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Changing Transfer Oil
Oil capacity:2.3 liters (2 Imp qt)
When changing transfer oil completely, either ªDEXRON
TMº type
Automatic Transmission Fluid or gear oil (API GL-4) may be used.
Do not mix Automatic Transmission Fluid and gear oil.
Checking Propeller Shaft
Check propeller shaft for damage, looseness or grease leakage.
Checking Differential Gear Oil
1. Check differential for oil leakage.
2. Check oil level.
YMA019
SMA566
SMA118A
SMA440B
SMA417
CHASSIS AND BODY MAINTENANCE
MA-38
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Page 90 of 1833

Chassis and Body Maintenance
INSPECTION AND ADJUSTMENT
Clutch
Unit: mm (in)
Vehicle modelAll
Pedal free height RHD
210 - 220
(8.27 - 8.66) LHD
227 - 237
(8.94 - 9.33)
Pedal free play 1.0 - 3.0 (0.039 - 0.118)
Pedal free travel 155 - 160 (6.10 - 6.30)
Front axle and front suspension
(Unladen)*1
Unit: degree
Model H/T VAN H/T WAGON
Camber 0É30¢ 30¢
Caster 0É29¢ 30¢ 0É30¢ 30¢ 0É30¢ 30¢
Kingpin inclination 12É37¢
Toe-in
A-B mm (in) 3.5 - 5.5
(0.14 - 0.22) 3-5
(0.12 - 0.20) 3-5
(0.12 - 0.20)
Front wheel turning
angle (degrees) (Full turn)*2
Inside 34É27¢
Outside 33É38¢
*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
*2: Wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 lb) with engine idle.
Brake
Disc brake mm (in)
LD28VA
PadStandard thickness 15.5 (0.610)
Minimum thickness 2.0 (0.079)
Rotor Standard thickness 2.60 (0.1024)
Minimum thickness 24.0 (0.945)
Drum brake mm (in)
LT28 LiningStandard thicknessLeading 8.95 (0.3524)
Trailing 3.95 (0.1555)
Minimum thickness 1.52 (0.0598)
Drum Standard diameter 280 (11.02)
Maximum diameter 282 (11.10)
Pedal mm (in) RHD LHD
Free height 196 - 206
(7.7 - 8.1) 210 - 220
(8.3 - 8.7)
Free play 1.0 - 3.0 (0.039 - 0.118)
Full stroke 137.7 - 148.7
(5.42 - 5.85) 142.5 - 152.5
(5.61 - 6.00)
Parking brake Number of notches [at pulling
force 196 N (20 kg, 44 lb)] 9-10
Wheel runout
Unit: mm (in)
Wheel typeSteel Aluminum
16² x7J 16 ²x7J
Radial runout limit 0.5 (0.020) 0.3 (0.012)
Lateral runout limit 0.8 (0.031) 0.3 (0.012)
Wheel bearing
Axial end play limit mm (in) 0
SERVICE AND SPECIFICATIONS (SDS)
MA-49
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Page 100 of 1833

NVH Troubleshooting Chart Ð Engine Noise
Use the chart below to help you find the cause of the symptom.
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
Location ofnoise Type of
noise Operating condition of engine
Source of
noise Check item Reference
page
Before
warm-up After
warm-up When
starting When
idling When
racing While
driving
To p o f
engine
Rocker
cover
Cylinder
head Ticking or
clicking
C AÐA BÐ Tappet
noiseValve clearance MA section
(ªAdjusting
Intake &
Exhaust
Valve
Clearanceº,
ªENGINE
MAINTE-
NANCEº)
Rattle C A Ð A B C Camshaft
bearing
noiseCamshaft bushing clearance
Camshaft runout
EM-31, 31
Crankshaft
pulley
Cylinder
block (Side
of engine)
Oil pan Slap or
knock
ÐAÐB BÐ Piston pin
noisePiston and piston pin clear-
ance
Connecting rod bushing
clearance
EM-71, 73
Slap or rap A Ð Ð B B A Piston slap
noisePiston-to-bore clearance
Piston ring side clearance
Piston ring end gap
Connecting rod bend and
torsion EM-75, 72,
72, 73
Knock A B C B B B Connecting
rod bearing
noiseConnecting rod bushing
clearance (Small end)
Connecting rod bearing
clearance (Big end)
EM-73, 77
Knock A B Ð A B C Main bear-
ing noiseMain bearing oil clearance
Crankshaft runout
EM-78, 76
Front of
engine
Timing gear
cover Tapping or
ticking
AAÐBBB Timing gear
noiseTiming gear backlash EM-41
Front of
engine Squeaking
or fizzing
A BÐBÐC Other drive
belts (Stick-
ing or slip-
ping)Drive belts deflection
MA section
(ªChecking
Drive Beltsº,
ªENGINE
MAINTE-
NANCEº)
Creaking
ABABAB Other drive
belts (Slip-
ping)Idler pulley bearing operation
Squall
Creak ABÐBAB Water pump
bearing
noiseWater pump bearing opera-
tion LC section
(ªWater
Pump
Inspectionº,
ªENGINE
COOLING
SYSTEMº)
A: Closely related B: Related C: Sometimes related Ð: Not related
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGZD
EM-9
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Page 231 of 1833
2. Install pistons with connecting rods.
(1) Install them into corresponding cylinder using Tool.
IBe careful not to scratch cylinder wall with connecting rod.
I Apply engine oil to cylinder wall, piston and bearing.
I The leaf type combustion chamber on piston head must be
facing toward the fuel pump side.
(2) Install connecting rod bearing caps.
3. Measure connecting rod side clearance. Connecting rod side clearance:Standard0.10 - 0.32 mm (0.0039 - 0.0126 in)
Limit 0.32 mm (0.0126 in)
If beyond the limit, replace connecting rod and/or crankshaft.
4. Install oil strainer and oil pan.
5. Install all removed parts.
GEAR TRAIN
1. Set No. 1 piston at its Top Dead Center.
2. Align each gear mark and install gears.
EEM108
SEM678B
SEM488
NEM177
ENGINE OVERHAULTD27Ti
Assembly (Cont'd)
EM-140
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Page 249 of 1833
OIL FILTER
The oil filter is an element type. Refer to ªChanging Oil Filterº in MA
section.
Oil Cooler
REMOVAL AND INSTALLATION
1. Drain engine oil and coolant.Remove catalyst and turbocharger. Refer to ªCATALYST AND
TURBOCHARGERº in EM section.
2. Remove bolts A to C then remove oil cooler assembly.
I Do not remove ªDº nuts when removing oil cooler assem-
bly.
Bolt length: A: 20 mm (0.79 in)
B: 45 mm (1.77 in)
C: 65 mm (2.56 in)
3. Installation is in reverse order of removal.
I Do not spill coolant on the drive belt.
INSPECTION
1. Check oil cooler for cracks.
2. Check oil cooler for clogging by blowing through coolant inlet.
If necessary, replace oil cooler assembly.
YLC030
JLC381B
ENGINE LUBRICATION SYSTEMZD
Oil Jet (Cont'd)
LC-8
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Page 811 of 1833
General Specifications
EngineTD27Ti and ZD30DDTi
Transmission model FS5R30A
No. of speeds 5
Shift pattern
Synchromesh type Warner
Gear ratio 1st 3.580
2nd 2.077
3rd 1.360
4th 1.000
OD 0.811
Reverse 3.631
No. of teeth Mainshaftdrive
1st 32
2nd 30
3rd 29
4th 22
OD 24
Reverse 30
Countershaft Drive
1st 13
2nd 21
3rd 31
4th 32
OD 43
Reverse 12
Reverse idler gear 22
Oil capacity (lmp pt) 3.6 (6-3/8)
SERVICE DATA AND SPECIFICATIONS (SDS)
MT-34
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Page 1150 of 1833

Inspection and Adjustment
WHEEL ALIGNMENT (Unladen *1)
Applied modelHardtop
(short wheel- base) Wagon
(long wheel- base)
Camber degree 0É30¢ 30¢0É29¢ 30¢
Caster degree 1É53¢ 30¢1É58¢ 30¢
Kingpin inclination degree 12É39¢
Total toe-in
Radial tire mm (in)3.15 - 5.15
(0.1240 -0.2028) 2.72 - 4.72
(0.1071 -0.1858)
Front wheel turning angle Full turninside 34É24¢34É22¢
outside 33É35¢33É33¢
Vehicle posture Lower arm pivot
height (H) mm (in)33
(1.30) 31
(1.22)
NFA021
*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
WHEEL BEARING
Axial end play limit mm (in)0 (0)
Lock nut Tightening torque N×m (kg-m, ft-lb) 78-98(8-10,58-72)
Retightening torque N×m (kg-m, ft-lb) 0.5 - 1.5
(0.05 - 0.15, 0.4 -1.1)
Turning resistance at wheel
hub bolt A
Tightening angle degree 15É - 30É
Turning resistance at wheel
hub bolt B
PreloadC=BþA N(kg, lb) 7.06 - 20.99
(0.72 - 2.14, 1.59 - 4.72)
DRIVE SHAFT INSTALLATION
Axial end play mm (in)
At wheel hub 0.1 - 0.3 (0.004 -0.012)
Available drive shaft end snap rings
Thickness mm (in) Part number 1.1 (0.043) 39253-31G10 39253-88G10
1.3 (0.051) 39253-31G11 39253-88G11
1.5 (0.059) 39253-31G12 39253-88G12
1.7 (0.067) 39253-31G13 39253-88G13
1.9 (0.075) 39253-31G14 39253-88G14
2.1 (0.083) 39253-31G15 39253-88G15
2.3 (0.091) 39253-31G16 39253-88G16
UPPER BALL JOINT
Swinging force at cotter pin hole N (kg, lb)31.87 - 199.38
(3.25 - 20.33, 7.17 - 44.83)
Rotating torque N×m (kg-cm, in-lb) 1.0 - 4.9 (10 - 50, 8.7 - 43.4)
Axial endplay limit mm (in) 1.6 (0.063)
LOWER BALL JOINT
Swinging force at cotter pin hole
N (kg, lb)0 - 67.7 (0 - 6.9, 0 - 15.2)
Rotating torque N×m (kg-cm, in-lb) 0 - 4.9 (0 - 50, 0 - 43)
Axial end play limit mm (in) 0.5 (0.020)
WHEEL RUNOUT
Wheel type Steel
(15² )
Radial runout limit mm (in) 0.5 (0.02)
Lateral runout limit mm (in) 0.8 (0.031)
SERVICE DATA AND SPECIFICATIONS (SDS)
FA-39
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Page 1167 of 1833
General Specifications
COIL SPRING AND SHOCK ABSORBER
ModelHardtopWagon
Coil spring Wire diameter mm (in) 13.0 (0.512) 13.5 (0.531)
Free length mm (in) 400 (15.75) 417 (16.42)
Spring constant N/mm (kg/mm, lb/in) 25.5 (2.6, 146) 29 (3.0, 168)
Shock absorber Shock absorber type Non-adjustable (hydraulic)
Maximum length mm (in) 586 (23.07) 596 (23.46)
Minimum length mm (in) 350 (13.78) 356 (14.02)
Damping force
[at 0.3 m (1.0 ft)/sec.] N (kg, lb)
Expansion 990 - 1,330
(101 - 136, 223 - 229) 1,169 - 1,563
(119 - 159,223 - 351)
Compression 346 - 524
(35.3 - 53.4,
77.8 - 117.8) 301 - 461
(30.7 - 47.0,
67.7 - 103.6)
RA260
STABILIZER BAR
Model HardtopWagon
Diameter mm (in) 23 (0.91) 24 (0.94)
Spring constant N/mm (kg/mm, lb/in) 24.5 (2.5, 140) 29.0 (3.0, 166)
Inspection and Adjustment
WHEEL BEARING
Total end play mm (in)
0 (0)
SERVICE DATA AND SPECIFICATIONS (SDS)
RA-16
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