
6-18CLUTCH - Clutch Cover and Disc
I6CLO33
Clutch disc
T& assemblyClutch cover
6CLO26
SERVICE POINTS OF INSTALLATIONNWGDAT
5. A,PPLlCATlONOF GREASE TO RELEASE FORKAi&
(1) Apply a coating of the specified grease to the point of
contact with the fulcrum and the point of contact withi(the release bearing.
Specified grease: MOPAR Multi-mileage Lubricant
Part Nq.2525035 or equivalentCautionWhen installing the
clutch, apply grease to each
part, but be careful not to apply excessive grease;
excessive grease will cause clutch slippage and
shudder.
(2) Apply a coating of the specified grease to the end of therelease cylinder’s push rod and to the push rod hole in
the release fork.
Specified grease: MOPAR Multi-mileage Lubricant
Part No.2525035 or equivalent
4. APPLICATION OF GREASE TO CLUTCH RELEASE
BEARING
Pack the inner surface of the clutch release bearing and thegroove with the specified grease.
L4r
Specified grease: MOPAR Multi-mileage Lubricant _
Part No.2525035 or equivalentCaution
For the release bearing of a resin sleeve, grease mustnot
be applied to the sleeve part.
2. APPLICATION OF GREASE TO CLUTCH DISC/ 1.
CLUTCH COVER ASSEMBLY
(1) Apply a coating of the specified grease to the clutch
disc spline, and then use a brush to rub it in.
Specified grease: MOPAR Multi-mileage Lubricant
Part No.2525035 or equivalent
(2) Using the special tool (clutch disc center guide),
position the clutch disc to the flywheel.
(3) Install the clutch cover assembly. Tighten the bolts a
little at a time, working in a diagonal sequence, finally
tightening them to the specified torque.

9-18ENGINE - Specifications
TORQUE SPECIFICATIONS
NO9CG-Items
Engine mount insulator nut (large)
(small)
Engine mount bracket nut or bolt
Transaxle mount insulator nut
Transaxle mount to body
Front roll stopper insulator nut
Front roll stopper bracket to centermember
Rear roll stopper insulator nut
Rear roll stopper bracket to centermember
Accelerator cable adjusting bolts
Fuel high pressure hose to delivery pipe
Ground cable to air intake manifold
Control wiring harness to air intake plenum
Power steering oil pump to bracket
Air conditioner to bracketcompressor
Exhaust pipe clamp bolt
Exhaust pipe to rubber hanger
Oil drain plug
panOil (bolts)
pan(nuts)VVater pulley
pump
Tensioner pulley bracket (air conditioner compressor)
Timing belt front coverCrankshaft sprocket
Camshaft sprocket
Timing belt “B” tensioner bolt
-eft engine support bracket3il switch
pressure3il unit
pressure gauge
Iii filter bracket
Iii cover
pumpqelief plug
‘lywheel or drive plate
ixhaust pipe bracket
support
‘rant roll stopper bracket
Iear roll stopper bracket‘rant engine bracket
support
:1.8L Engine>
Oil screen
Rocker cover
Camshaft bearing cap bolt (6 x 20)
(8 x 65)
Exhaust pipe to exhaust manifold
Intake manifold bolt
stay
Cylinder head bolt
Crankshaft pulley
Crankshaft damper pulleyNm
ftlbs.
60-8043-58
30-4022-29
50-6536-47
60-8043-58
40-5029-36
50-6536-47
40-5029-36
40-5029-36
40-5029-36
4-63-4
4-6
3-4
4-6
3-4
4-6
3-4
35-45
25-33
23-27
17-20
30-4022-29
10-157-l 135-45
25-33
6-84-6
5-73.5-5
8-106-7
23-27
17-20
10-127-9
110-13080-94
80-10058-72
15-2211-16
30-4222-308-126-9
8-126-9
15-2211-16
15-1811-13
40-5029-36
130-14094-101
30-4222-3055-75
40-54
110-13080-94
50-7036-51
18-2513-18
5-74-5
20-2714-2019-21
14-15
30-4022-29
18-2513-18
70-7551-5415-1811-13
15-1811-13

ENGINE - Crankshaft, Flwvheel and Drive Plate9-71
3EN30’lrrow mark toward
cap No,
I
RING GEAR (Engine with a manual transaxle)Check the ring gear for worn, damaged or broken teeth.
Replace the ring gear if teeth are faulty, and also check the
starter motor pinion.
Ring Gear Replacement Procedure(1) Strike outer circumference of ring gear at several points.
Caution
The ring gear cannot be removed if it is heated.(2) Install the ring gear on flywheel after heating the ring gear
to
260-280°C (500-536°F) for shrink fit.
FLYWHEEL (Engine with a manual transaxle)
(1) Visually check the clutch disc friction surface of flywheel forridge wear, streaks and seizure. Replace as necessary.
(2) If the flywheel
runout exceeds the limit, replace it.
Limit: 0.13 mm (0051 in.)
DRIVE PLATE (Engine with an automatic transaxle)Replace if deformed, damaged or cracked.
SERVICE POINTS OF REASSEMBLY
NOSUDAA
15. INSTALLATION OF UPPER BEARINGWhen reusing the main bearings, install them in their
original positions by referring to location marking made at
the time of removal.
Be sure that oil holes in bearings align with those in cylinder
block.
13. INSTALLATION OF LOWER BEARINGMake sure that a bearing without oil groove is used as
lower bearing.
12. INSTALLATION OF BEARING CAP(1) Install the bearing caps with their arrow mark directed
toward the timing belt side of engine. Cap numbers
must be in correct order.(2) Tighten cap bolts in the sequence of center,
No.2,
No.4. front and rear cap bolts.
(3) Cap bolts should be tightened evenly in 2 to 3 steps
before they are finally tightened.
(4) Make certain that the crankshaft turns freely and has a
proper end play by checking the clearance between
center main bearing thrust flange and connecting rod
big end bearing.
Crankshaft end play:
0.05-0.18 mm (.0020-.0071 in.)
Limit:0.25 mm (.0098 in.)

ENGINE <2.0L DOHC Engine>- Crankshaft, Flywheel and Drive Plate,91133
INSPECTIONNOSUHAD
CRANKSHAFT(1) Check the crankshaft journals and pins for streaks and
seizure. Replace if necessary.
6EN0’228
\3EN056
Plastic
6EN043
. .
I1 EN067-(2) Measure the journal O.D. and main bearing I.D. to obtain
the clearance between the two (oil clearance). If the
clearance exceeds the limit, replace the main bearing and,if necessary, the crankshaft.
Standard value:
0.02-0.05 mm (.OOOS-.0020 in.)
Limit: 0.1 mm
(.0040 in.)
Caution
A special
surface treatment has been applied to
crankshaft. Do not machine it to undersize.
CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE
METHOD)
The crankshaft oil clearance can be measured easily by using aplastic gauge, as follows:
(1) Remove oil and grease and any other foreign matters from
crankshaft journal and bearing inner surface.
(2) Install the crankshaft.
(3) Cut the plastic gauge to the same length as the width of
bearing and place it on journal in parallel with its axis.
(4) Gently place the crankshaft bearing cap over it and tighten
the bolts to the specified torque.
(5) Remove the bolts and gently remove the crankshaft
bearing cap.(6) Measure the width of the smashed plastic gauge at its
widest section by using a scale printed on the plastic gauge
bag.

Special Tools/Troubleshooting/REAR SUSPENSION
SPECIAL TOOLN17DA.A
ToolNumberName1 Use1
L-451 4
Spring compressorRemoval and installation of the coil spring
bodyTROUBLESHOOTINGNI’IEA-A
Symptom
Squeaks or other
abnormal noiseProbable cause
Loose rear suspension installation bolts and nuts
Malfunction of shock absorber
Worn bushings
Remedy
Retighten
Replace
Poor rideExcessive tire inflation pressure
Malfunction of shock absorberWeak or broken springs
Adjust the pressure
Replace
Body tiltingWeak or deteriorated bushings
Weak or broken springs
Replace
SERVICE ADJUSTMENT PROCEDURES
REAR WHEEL ALIGNMENT INSPECTIONN17FAAC
The rear suspension assembly must be free of worn, loosen or
damaged parts prior to measurement of rear wheel alignment.
Standard value:
Toe-in (Left-right difference)
Of3 mm (Of.118 in.)
Camber-45’ + 30’
NOTEThe rear wheel alignment is set at the factory and cannot be
adjusted.If toe-in or camber is not within the standard value, replace
bent or damaged parts.
WHEEL BEARING END PLAY ADJUSTMENT,7FBA0
1.Inspect the play of the bearings while the vehicle is jacked
up and resting on floor jack.
2.Remove the hub cap and then release the parking brake.
3. Remove the caliper assembly and the brake disc.
4. Check the bearing’s end play.
Place a dial gauge against the hub surface; then move the
hub in the axial direction and check whether or not there isend play.
Limit: 0.01 mm
(.004 in.) or less
NOTE12AO531If the limit value is exceeded, the lock nut should be
tightened to the specified torque and check the end play
again.
5.Replace the rear hub bearing unit if an adjustment cannot
be made to within the limit.

17-6REAR SUSPENSION
Drive out
BayArbor
Race
BearingSERVICE POINTS OF REMOVAL
Nl7QBh
1.REMOVAL OF REAR SPEED SENSOR
5-Wheel Speed Sensor.
11. REMOVAL OF LATERAL ROD MOUNTING BOLT
(1) Remove the lateral rod mounting bolt.
(2) Secure and hold the lateral rod to the axle beam with
wire, etc.
13. REMOVAL OF SHOCK ABSORBER UPPER ‘MOUNTINGNUTS/14. TRAILING ARM MOUNTING BOLTS/15
REAR SUSPENSION ASSEMBLY(1) Jack up the torsion axle and arm assembly in order to
raise it slightly.
Caution
1.Always insert a wooden block between the jack
receptacle and the axle beam and place the jackat the center of the axle beam.
2. Make sure that the jack does not contact the
lateral rod.(2) Remove the shock absorber
m,ounting nuts and trailing
arm mounting bolts.
(3) Lower the jack slowly, and then remove the rear
suspension assembly.
#-
INSPECTIONNl7QCAL
lCheck the trailing arm and axle beam for deformation or
damage.l Check the torsion bar for damage.
l Check the lateral rod for damage or deformation.
lCheck the bushings for cracking, deterioration, or unusual
wear.
BUSHING REPLACEMENTNl)GTAE
TRAILING ARM BUSHING(1) Drive out the trailing arm bushing as shown in the
illustration.
Caution
The bearing within the special tool should be installed,
as shown in the figure, at the race surface nut side of7
the bearing.

REAR SUSPENSION
Inut
-
-Spindle
14AO419
SERVICE POINTS OF REMOVALNliP9AG
1.REMOVAL OF REAR SPEED SENSOR
5-Wheel Speed Sensor.
4. REMOVAL OF CALIPER ASSEMBLYRemove the caliper assembly and suspend it with a piece
of wire.
9. REMOVAL OF REAR HUB BEARING UNIT
NOTERear hub bearing unit cannot be disassemble.
12. REMOVAL OF SHOCK ABSORBER LOWER MOUNTING
BOLT/lB. TRAILING ARM MOUNTING BOLT/ 14.
TORSION AXLE AND ARM ASSEMBLY
(1) Jack up the torsion axle and arm assembly in order to
raise it slightly.
Caution
1.Always insert a wooden block between the jack
receptacle and the axle beam and place the jackat the center of the axle beam.
2. Make sure that the jack does not contact the
lateral rod.(2) Remove the shock absorber’s mounting bolts and the
trailing arm mounting bolts.
(3)Lower the jack slowly, and then remove the torsion axleand arm assembly.
INSPECTIONN17PCAAa
l Check the trailing arm and axle beam for deformation or
damage.l Check the torsion bar for damage.
0Check the bushings for cracking, deterioration, or unusual
wear.
NOTEFor information concerning the replacement of the trailing
arm bushing, refer to
P.17-6.
SERVICE POINTS OF INSTALLATIONN17PDAI
11. INSTALLATION OF LATERAL ROD MOUNTING
BdLT
(AXLE BEAM SIDE)Install the lateral rod mounting bolt from the direction
shown in the illustration.
9. INSTALLATION OF REAR HUB BEARING UNITPress inner race further until inner race contacts with
spindle end.
7. INSTALLATION OF WHEEL BEARING NUTAfter tightening the wheel bearing nut, align with the
spindle’s indentation and crimp.
1. INSTALLATION OF REAR SPEED SENSOR
5-Wheel Speed Sensor.

17-20REAR SUSPENSION
12R0556-- Upper arm
(L.H.)
12A0081
SERVICE ADJUSTMENT PROCEDURES
REAR WHEEL ALIGNMENT INSPECTIONN17FDAB is.Measure the wheel alignment with the vehicle parked on level
--’
ground.The rear suspension and wheels should be inspected for
wear’or damage and repaired prior to measurement of wheel,
alignment.
TOE-IN
(1) Measure the toe-in with a toe-in gauge.
Standard value:
3.6f3 mm (.14+ .I18 in.)
(2) If the toe-in is not within the standard value, adjust it by
moving the mounting bolts located on the crossmember
side of the trailing arm.
NOTEMake the adjustment by moving the left and the right bolts
r;hr
equally.Movement of one division on the scale will cause toe-in
variation of about 2 mm
(.08 in.).
CAMBER
(1) Measure the camber with a camber/caster/kingpin gauge.
Standard value:
-1”33’f30’(2) If the camber is not within the standard value, adjust it by
moving the mounting bolt located on the crossmember
side of the upper arm.
NOTEMovement of one division on the scale will cause camber
variation of about 15’.
Caution
1. As toe-in will vary 0.9 mm
(.035 in.) for every
camber scale adjustment, adjust the toe after
adjusting camber.
2. The difference between the left and the right
camber shall be less than 15’.