Front Suspension
Torque Specifications
CAUTION:
• Replace the self-locking nuts after removal.
• The vehicle should be on the ground before any bolts or nuts connected to rubber mounts or bushings are tightened.
• Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the pin
hole. Do not align the nut by loosening.
NOTE: Wipe off the grease before tightening the nut at the ball joint.
SELF-LOCKING NUT
10 x
1.25
mm
29 N-m (3.0 kgf-m, 22 Ibf-ft)
Replace.
SELF-LOCKING NUT
12 x
1.25
mm
64 N-m (6.5 kgf-m, 47 Ibf-ft)
Replace.
SELF-LOCKING NUT
10 x
1.25
mm
29 N-m (3.0 kgf-m, 22 Ibf-ft)
Replace.
FLANGE BOLT
10 x
1.25
mm
43 N-m (4.4 kgf-m, 32 Ibf-ft)
SELF-LOCKING NUT
8 x
1.25
mm
19 N-m (1.9 kgf-m, 14 Ibf-ft)
Replace.
FLANGE BOLT
12 x
1.25
mm
54 N-m (5.5 kgf-m, 40 Ibf-ft)
FLANGE BOLT
10 x
1.25
mm
39 N-m
(4.0 kgf-m, 29 Ibf-ft)
SELF-LOCKING NUT
12 x
1.25
mm
54 N-m (5.5 kgf-m, 40 Ibf-ft)
Replace.
FLANGE NUT
10 x
1.25
mm
38 N-m (3.9 kgf-m, 28 Ibf-ft)
CASTLE NUT
10 x
1.25
mm
39 - 47 N-m (4.0 - 4.8 kgf-m, 29 - 35 Ibf-ft)
CALIPER BRACKET MOUNTING BOLT
12 x
1.25
mm
108 N-m (11 kgf-m, 80 Ibf-ft)
FLANGE BOLT
10 x
1.25
mm
44 N-m (4.5 kgf-m, 33 Ibf-ft)
CASTLE NUT
12 x
1.25
mm
49 - 59 N-m (5.0 - 6.0 kgf-m,
36-43 Ibf-ft)
FLANGE BOLT
12 x
1.25
mm
103 N-m (10.5 kgf-m, 76 Ibf-ft)
SELF-LOCKING NUT
12 x
1.25
mm
64 N-m (6.5 kgf-m, 47 Ibf-ft)
Replace.
CASTLE NUT
14 x 2.0 mm
49-59 N-m (5.0 - 6.0 kgf-m, 36-43 Ibf-ft)
SPINDLE NUT
24 x 1.5 mm
245 N-m (25 kgf-m, 181 Ibf-ft)
Replace.
NOTE: After tightening, use a drift to
stake the spindle nut shoulder against
the driveshaft.ProCarManuals.com
Installation
1. Loosel y instal l th e dampe r o n th e fram e wit h th e
alignin g ta b facin g inside , the n loosel y instal l th e
thre e flang e nuts .
FLANG E NUT S10 x 1.2 5 mm38 N- m (3. 9 kgf-m , 2 8 Ibf-ft )Tighte n to thi s torqu e in ste p 8 .
DAMPE R
ALIGNIN G TA B
2. Instal l th e dampe r for k ove r th e driveshaf t an d ont o
th e lowe r arm . Instal l th e fron t dampe r i n th e
dampe r for k s o th e alignin g ta b i s aligne d wit h th e
slo t i n th e dampe r fork .
3 . Loosel y instal l th e flang e bol t int o th e damper fork.
4. Loosel y instal l a ne w self-lockin g nu t wit h th e
flang e bolt .
5. Rais e th e knuckl e wit h a floo r jac k unti l th e vehicl e
just lift s of f th e safet y stand .
Th e floo r jac k mus t b e securel y posi -
tione d o r persona l injur y ma y result . 6
. Tighte n th e flang e bolt .
BRAK E HOS E MOUNTIN G BOL T(8 x 20 mm )22 N- m (2. 2 kgf-m , 1 6 Ibf-ft ) BRAK E HOS E MOUNTIN G BOL T(8 x 1 6 mm )22 N- m (2. 2 kgf-m , 1 6 Ibf-ft )
ALIGNIN G TA B
FLANG E BOL T
SELF-LOCKIN G NU T
12 x 1.2 5 mm64 N- m (6. 5 kgf-m , 4 7 Ibf-ft )
Replace . FLANG
E BOL T10 x 1.2 5 mm43 N- m (4. 4 kgf-m , 3 2 Ibf-ft )
7. Tighte n th e self-lockin g nut .
8. Tighte n th e flang e nut s o n th e to p o f th e damper to
th e specifie d torque .
9. Instal l th e brak e hos e mount s wit h th e brak e hos e
mountin g bolts .
10. Instal l th e fron t whee l (se e pag e 18-16 ).
ProCarManuals.com
Rear Suspensio n
Torque Specification s
CAUTION:
• Replac e th e self-lockin g nut s afte r removal .
• Th e vehicl e shoul d b e o n th e groun d befor e an y bolt s o r nut s connecte d to rubbe r mount s o r bushing s ar e tightened .
• Torqu e th e castl e nu t t o th e lowe r torqu e specification , the n tighte n i t onl y fa r enoug h t o alig n th e slo t wit h th e pi n
hole . D o no t alig n th e nu t b y loosening .
NOTE : Wip e of f th e greas e befor e tightenin g th e nu t a t th e bal l joint .
SELF-LOCKIN G NU T10 x 1.2 5 mm29 N- m (3. 0 kgf-m , 2 2 Ibf-ft )Replace .
FLANGE NU T10 x 1.2 5 mm38 N- m (3. 9 kgf-m , 2 8 Ibf-ft ) FLANG
E BOL T10 x 1.2 5 mm38 N- m (3. 9 kgf-m , 2 8 Ibf-ft )
SELF-LOCKIN G NU T
10 x 1.2 5 mm35 N- m (3. 6 kgf-m , 2 6 Ibf-ft )Replace .
8 m m BOL T
2 2 N- m (2. 2 kgf-m , 1 6 Ibf-ft )
FLANG E BOL T
12 x 1.2 5 mm64 N- m (6. 5 kgf-m ,
SELF-LOCKIN G NU T
10 x 1.2 5 mm54 N- m (5. 5 kgf-m , 4 0 Ibf-ft )
Replace . CASTL
E NU T
10 x 1.2 5 mm39 - 4 7 N- m (4. 0 - 4. 8 kgf-m ,
2 9 - 3 5 Ibf-ft )
CALIPE R BRACKE T
MOUNTIN G BOLT S
3 8 N- m (3. 9 kgf-m , 2 8 Ibf-ft )
FLANG E BOL T
12 x 1.2 5 mm64 N- m (6. 5 kgf-m , 4 7 Ibf-ft )SELF-LOCKIN
G NU T
8 x 1.2 5 mm13 N- m (1. 3 kgf-m , 9 Ibf-ft )Replace .
SELF-LOCKIN G NU T10 x 1.2 5 mm35 N- m (3. 6 kgf-m , 2 6 Ibf-ft )Replace .
SELF-LOCKIN G NU T10 x 1.2 5 mm35 N- m (3. 6 kgf-m , 2 6 Ibf-ft )
Replace .
FLANGE BOL T
10 x 1.2 5 mm54 N- m (5. 5 kgf-m , 4 0 Ibf-ft )
SPINDL
E NU T 2 2 x 1. 5 m m
18 1 N- m (18. 5 kgf-m , 13 4 Ibf-ft )
Replace .NOTE: Afte r tightening , us e a drif t t ostak e th e spindl e nu t shoulde r agains tthe spindle .
SELF-LOCKIN G NU T 1 2 x 1.2 5 m m
6 4 N- m (6. 5 kgf-m , 4 7 Ibf-ft )
Replace .
ProCarManuals.com
Rear Dampe r
Installatio n
1. Lowe r th e rea r suspension , an d positio n th e dampe r
wit h th e welde d nu t pointe d towar d th e fron t o f th e
vehicle .
DAMPE R
WELDED NU T
2. Loosel y instal l th e tw o flang e nuts .
FLANG E NUT S10 x 1.2 5 mm38 N- m (3. 9 kgf-m , 2 8 Ibf-ft )
Tighte n thes e nut s i n ste p 6 .
3. Loosel y instal l th e flang e bolt .
4 . Rais e th e rea r suspensio n wit h a floo r jac k unti l th e
vehicl e jus t lift s of f th e safet y stand .
Th e floo r jac k mus t b e securel y posi -
tione d o r persona l injur y ma y result .
5 . Tighte n th e flang e bolt .
FLANG E BOL T10 x 1.2 5 mm54 N- m (5. 5 kgf-m , 4 0 Ibf-ft )
6. Tighte n th e tw o flang e nut s o n to p o f th e dampe r t o
th e specifie d torque .
7 . Instal l th e rea r sea t (se e sectio n 20 ).
8 . Instal l th e rea r wheel s (se e pag e 18-27 ).
ProCarManuals.com
Pushrod Clearanc e Adjustmen t
NOTE: Maste r cylinde r pushrod-t o pisto n clearanc e mus t
b e checke d an d adjustment s made , i f necessary , befor e
installin g maste r cylinder .
1.
2 .
3.
4 .
5 .
Se t th e specia l too l o n th e maste r cylinde r body ;
pus h in th e cente r shaf t unti l th e to p o f i t contact s th e
en d o f th e secondar y pisto n b y turnin g th e adjustin g
nut.
NOTE : '9 7 - 9 8 model s i s shown .
PUSHRO D ADJUSTMEN T GAUG E07JAG-SD4010 0
CENTERSHAFT
ADJUSTIN G NU T
Withou t disturbin g th e cente r shaft' s position , instal l
th e specia l too l upsid e dow n o n th e booster .
Instal l th e maste r cylinde r nut s an d tighte n t o th e
specifie d torque .
Connec t th e booste r in-lin e wit h a vacuu m gaug e 0 -
10 1 kP a ( 0 - 76 0 mmHg , 3 0 in Hg ) t o th e booster' s
engin e vacuu m supply , an d maintai n a n engin e
spee d tha t wil l delive r 6 6 kP a (50 0 mmHg , 2 0 in Hg )
vacuum .
With a feele r gauge , measur e th e clearanc e betwee n
th e gaug e bod y an d th e adjustin g nu t a s shown .
Clearance : 0 - 0. 4 m m (0 - 0.0 2 in )
FEELE R GAUG E
ADJUSTIN G NU T VACUU
M GAUG E
(Commerciall y available )0 -101 kPa(0-760mmHg,30in.Hg )
BRAKEBOOSTE R
MASTER CYLINDE R NU T
1 5 N- m (1. 5 kgf-m , 1 1 Ibf-ft )
NOTE : I f th e clearanc e betwee n th e gaug e bod y
an d adjustin g nu t i s 0. 4 m m (0.0 2 in) , th e pushrod -
to-pisto n clearanc e i s 0 mm . However , i f th e clear -
anc e betwee n th e gaug e bod y an d adjustin g nu t i s
0 mm , th e pushrod-to-pisto n clearanc e i s 0. 4 m m
(0.0 2 in ) o r more . Therefor e it mus t b e adjuste d an d
rechecked .
6. I f clearanc e i s incorrect , loose n th e sta r locknu t an d
tur n th e adjuste r i n o r ou t t o adjust .
NOTE:
Adjust th e clearanc e whil e th e specifie d vacuu m
i s applie d t o th e booster .
Hol d th e clevi s whil e adjusting .
7 . Tighte n th e sta r locknu t securely .
8 . Remov e th e specia l tool .
0-0. 4 m m (0-0.0 2 in )
STA R LOCKNU T22 N- m(2.2 kgf-m , 1 6 Ibf-ft )
PUSHRO D
LOCKNU T
1.5N- m (1. 5 kgf-m , 1 1 Ibf-ft )
10. Instal l th e maste r cylinde r (se e pag e 19-16 ).
MASTE R CYLINDE RSECONDAR
Y
PISTO N
CLEVIS
ADJUSTE R
PUSHRO D
ADJUSTMEN T GAUG E
07JA G - SD4010 0
122 ±0. 5 mm(4.8 ± 0.0 2 in)
CLEVI S
PUSHRO D
ProCarManuals.com
ABS Functio n Tes t
Modulato r Functio n Chec k
NOTE : Thi s inspectio n determine s whethe r th e basi c
brake syste m continue s t o operat e normall y whe n th e
modulato r uni t flui d pressur e i s low .
CAUTION :
Thi s inspectio n i s mad e b y relievin g th e high-pres -
sur e flui d i n th e modulato r uni t an d checkin g fo r
brak e operation . Afte r inspection , b e sur e t o ad d
fres h brak e flui d t o th e specifie d leve l o f th e reser -
voir , an d star t th e engin e t o restor e th e AB S t o it s
norma l operatin g condition .
D o no t spil l brak e flui d o n th e car ; i t ma y damag e th e
paint ; i f brak e flui d doe s contac t th e paint , was h i t
of f immediatel y wit h water .
D o no t reus e th e draine d brak e fluid .
D o no t loose n th e relie f plu g o n th e accumulator .
1.Remov e th e bleede r ca p fro m th e maintenanc e
bleede r o n th e modulato r unit .
BLEEDE R CA P
RUBBE R TUB EMODULATO R UNI T
MAINTENANC E BLEEDE R11 N- m (1. 1 kgf-m , 8 Ibf-ft )
2. Attac h a wrenc h t o th e maintenanc e bleeder .
3 . Connec t a rubbe r tub e o f th e appropriat e diamete r
t o th e maintenanc e bleeder , an d se t th e othe r en d o f
th e rubbe r tub e in a suitabl e container .
4 . Whil e holdin g th e rubbe r tub e wit h you r hand , slowl y
loose n th e maintenanc e bleede r 1/ 8 to 1/ 4 tur n t o col -
lec t th e brak e flui d in th e container .
CAUTION : D o no t loose n th e maintenanc e bleede r
to o much . Th e high-pressur e brak e flui d ca n burs t out .
5 . Afte r th e brak e flui d stop s flowin g out , loose n th e
maintenanc e bleede r mor e t o releas e th e pressur e
completely .
6 . Tighte n th e maintenanc e bleede r t o th e specifie d
torque .
7. Rais e th e ca r of f th e ground , an d suppor t i t wit h
safet y stand s (se e sectio n 1 ).
8 .Hav e a n assistan t depres s th e brak e peda l firmly ,
an d chec k tha t th e wheel s d o no t rotate .
9 . Remov e th e cap , an d refil l th e reservoi r t o th e MA X
(upper ) leve l wit h fres h brak e fluid .
NOTE : Pou r th e brak e flui d slowl y s o tha t i t doe s
no t foam , an d wai t fo r a fe w minutes .
10 . Star t th e engin e an d le t i t idl e fo r a minute . Sto p th e
engine .
11 . Chec k th e brak e flui d leve l i n th e reservoir . I t shoul d
b e belo w th e MA X (upper ) leve l line . Refil l th e
reservoi r wit h fres h brak e flui d t o th e MA X leve l lin e
again .
CAPRESERVOI R
MAX (UPPER ) LEVE RLINE
MIN (LOWER )LEVEL LIN E
12. Afte r inspection , star t th e engin e an d mak e sur e
tha t th e AB S indicato r ligh t goe s off .
ProCarManuals.com
Modulator Uni t
Relievin g Syste m Pressur e
CAUTION :
Be sur e t o drai n th e high-pressur e brak e flui d com -
pletel y befor e performin g th e modulato r functio n
check, disposin g th e modulato r unit, accumulato r
and AB S pum p moto r replacement .
D o no t spil l brak e flui d o n th e car ; i t ma y damag e th e
paint ; i f brak e flui d doe s contac t th e
paint , wash i t
of f immediatel y wit h water .
Do no t reus e th e draine d brak e fluid .
D o no t loose n th e relie f plu g o n th e accumulator .
1 . Remov e th e bleede r ca p fro m th e maintenanc e
bleeder o n th e modulato r unit .
RUBBE R TUB E
BLEEDE R CA P
MODULATOR UNIT
MAINTENANC E BLEEDE R11 N-m(1. 1 kgf-m, 8 Ibf-ft)
2. Attac h a wrenc h t o th e maintenanc e bleeder .
3 . Connec t a rubbe r tub e o f th e appropriat e diamete r
t o th e maintenanc e bleeder , an d se t th e othe r en d
o f th e rubbe r tub e in a suitabl e container .
4 . Whil e holdin g th e rubbe r tub e wit h you r hand , slowl y
loosen th e maintenanc e bleede r 1/ 8 to 1/ 4 tur n to col -
lect th e brak e flui d in th e container .
CAUTION : D o no t loose n th e maintenanc e bleede r
to o much . Th e high-pressur e brak e flui d ca n burs t out .
5 . Tighte n th e maintenanc e bleede r t o th e specifie d
torque .
ProCarManuals.com
Modulator Uni t
Brak e Flui d Replacement/Bleedin g (cont'd )
6. Star t th e engin e an d le t i t idl e fo r a minute . Sto p th e
engine .
7 . Chec k th e brak e flui d leve l i n th e reservoir . I t shoul d
b e belo w th e MA X (upper ) leve l line .
8 . Repea t th e step s 4 throug h 7 to drai n th e res t o f th e
brak e flui d fro m th e modulato r unit .
NOTE : Th e modulato r ha s a capacit y o f approximatel y
150 ( 5 fl-oz , 5. 3 Imp-oz) . Approximatel y 3 5 - 4 5
(1 1/6- 1 1/ 2 fl-oz , 1.2-1. 6 Imp-oz ) o f th e flui d i s
draine d a t eac h try .
9 . Remov e th e cap , an d refil l th e reservoi r t o th e MA X
(upper ) leve l wit h fres h brak e fluid .
NOTE : Pou r th e brak e flui d slowl y s o tha t i t doe s no t
foam , an d wai t fo r a fe w minutes .
10.
CA P
MA X (UPPER ) LEVE LLINE
Repea t step s 4 throug h 7 twice , an d refil l th e reser -
voi r t o th e MA X (upper ) leve l wit h fres h brak e fluid .
11 . Tighten the maintenanc e bleede r t o th e specifie d
torque .
12 . Afte r replacement , star t th e engin e an d mak e sur e
tha t th e AB S indicator light goe s off .
Bleeding :
NOTE: Th e AB S ca n als o b e ble d b y usin g th e PG M
Teste r an d th e AB S Diagnosti c Ki t t o ru n th e AB S pump .
Connec t th e teste r an d modul e A as describe d i n th e
PG M Teste r Anti-Loc k Brak e Syste m (ABS ) Vehicl e
Syste m Supplement , the n follo w th e tester' s prompt s
instea d o f thi s procedure .
Whe n th e brak e flui d i s completel y draine d fro m th e
reservoi r (ai r enter s i n th e modulato r unit ) durin g brak e
fluid replacement , blee d th e ai r fro m th e modulato r uni t
as follows .
1 . Fil l th e reservoi r t o th e MA X (upper ) leve l wit h fres h
brak e fluid .
2 . Connec t th e rubbe r tub e t o th e bleede r o n th e mod -
ulato r unit , an d se t th e othe r en d o f th e rubbe r tub e
i n a containe r (se e page 19-115 ).
3 . Loose n th e bleeder , an d star t th e engin e t o activat e
th e pum p motor .
NOTE : Tak e car e no t t o spil l th e brak e flui d fro m
th e container .
4 . Tighte n th e bleede r whe n th e flui d start s t o flo w ou t
o f th e bleeder .
5 . Sto p th e engin e afte r th e pum p moto r stop s
NOTE : I f th e AB S indicato r ligh t come s o n an d th e
pum p moto r stops , restar t th e engin e an d repea t
step s 3 throug h 5 above .
ProCarManuals.com