Rear Damper
Lower the rear suspension and position the damper
with the welded nut pointed toward the front of the
vehicle.
DAMPER
2. Loosely install the two flange nuts.
Hatchback:Sedan:
lnstallation
. ',.?7,:..r9\,ir '..
EY
FLANGE NUTS10 x 1.25 mmTighten these nuts in step 7 on the next page.
18-40
3. Install the wheel sensor wire bracket.
NOTE: Be careful when installing the sensors to
avoid twisting wires.
Raise the rear suspension with a floor iack until the
vehicle just lifts off the safety stand.
@ The floor jack must be securely posi-
tionod or personal iniury may result.
5. Install the damper mounting bolt and the flange
bolt, then tighten the bolts.
NOTE: The damper mounting bolt and the flange
bolt should be tightened with the damper under
vehicle load.
FLANGE EOLT10 x 1.25 m.n54 N.m (5.5 kgf m, 40 lbt.ftl
FLANGE BOLT10 x 1-25 mm54 N.m ls.s kgf m, 40 lbtft)
6. Tighten the three wheel sensor wire bracket bolts
{for vehicles with ABS).
9.8 N.m {1.0 kg{.m, 7.2 lbtftlBOLTS
Front
Disc
Brake
Runout
Disc
InspectionDisc Thickness and Parallelism
\'L
2.
Loosen the front wheel nuts slightly, then raise the
vehicle and suppon it on safety stands. Remove the
front wheels.
Remove the brake pads (see page 19-8).
Inspect the disc surface for damage or cracks. Clean
the disc thoroughly and remove all rust.
Use wheel nuts and suitable plain washers to hold
the disc securely against the hub, then mount a dial
indicator as shown, and measure the runout aat 10
mm (0.4 in) from the outer edge of the disc.
B;ake Disc Runoul:
Service Limit: 0.10 mm (0.OO4 in)
3.
1O mm{0.4 inl
PLAIN WASHER108Nm(11 ksl.m, 80 lbf.ft)
5. lf the disc is beyond the service limit, refinish the
brake disc with an on-car brake lathe. The Kwik
Lathe produced by Kwik-way manutacturing Co. and
the "Front Brake Disc Lathe" oflered by Snap-on
Tools Co. are approved {or this operation.
Max. Rofinish Limit:
Type R Model:
21.0 mm (0.83 in)
All €xcept Type R Model:
19.0 mm (0.75 inl
NOTE:
o A new disc should be relinished if its runout is
greater than 0.10 mm (0,004 in).
. See section 18 for brake disc replacement.
. When the vehicle is equipped with a limited slip
differential, raise both front wheels off the
ground.
3.
Loosen the front wheel nuts slightly, then raise the
vehicle and support it on safety stands, Remove the
front wheels.
Remove the brake pads (see page 19-8).
Using a micrometer, measure disc thickness at
eight points, approximately 45'apart and 10 mm
(0.4 in) in from the outer edge of the disc. Replace
the brake disc if the smallest measurement is less
than the max. refinishing limit.
Inspection
2.
1.
Brake Disc Thickness:
Standard:
Type R Model:
22.9 - 23.1 mm (0.90 - 0.91 inr
All oxcept Typ€ R Mod€l:
2O.9 -21.1mm 10.82 - 0.tB inl
Max. Relinishing Limit:
Type R Model:
21.0 mm 10.83 inl
All €xc€pt Type R Model:
19.0 mm {0.75 inl
Brake Disc Parallelism: O.O15 mm (0.0006 inl max.
NOTE: This is the maximum allowable difference be-
tween the thickness measurements.
4. lf the disc is beyond the service limit lor parallelism,
refinish the brake disc with an on-car brake lathe.
The Kwik-Lathe produced by Kwik-Way Manufac-
turing Co. and the "Front Brake Disc Lathe" offered
by Snap-on Tools Co. are approved for this
operaton.
NOTE:
. See section 18 for brake disc replacement.
. When the vehicle is equipped with a limited slip dif-
ferentjal, raise both front wheels off the ground.
1.
8.
NOTE: lf the clearance between the gauge body
and adjusting nut is 0.4 mm (0.02 in), the pushrod-
to-piston clearance is 0 mm. However, if the clear-
ance between the gauge body and adjusting nut is
0 mm, the pushrod-to-piston clearance is 0.4 mm(0.02 in) or more. Therefore it must be adjusted and
rechecked.
lf clearance is incorrect, loosen the star locknut and
turn the adjuster in or out to adjust.
NOTE:
. Adjust the clearance while the specified vacuum
is applied to the booster.
. Hold the clevis while adjusting.
Tighten the star Iocknut securely.
Remove the special tool.
0 - o.il mm l0 - 0.02 inl
Brake Booster Inspection
Functions Tgst
1. With the engine stopped, depress the brake pedal
several times to deplete the vacuum reservoir, then
depress the pedal hard and hold it for 15 seconds. ll
the pedal sinks, either the master cylinder is
bypassing internally; or the brake system (master
cylinder, lines, modulator proportioning valve, orcaliper) are leaking.
Start the engine with the pedal depressed. lf thepedal sinks slightly, the vacuum booster is operat-
ing normally. lf the pedal height does not vary, the
booster or check valve is faulty.
With the engine running, depress the brake pedal
lightly. Apply just enough pressure to hold back
automatic transmission creep, lf the brake pedal
sinks more than 25 mm (1.0 in.) in three minutes,
the master cylinder is faulty. A slight change inpedal height when the A,,/C compressor cycles on
and off is normal. (The A/C compressor load
changes the vacuum available to the booster.)
Leak Test
1. Depress the brake pedal with the engine running,
then stop the engine. lf the pedal height does not
vary while depressed for 30 seconds, the vacuum
booster is OK. lf the pedal rises, the booster is
fau lty.
2. With the engine stopped, depress the brake pedal
several times using normal pressure. When thepedal is first depressed, it should be low. On con-
secutive applications, the pedal height should grad-
ually rise. lf the pedal position does not vary, check
the booster check valve.
Boostor Ch€ck Valve T6st
1. Disconnect the brake booster vacuum hose at the
booster,
Start the engine and let it idle. There should be vac-
uum available. It no vacuum is available. the check
valve is not working properly. Replace the brake
booster vacuum hose and check valve, and retest.
VACUUM HOSE(Check valve built-in)
STAR LOCKNUT22 t{.m12.2 ksl.m, 16lbf.ftl
cLEVtS
ADJUSTER
ADJUSTMENT GAUGE07JAG - SD40t00
9. Adjust the pushrod length as shown if the booster
is removed.
1161 0.5 mm14.61 0.02 inl
PUSHRODLOCKNUT15 N m 11.5 kgf m, 11 lbf'ftl
10. Instali the master cylinder.
Inspection
rrii tlmm {0.4 inl10
l.
Rear Brake Disc
Disc Runout Inspection
Loosen the rear wheel nuts slightly, then raise the
vehicle and support it on safety stands. Remove the
rear wneers.
Remove the brake pads (see page 19-16).
Inspect the disc surface for damage or cracks. Clean
the disc thoroughly and remove all rust.
Use wheel nuts and suitable plain washers to hold
the disc securely against the hub, then mount a dial
indicator as shown, and measure the runout at 10
mm (0.4 in) in from the outer edge of the disc.
Brake Disc Runout:
Se.vice Limit: O.1O mm {0.0O4 in) max.
ll the disc is beyond the service limit, refinish the
brake disc.
Max. Refinishing Limit: 8.0 mm (0.32 in)
DIAL INDICATOR
NOTEi A new disc should be refinished if its runout
is greater than 0.'10 mm (O.O04 in).
Disc Thickness and Parallelism
Loosen the rear wheel lug nuts slightly, then raise
the vehicle and support it on safety stands. Remove
the rear wheels.
Remove the brake pads (see page 19-16).
Using a micrometer, measure disc thickness at
eight points, approximately 45" apart and 10 mm
(0.4 in) in from the outer edge of the disc. Replace
the brake disc if the smallest measurement is less
than the max. retinishing limit.
Bfake Disc Thickness:
Standard: 8.9 - 9.1 mm
(0.35-0.36 in)
Max. Refinishinq Limit:8.O mm (0.31 in)
NOTE: Replace the brake disc it the smaLlest mea-
surement is less than the max. retinishing limit.
Brake Disc Parallelism: O.O15 mm
(O.00O6 in) max.
NOTE: This is the maximum allowable difference be-
tween the thickness measurement.
lf the disc is bevond the service limit for parallelism,
refinish the brake disc.
NOTE: See section 18 for brake disc replacement.
\S rnrn .\'rn)
19-18
Brake Hoses/Lines
Inspection/Torque Specif icationsInspecuon/ | orque Dpecl carlon
1. Inspect the brake hoses for damage, deterioration, leaks, interference and twisting
2. Check the brake lines for damage, rusting and leakage. Also check tor bent brake lines.
3. Check ior leaks at hose and line joints and connections, and retighten if necessary.
4. Check the master cylinder and ABS modulator unit (if equipped) for damage and leakage.
CAUTION: Replace the braks hose clip whenever the brake hose is serviced.
15 N.m 11.511 tbl.f0
MASTER CYLINDER'Io'BBAKE UNE
15 N.m {1.5 kgt'm, 11 lbf ft}
BnAKE HOSE-Io-CALIPER
IMNJO BOLTI3a N'm 13.5 kgf.m. 25 lbl ft)
BLEED SCREWI N.m 10.9 ks{.m,6.5 lbf.ftl
ABS MODULATOR UNIT-Io-BRAKE LINE15 N.m (1.5 kg{.m, 11 lbtftl
BRAKE LINE-Io-BRAKE HOSE15 N'm lt.5 kgf.m, 11 lbf.ftl
BnAKE HOSE-Io-CALIPER
IBAruO BOLTI3il N.m (3.5 kgt m, 25 lbf.ft)ALEED SCREWI N'm 10.9 kgtm,6.5lbf.ftl
BRAKE LINE-Io-BRAKE HOSE15 N.m 11.5 kgfm, 11 lbf.ftl
BMKE LINE-Io-FCV
l
It
I
i
i
i
Doors
Outer Handle Replacement (cont'dlLatch Replacement
NOTEr Raise the glass fully.
'1. Remove:
a Door panel (see page 20 4)
a Plastic cover lsee page 20-4)
a Outer handle (see page 20 7)
2. Disconnect the inner handle rod and lock rod from
the latch.
Detach the inner handle rod and lock rod, then
remove the inner handle.
NOTE: Take care not to bend the rods.
>: Screw locations, 2
@t" ,
J
INNER HANDLEROD
INNER I{ANDLE
-1"'-
\
\LOCK ROD
)
INNER HANDLEROD
6.
8.
Disconnect the cylinder rod as shown.
NOTE: Take care not to damage the lock cylinder
joint.
OUTERHANDLECYLINDERROD
7.
V
SHOP TOWEL
Remove the cylinder switch lrom the outer handle.
: Scrsw location, 1
OUTERHANDLE
i4) cYLtNDERswtTcH
Pull out the retainer clip, then
cylinder and cylinder protector.
LOCK CYLINDER
li) clrPReplace
S*-.o"* .YLTNDER
CYLINDERPROTECTOR
RETAINERCLIP
Installation is the reverse of the removal procedure.
NOIE:
a Make sure the outer handle rod and connector are
connected securely.
a Make sure the wire harness is routed properly.
a Make sure the door locks and opens properly.
20-8
Doors
Outer HandleReplacement (cont'd)
irl
lii
,l
r
LatchReplacement
NOTE: Raise the glass fully.
1. Remove:
a Door panel (see page 20 20)
a Plastic cover (see page 20 20)
a Outer handle (see page 20'23)
2- Remove the screws and disconnect the connector,
then remove the inner handle and latch.
NOTEr Take care not to bend the rods.
> | Screw locations, 2
6bD l
:)CYLINDER ROO
>: Clip locaiions, 2
3.Installation is the reverse of the removal procedure.
NOTE: Make sure the inner handle rod, lock rod and
connector are connected properly.
6.
7.
v:
Disconnect the cylinder rod as shown.
NOTE: Take care not to damage the lock cylinder
Jornt.
OUTERHANDLE
SHOP TOWEL
Remove the cylindef switch from the outer handle.
Pull out the retainer clip, then remove the lock
cylinder and cylinder protector.
8.
L
g--.-.o"*
cYLTNDER
lnstallation is the reverse of the removal procedure.
NOTE:
a Make sure the outer handle rod and connector are
connected securely.
a Make sure the wire harness is routed properly.
a Make sure the door locks and opens properly.
LOCK CYLINOEB
Front Door:
1 1. Adjust clearance "H" as follows.
-1
" {see page 20-42}
Loosen the bolts and locknut securing the front
sash, and move the front sash all the way
forw ard.
NOTE: Hold the adjusting bolt with a hex
wrench when loosening the locknut.
-2 Loosen the nut securing the stopper plates.
-3 Loosen the bolts securing the glass, and move
the glass up or down to align it with the retain
STOPPER €-r7 -\---
PLATE lErt-:<'7--
LOCKNUT
4 Loosen the nuts and locknuts securing the glass
guide, and regulator. Adjust the glass lore and
aft by moving the glass guide and regulator.
NOTE: Hold rhe adjusting bolts with a hex
wrench when loosening the locknuts.
-5 Repeat steps -3 thru -4 until clearance "H"
is within the specified limits, then tasten the
glass guide and regulator.
Press the stopper plates against the glass stop-
pers, then fasten the stopper plates.
NOTE: Check that the stopper plates contact
the glass stoppers evenly.
- 6 Align the front sash with the glass, then lasten
the front sash.
(cont'd)
20-43