
CHASSIS
7 
Turn 
drive
pinion 
in 
both 
directions 
several 
times 
to
set
bearing 
rollers 
And
adjust 
bearing 
preload 
to
specifi
cations
Drive
pinion 
bearing 
preload 
with
oil 
seal
7
to 
9
kg
cm 
6 
1
to 
7
8 
in 
1b
At
companion
flange 
bolt 
hole
2 
25 
to 
2 
95
kg 
4
96 
to 
6
50
1b
Pinion 
nut
tightening 
torque
12
to 
17
kg 
m
86 
8 
to 
122 
9 
ft
1b
Fig 
PD 
24
Measuring 
pinion 
preload
Setting 
and
adjusting 
side
bearing 
shims
When
reassembling 
the 
side
bearing 
without 
replacing
be
sure 
to
install 
a 
shim
having 
same 
thickness 
as 
that
before
disassembly
The
following 
instructions
apply 
when 
the
hearing 
is
replaced
I 
Place 
an
approximately 
2 
5
kg 
5
5 
Ib
weight 
on 
the
side
bearing 
and
measure
bearing 
thickness
ST3250S000
Standard 
side
bearing 
width
17 
5
mm 
0 
689 
in 
Note 
With 
the
weight 
placed 
on 
the 
side
bearing 
turn
the
bearing 
two 
to 
three 
turns 
and 
measure
thickn
1
ST3250S000
Fig 
PD 
25
Measuring 
for 
bearing
2 
Side
bearing 
adjusting 
shim 
thickness
calculating
formula
Left 
side 
drive
gear 
side
Tl 
A 
C 
D 
H 
xO
01 
0 
2 
E 
mm
Right 
side
pinion 
mate 
side
T
2 
B 
D 
H 
x 
0 
01 
0 
2 
F
mm
Figures 
for 
A 
B
C 
D 
and 
H
are 
dimensional
variations 
in 
a 
unit
of 
1 
100
mm
against 
each 
standard
measurement
Where 
A 
The
figure 
marked 
on 
the
left 
side
bearing 
housing 
of
gear 
carrier
The
figure 
marked 
on 
the
right 
side
bearing 
housing 
of
gear 
carrier
The
figure 
marked 
on 
the 
differential
case
B
C 
D
E 
F 
These 
are 
differences 
in 
width 
of 
left
or
right 
side
bearing 
against 
the
standard
width 
17
5 
mm
0 
6890 
in
Figure 
is
given 
in 
a
unit 
of 
1
100 
mm
PD 
12 

Clearance 
between 
side
gear 
and
thrust 
washer 
CHASSIS
rrun 
in 
0
10 
to
0 
20 
0 
004 
to 
0
008
Side
bearing
Standard 
width 
rom 
in
Thickness 
of
side
bearing 
adjusting
shims 
rom 
in
Tightening 
torque
Drive
pinion 
nut
Ring 
gear 
bolts
Side
bearing
cap 
bolts
Differential 
carrier 
to 
axle
housing
fIx 
nuts
Companion 
flange 
to
propeller 
shaft
fIx 
nuts
Oil 
filler
plug 
17
5 
0
689
0
05 
0 
07 
0 
10 
0 
20 
0 
50
0
0020 
0 
0028 
0 
0039 
0
0078 
0 
0197
kg 
m
ft 
lb
kg 
m
ft 
lb
kg 
m
ft 
lb 
12 
to 
17 
86
8 
to 
123
6 
to 
7 
43
4 
to 
50 
6
5 
to 
6 
36 
2 
to 
43 
4
kg 
m
ft 
1b 
17 
to 
2
5
12
3 
to 
18 
1
kg 
m
ft 
lb
kg 
m
ft 
lb 
2 
0 
to
2 
7 
14 
5 
to 
19 
5
6 
to 
10 
43
4 
to 
72 
3
SERVICE 
JOURNAL 
OR 
BULLETIN
REFERENCE
DATE 
JOURNAL
or
BULLETIN
No
I
I
I
I 
PAGE 
No
SUBJECT
PO 
1S 

BRAKE
SERVICE 
DATA 
AND 
SPECIFICATIONS
Brake
pedal
Pedal 
free
height
Full
stroke 
of
pedal 
head
Master
cylinder 
mm 
in
mm 
in 
141
5 
t2 
5
57 
to 
0787
120 
4 
72
17
5 
11
16
Inner
diameter 
of 
master
cylinder 
mm 
in
Allowable 
maximum 
clearance 
between
cylinder 
and
piston 
mm 
in
Wheel
cylinder
Inner 
diameter 
of 
wheel 
cylinder
Front 
drum
disc
Rear
front 
disc
Allowable 
maximum
clearance 
between
cylinder 
and
piston
Brake 
drum 
and 
rotor 
disc
Drum
brake 
inner 
diameter
Rotor
disc 
outer 
diameter
Rotor 
thickness
Drum 
inside 
out 
of 
roundness
Max
allowable 
drum
inner
diameter
Run 
out 
of 
the
rotor
Max
allowable 
rotor
thickness
Lining 
dimensions
Front 
drum 
brake
Lining 
width
x 
thickness 
x
length
Total
braking 
area 
0
13 
0
0051
mm 
in
mm 
in
mm
in
mm 
in 
20 
6
13 
16
48 
1 
1
894
20
6 
13
16
1746 
11 
16
mm 
in 
0
18 
0
0071
mm 
in
mm 
in
mm
in
mm 
in 
203 
2 
8 
00
212
5 
837
9
5
03740
Below 
0
Q2 
0
0008
mm 
in
mm 
in 
204 
5
8 
051
Below 
0
03 
0
0012
mm 
in 
8
4 
03307
mm 
in
cm2
sq 
in 
35 
x 
4 
8 
x 
195 
1
378 
x 
0
1890 
x 
7 
68
273 
423
BR
2J 

Lining 
material
Front
disc 
brake
Pad 
width 
x 
thickness 
x
length
Total
braking 
area
Rear 
brake
Lining 
width 
x 
thickness 
x
length
Total
braking 
area
Tightening 
torque
Brake
pedal 
fulcrum
pin
Master
cylinder 
installation 
bolt
Brake 
tube 
installation
flare 
nut
Rear 
brake 
hose
and 
connector
installation 
nut
Front 
wheel
cylinder 
installation 
bolt
Brake
warning 
switch 
installation
bolt
Front
brake 
disc 
installation
bolt
Caliper 
assembly 
installation 
bolt
Rear 
brake
adjuster 
installation 
bolt
Hand
brake 
cable
hanger 
strap
installation 
bolt
Hand 
brake 
lever 
installation 
bolt
Rotor 
and 
hub
installation 
bolt 
CHASSIS
mm
in
cm2
sq 
in
mm 
in
cm2
sq 
in
kg 
m
ft 
1b
kg 
m
ft 
lb
kg 
m
ft 
lb
kg 
m
ft 
lb
kg 
m
ft 
lb
kg 
m 
ft 
lb
kg 
m
ft 
lb
kg 
m
ft 
lb
kg 
m
ft 
lb
kg 
m
ft 
lb
kg 
m
ft 
lb
kg 
m
ft 
Ib 
B40 
Akebuno
make
42 
5 
x 
10
3 
x 
53 
I 
1 
673
x 
0
406 
x 
2 
091
90
3 
14 
0
35
x 
4 
8 
x 
195 
1
378
x 
0
1890 
x 
7
68
273
42
3
2 
0 
to 
3 
0
11 
6 
to 
217
2
1 
to 
2 
9 
15
2 
to
21 
0
1
5 
to
1 
8
l 
0 
8 
to 
13 
0
1
5
to 
1 
8 
10 
8 
to 
13 
0
a 
0 
5
to 
0 
7 
3
6 
to 
5 
I
b 
1 
6 
to 
2 
2
I 
1 
6 
to 
15 
9
0
32 
to 
0 
44
2
31 
to 
3 
18
2 
7 
to 
3 
7
19
5 
to
26 
8
4 
6 
to 
6 
1 
33
3 
to 
44
1
1 
6 
to 
2 
2 
11 
6 
to 
15
9
0
32
to 
0 
44
2
31 
to 
3 
18
1 
0
to 
I 
4 
7
23 
to
10
1
44
to 
59 
31 
8 
to 
42 
7
TROUBLE 
DIAGNOSES 
AND
CORRECTIONS
Condition
Spongy 
pedal 
Air 
in 
brake 
lines 
Probable
cause
Swollen 
hose
due 
to 
deterioration 
or
use 
of
poor 
quality 
brake
fluid
BR 
24 
Corrective 
action
Bleed
thoroughly
Replace 
hose
and 
bleed 
the
system 

BODY
Removal 
and 
installation
The
rear 
window 
electric 
defroster
glass 
is 
removed
from 
or 
installed 
on 
its
position 
in 
the
same 
manner
as
that 
for 
the 
standard
rear 
window
glass
Heat 
wire 
harness
1
Fig 
BF 
66 
Rear
floor 
wiring 
Note 
a
Use 
care 
not 
to
give 
scratches 
and
wiring
b 
Remove 
weather
strip 
whenever
glass 
is 
to 
be
replaced
After
glass 
is 
installed 
in
place 
apply 
sealant
between
panel 
and 
weather
strip
1
Connection 
Specifications
Glass
Semi
tempered 
heat
absorbing
type
Power
consumption 
75W
l2V
Heating 
wire 
Baked
on 
rear 
window
Interior 
side
Heating 
wire
coverage
Horizontal
Vertical 
Full 
width
390 
mm 
15
35 
in
Inspection 
and
repair
Ground 
terminal 
How 
to
locate 
a 
broken
heat 
wire
and 
a 
break
a 
Method 
I
Start 
the
engine 
and 
turn
on 
the 
window
defogger 
system 
If 
the 
area 
around 
a
specific 
heat 
wire
is 
not
defogged 
that 
line
is 
broken
n 
if 
U
i
p 
w 
w
j 
w
j
fj
f
i
j 
L 
1
2 
Defogged 
area
Broken 
heat 
wire
Fogged 
area
Fig 
BF 
69
Defogging 
pattern
BF 
34 

SERVICE
EQUIPMENT
Tool
number 
S 
M
reference
Tool 
name 
Figure
Description
page 
See
Fig 
No
GG930 
10000
Torque 
wrench
Use
for
tightening 
correct
torque 
Fig 
A
T 
69
Max
torque 
4 
6
kg 
m 
0 
33 
ft
lb
Drive
angle 
3 
8
square
SE123
ST255 
12001
Socket
extension
Socket 
extension 
to
connect
Fig 
A 
T
69
0 
torque 
wrench
GG930 
I
000
with 
1 
2
square 
socket 
wrench
SE124
ST25 
160000
Torque 
driver
Use 
for
tightening 
correct
Fig 
AT
107
torque 
Max
torque 
1 
04
kg 
m 
Fig 
AT
108
u
90 
ft
Ib
SE125
HT69860000
Snap 
ring 
Use 
for
removing 
and
replacing
Fig 
AT
59
remover
snap 
ring
SE126
ST25320001
Snap 
ring 
Use 
for
removing 
and
replacing
Fig 
AT
79
snap 
ring
remover
Go
O
SE127
ST25570000
Hex 
head 
Use
for
removing 
and
installing
Fig 
AT
64
extension 
one
way 
clutch 
inner
race 
with
Fig 
AT
69
torque 
wrench 
Drive
angle 
1 
2
square 
and 
6 
mm 
across 
flat
SE128 
width
sE 
8 

Tool 
number
Tool 
name
ST30031000
Drive
pinion 
rear
bearing 
inner 
race
replacer 
SERVICE
EQUIPMENT
Figure
mm 
inch
Front 
axle 
and
suspension 
tool
ST353 
10000
Front 
wheel
hub
bearing 
outer 
race
drift
ST35650000
Coil
spring
compressor 
set
ST35500000
Gland
packing
wrench 
rU
jb
1118
1
1
width
across 
flats
55 
12
71
SE 
12 
Descrip 
tion
For
removing 
the 
drive
pinion
rear
bearing 
inner 
race
For
removing 
and
installing 
the
front 
wheel 
hub
bearings
For
assembly 
and
disassembly
of
the 
coil
spring
For
tightening 
the
gland 
packing 
S 
M
reference
page 
See
Fig 
No
Fig 
PD 
13
Fig 
FA 
22
Fig 
FA 
32
Fig 
FA 
34 

ENGINE 
MECHANICAL
Standard 
Maximum
Crankshaft 
bend
mm 
in 
0 
05
0
0020
0
015
0
0006
Note
When 
measuring 
bend 
use 
a 
dial
gauge
Bend 
value 
is
a 
half 
of 
the 
reading 
obtained 
when
the 
crankshaft 
is 
turned 
once 
with 
the 
dial
gauge
applied 
to
its 
center 
journal
3
After 
regrinding 
the 
crankshaft 
fmish 
it 
to 
the
necessary 
size 
indicated 
in 
the 
lists
on
pages 
EM 
25
by
using 
an
adequate 
undersize 
bearing 
according 
to 
the
extent 
of
required 
repair
4 
Install 
the 
crankshaft 
in 
the
cylinder 
block 
and
measure 
the 
thrust 
clearance
Fig 
EM 
60
Crankshaft 
end
pldy 
check
Standard 
Limit
Crankshaft 
free 
end
play 
rom
in 
0 
05 
to 
0
15
0 
0020 
to 
0 
0059 
0
30
0
D118
5 
Check 
the
main 
drive 
shaft
pilot 
bearing 
at 
the 
rear
end 
of 
the 
crankshaft 
for 
wear 
and
damage
Replace 
it 
if
any 
defects 
are 
detected 
BUSHING 
AND 
BEARING
Measuring 
main
bearing
clearance
Check 
all
bearings 
and
bushings 
for 
seizure 
melt 
scar
and
burr
Replace 
bushings 
if
any 
defects 
are 
detected
2
Wipe 
off 
oil
and 
dust
especially 
the 
rear 
of 
the
bushing
3
Set 
the 
main
bearing 
on 
the
cap 
block
Scale
Plastigage
EM141
Fig 
EM 
61
Plastigage
4 
Cut 
a
plastigage 
to 
the
width 
of 
the
bearing 
and
place
it 
in
parallel 
with 
the 
crank
pin 
getting 
clear
of 
the 
oil
hole
Install 
the
cap 
on 
the 
assembly 
and
tighten 
them
together 
with 
the
specified 
torque
Tightening 
torque
5
0 
to 
6
0
kg 
m 
36
to 
43
ft 
lb
Note 
Be
sure 
not 
to 
turn
the 
crankshaft 
when 
the
plastigage 
is
inserted
5 
Remove 
the
cap 
and 
measure 
width 
of 
the
plastigage
at 
its 
widest
part 
with 
the 
scale
printed 
in 
the
plastigage
envelope
EM 
21