille 
frorn 
the
body
The 
radiator
grille 
for
coupe 
is 
made 
of
ABS 
resin
Be
careful 
not 
to
allow 
brake 
fluid
or 
oil
slicking 
to 
it
7
7f
rl4
o
j
j
iiA
i
DIATIJR 
GR 
L 
SEt 
SC 
8N 
S
i
e
t
II
L
T
RADIATOR 
GRill 
SET 
SCREWS
Fig 
BF 
30
Removing 
radiator
grille 
Coupe 
OUTSIDE 
MIRROR
Indicates
outside 
mirror
installing
positions
liMA
t
o 
e
O
I
I 
Dimen
sIons
Item 
A 
B 
c 
D
E
27
to 
6 
to
Round
shape
817 
29 
5 
25 
27
8 
dia
6 
2 
dia
movable
32 
2
1
161 
0
98431 
1
063 
to 
0 
2362
te
mirror
1
094 
0 
2441
6 
to
Round
shape 
817 
35
40 
9
dia 
6 
2 
dia
mirror
32 
2
1
378 
l
575 
0
3543 
0
2362 
to
0
2441
Unit 
mm
in
Fig 
BF 
31
Fender 
mirror
installing 
positions
IW
36
l 
71
Ta 
h
Le
O 
II
coo
c
l
2 
f
4
5 
358
17
77 
74
7
Unit
mm
inl
Fig 
RF 
32 
Door 
mirror
installing 
position 
for
right 
hand 
drive 
vehicle
SF 
18 

BODY
I
1
I
Ik
I 
ro
I
W 
a
21
zrl
l 
11
J
1
3781 
I
1
Ii 
100
tJ94t
I 
100 
3 
94
0 
0551
A
I 
10013 
94
1 
510 
0984 
100
13 
94
I 
J
10 
1378 
2010 
787
L 
I
l
0 
433
O 
I
l
JS
348 
13 
7 
5 
1 
77
Fig 
BF 
33
Template 
for 
door 
mirror 
installation
for 
left 
hand 
drive 
vehicle
INSTALLING
OSITION
SECTION 
A 
A 
When
installing 
round
shape 
movable 
outside 
fender
rnirror
tighten 
the 
nut 
to
tightening 
torque
range 
from
0
4
to 
0 
5
kg 
m 
2
9 
to 
3
6 
ft 
lb
so 
that
fender 
rnirror
rnovernent
starting
torque 
is 
in
range 
from 
20 
to 
75
kg 
rn
I74 
to 
65 
1
in 
lb 
When 
the
nut 
is
tightened 
to
tightening 
torque 
of 
1
5
kg 
m 
10 
8 
ft 
lb
higher 
the
fender 
mirror
stud 
bolt
may 
be
broken
Tl4
11 
I 
Mirror
stay
2 
I 
Mirror 
base
31 
Cap
Fig 
BF 
34
Round
shape 
movable 
outside
fender 
mirror
installing 
unit
TRUNK
LID 
AND 
REAR
BUMPER
CONTENTS
SEDAN 
AND
COUPE
TRUNK
LID 
LOCK
Removal
Adjustment
TRUNK 
LID
TORSION 
BAR
VAN
BACK 
DOOR 
LOCK 
BF 
20
BF 
20
BF
20
BF 
21 
Removal
Adjustment
BACK
DOOR 
TORSION 
BAR
Installation
REAR 
BUMPER
Removal 
BF 
21
BF 
22
BF 
24
BF 
24
BF 
24
BF 
24
BF
21
BF 
19 

Installation
Install 
the 
door
glass 
and
regulator 
in 
reverse
sequence
of
removal
Reinstall 
the
seal 
screen 
after
correctly 
adjusting 
door
window
closing
SIDE
WINDOW
Removal
I 
Remove 
the
lock
pillar 
moulding 
and
remove 
the
side
window 
handle 
set
screws 
from 
the
body 
side
2
Loosen 
the 
side
window
hinge 
installation 
screws
and
remove 
the
side 
window 
BODY
7
I 
I
I
c
t
2
3 
Side 
window
glass
Side
window
hinge
Side
hinge 
cover 
4 
Side
window 
handle
5 
Handle 
shim
6 
Catch 
handle 
bracket
Fig 
BF
59 
Side
window 
construction
WINDSHIELD 
AND 
REAR 
WINDOW
CONTENTS
REMOVAL
INSTAllATION
REAR 
WINDOW 
ELECTRIC
DEFROSTER
Option 
SF
31
SF
32
SF 
33
REMOVAL
1 
Place
a
protective 
cover 
over
the 
hood 
front 
fenders
instrument
panel 
and 
front 
seat
2
Remove
rear 
view 
mirror
support
3
Remove
windshield
wiper 
arm
assembly
4 
On
inside 
of
body 
loosen 
the
lip 
of 
the 
rubber
channel 
from
spot 
welded
flange 
along 
the
top 
and 
sides
of
windshield
opening 
With
the
palm 
of
the 
hand
apply
pressure 
to
glass 
near
edge 
At 
the
same 
time
use 
a
blunt
putty 
knife 
or 
other 
suitable 
tool
and
carefully 
assist
rubber 
channel 
over
spot 
welded
flange
5
After 
windshield
rubber 
channel
is 
free 
from
spot
welded
flange 
with 
aid
of
helper
carefully 
lift
windshield
assembly 
frorn
body 
opening 
and
place 
it 
on 
a
protected
bench 
Removal 
and 
installation
Specifications
I
nspection 
and
repair
WATERlEAK
CORRECTION 
BF 
34
SF
34
SF
34
SF 
36
Fig 
BF 
60
Removing 
windshield
Note 
The 
windshield
chrome
moulding 
are 
installed 
in
the
rubber 
channel 
and 
should 
be 
removed
prior 
to
removing 
rubber 
channel 
from 
the
gla55
SF 
31 

EMISSION 
CONTROL 
AND
TUNE 
UP
Appearance
1 
First
inspect 
whether 
vacuum 
hoses
are 
connected
to 
correct
positions
2
Inspect 
hoses
for 
cracks 
distortion 
or
plugging
Checking 
of 
vacuum 
motor
I
With
engine 
shut 
down
inspect 
the
position 
of 
valve
placing 
a 
mirror 
at 
the 
end 
of 
inlet
pipe 
for
inspec
tion
The 
correct 
condition 
of 
valve 
is 
that 
it
keeps 
the
inlet 
of 
underhood 
air
open 
and 
that 
of 
hot 
air
closed
Otherwise
inspect 
the
linkage 
of 
valve
Fig 
ET 
34
Inspecting 
valve
position
2 
Disconnect 
hose 
at 
vacuum
motor 
inlet 
and 
direct
ly 
apply 
vacuum 
of 
manifold 
to 
vacuum 
motor
by
connecting 
another 
hose
sucking 
by 
mouth
may 
be
substituted 
for 
this
process 
If 
underhood 
air 
inlet 
is
closed
by 
valve 
valve 
is 
in
good 
condition
Inspect
linkage 
if 
found 
otherwise 
And 
then 
no
defect 
is
found 
even 
in
linkage 
it
signifies 
the 
trouble 
of
vacuum 
motor
Fig 
ET 
35
Checking 
vacuum 
motor
ET 
21 
3 
The 
valve
shows 
correct 
condition 
if 
it
keeps
underhood 
air 
inlet 
closed 
when 
the
passage 
in
the 
hose
is
stopped 
by 
twisting 
or
clamping 
it 
while
applying
vacuum 
If 
otherwise 
it 
is 
an 
indication 
of
leakage
taking 
place 
in 
the 
vacuum 
motor
4 
When 
defect 
is 
found
in 
vacuum
motor
through 
this
check 
replace 
the 
air 
cleaner
assembly
Checking 
of 
sensor
I 
Perform 
the
engine 
test
by 
keeping 
the
temperature
around 
the
sensor 
below 
300C 
860F 
Make
sure 
that
the
engine 
is 
cooled 
down
before 
the 
test 
is 
conducted
2 
Before
starting 
the
engine 
make 
certain 
that 
the
valve
on 
underhood 
air 
side
fully 
opens
3 
Start 
the
engine 
and
operate 
it
at 
an
idling 
speed
The 
valve 
is 
in
good 
condition
if 
underhood 
air 
side
fully 
closes
immediately 
after
starting
4
Carefully 
watch 
the 
valve
to 
ascertain 
that
it
gradually 
begins 
to
open 
as 
the
engine 
warms
up 
But
when 
the 
ambient
temperature 
is 
low 
it 
takes
con
siderable
length 
of 
time
for 
the 
valve 
to
begine 
to
open
or 
in 
some 
case 
it
hardly 
opens 
This 
should
not
however 
be
regarded 
as 
trouble
If 
the 
valve 
does
not
operate 
satisfactorily 
or 
if 
the
condition 
of 
the 
valve 
is
questionable 
further 
conduct
the
following 
test
5 
Remove
the 
air
cleaner 
cover 
and
put 
a 
thermister
or 
a 
small 
thermometer 
as 
close 
to 
the
sensor 
as
possible 
with 
adhesive
tape 
Install 
the
air 
cleaner
cover
again
Fig 
ET 
36
Checking 
sensor
1