Page 969 of 2389
2. IF NECESSARY, REPLACE FRONT BEARING
(a) Remove the four screws, bearing retainer and bearing.
(c) Using SST and a press, press in a new bearing.
SST 09608±20012 (09608±00030)
3. INSPECT REAR BEARING
Check that the bearing is not rough or worn.(b) Using a socket wrench and press, press out the bear-
ing.
(d) Install the bearing retainer with the four screws.
± CHARGING SYSTEMAlternatorCH±11
Page 970 of 2389

ASSEMBLY OF ALTERNATOR
(See page CH±6)
1. INSTALL ROTOR TO DRIVE END FRAME
2. ASSEMBLE DRIVE END FRAME AND RECTIFIER END
FRAME
(a) Using a plastic±faced hammer, lightly tap in the end frame.
(b) Install the four nuts.
3. INSTALL PULLEY
(a) Install the pulley to the rotor shaft by tightening the
pulley nut by hand.
(b) Hold SST(A)with a torque wrench, and tighten SST (B) clock-
wise to the specified torque.
SST 09820±63010
Torque: 400 kg±cm (29 ft±Ib, 39 N±m)
(c) Check that SST (A) is secured to the pulley shaft.
(d) As shown in the illustration, mount SST (C) in a vise, and
install the alternator to SST (C).
(e) To torque the pulley nut turn SST (A) in the direction
shown in the illustration.
Torque: 1,125 kg±cm (81 ft±Ib, 110 N±m )
(f) Remove the alternator from SST (C).
(g) Turn SST (6) and remove SST (A and6). 4. IF NECESSARY, REPLACE REAR BEARING
(a) Using SST, remove the bearing cover and bearing.
SST 09820±00021
NOTICE: Be careful not to damage the fan.
(b) Using SST and a press, press in a new bearing and
bearing cover.
SST 09285±76010
± CHARGING SYSTEMAlternatorCH±12
Page 971 of 2389
5. INSTALL IC REGULATOR AND BRUSH HOLDER
(a) Install the brush holder cover to the brush holder.
(b) Install the IC regulator together with the brush holder
horizontally as shown.
(c) Install the five screws until there is a clearance of
approx. 1 mm (0.04 in.) between the brush holder and
connector. 4. INSTALL RECTIFIER HOLDER
(a) Install the four rubber insulators on the lead wires.
(b) Install the rectifier holder with the four screws.
(d) Fit the brush holder cover.
± CHARGING SYSTEMAlternatorCH±13
Page 972 of 2389
2. INSTALL DRIVE BELT
Adjust the drive belt tension. (See step 3 on page CH±3)
Drive belt tension:
w/ A/C New belt 175 + 5 lb
Used belt 130+ 10 lb
w/o A/C New belt 125 t 25 Ib
Used belt 95 + 20 Ib
3. CONNECT CONNECTOR AND WIRE TO ALTERNATOR
4. CONNECT CABLE TO NEGATIVE TERMINAL OF
BATTERY
5. PERFORM ON±VEHICLE INSPECTION
(See steps 5 to 7 on pages CH±4 and 5)
INSTALLATION OF ALTERNATOR
(3S±FE)
1. INSTALL ALTERNATOR
Mount the alternator on the alternator brackets with the
pivot bolt and adjusting lock bolt. Do not tighten the bolts
yet. 6. INSTALL REAR END COVER
(a) Install the end cover with the three nuts.
(b) Install the terminal insulator with the nut.
7. CHECK THAT ROTOR ROTATES SMOOTHLY
± CHARGING SYSTEMAlternatorCH±14
Page 973 of 2389
2. INSTALL DRIVE BELT
Adjust the drive belt tension. (See step 3 on page CH±3)
Drive belt tension:
New belt 175 ± 5 Ib
Used belt 115
+ 20 Ib
3. CONNECT CONNECTOR AND WIRE TO ALTERNATOR
4. CONNECT WIRE HARNESS TO CLIP
5. INSTALL NO.2 RH MOUNT STAY
Torque: Bolt 890 kg±cm (64 ft±Ib, 87 N±m)
Nut 530 kg±cm (38 ft±Ib, 52 N±m)
6. CONNECT CABLE TO NEGATIVE TERMINAL OF
BATTERY
7. PERFORM ON±VEHICLE INSPECTION
(See steps 5 to 7 on pages CH±4 and 5)
INSTALLATION OF ALTERNATOR
(2VA±FE)
1. INSTALL ALTERNATOR
Mount the alternator on the alternator bracket with the pivot
bolt and adjusting lock bolt. Do not tighten the bolts yet.
± CHARGING SYSTEMAlternatorCH±15
Page 974 of 2389
Page 975 of 2389

Clutch pedal freeplay excessive
Air in clutch lines
Clutch release cylinder faulty
Clutch master cylinder faulty
Clutch disc out of true, runout is excessive or
lining broken
Splines on input shaft or clutch disc dirty or
burred
Clutch pressure plate faulty
Clutch disc lining oily or worn out
Pressure plate faulty
Clutch diaphragm spring bent
Engine mounts looseClutch pedal freeplay insufficient
Clutch disc lining oily or worn out
Pressure plate faulty
Release fork binding
Inspect clutch disc
Replace clutch cover
Align clutch diaphragm spring
Repair as necessaryAdjust pedal freeplay
Bleed clutch system
Repair release cylinder
Repair master cylinder
Inspect clutch disc
Air in clutch lines
Clutch release cylinder faulty
Clutch master cylinder faultyAdjust pedal freeplay
inspect clutch disc
Replace clutch cover
inspect release fork
Bleed clutch system
Repair release cylinder
Repair master cylinder
Loose part inside housing
Release bearing worn or dirtyRepair as necessary
Replace clutch cover
TROUBLESHOOTING
Repair as necessary
Replace release bearing Hard to shift or will not
shiftCL±3
CL±4
CL±7
CL±5
CL±9
Clutch pedal spongyClutch grabs/
chattersCL±3
CL±9
CL±9
CL±9
CL±9
CL±9
CL±9
CL±4
CL±7
CL±5 Possible cause
Clutch noisy Clutch slipsProblem
RemedyPage
± CLUTCHTroubleshootingCL±2
Page 976 of 2389

CHECK AND ADJUSTMENT OF
CLUTCH PEDAL
1. CHECK THAT PEDAL HEIGHT IS CORRECT
Pedal height from asphalt shaft 181 ± 191 mm
(7:13 ± 7.52 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Remove the instrument lower finish panel and discon-
nect the air duct.
(b) Loosen the lock nut and turn the stopper bolt (w/o
Cruise control system) or clutch switch (w/ Cruise
control system) until the height is correct. Tighten the
lock nut.
HINT: Before rotating the clutch switch for pedal height
adjustment, disconnect the clutch switch connector.
3. CHECK THAT PEDAL FREEPLAY AND PUSH ROD
PLAY ARE CORRECT
(Pedal Freeplay)
Push in the pedal until the beginning of clutch resistance
is felt.
Pedal freeplay: 5 ± 15 mm (0.20 ± 0.59 in.)
Push rod play at pedal top: 1.0 ± 5.0 mm
(0.039 ± 0.197 in.)
4. IF NECESSARY, ADJUST PEDAL FREEPLAY AND
PUSH ROD PLAY
(a) Loosen the lock nut and turn the push rod until the free-
play and push rod play are correct.
(b) Tighten the lock nut.
(e) After adjusting the pedal freeplay, check the pedal
height.
(d) Connect the air duct and install the lower finish panel.
5. INSPECT CLUTCH RELEASE POINT
(a) Pull the parking brake lever and install wheel stopper.
(b) Start the engine and idle the engine.
(e) Without depressing the clutch pedal, slowly shift the
shift lever into reverse position until the gears contact.
(d) Gradually depress the clutch pedal and measure the
stroke distance from the point the gear noise stops
(release point) up to the full stroke end position.
Standard distance: 25 mm (0.98 in.) or more
(From pedal stroke end position to release point)
If the distance is not as specified, perform the following
operation.
wInspect pedal height.
wInspect push rod play and pedal free play.
wBleed the clutch line.
wInspect the clutch cover and disc.
± CLUTCHCheck and Adjustment of Clutch PedalCL±3