12. INSPECT BRAKE LINE PIPES AND HOSES
NOTE: Inspect in a well lighted area. Inspect the entire circumference and length of the brake hoses using a mirror as required. Turn the front wheels fully right or left before inspecting the front brake.
(a) Check all brake lines and hoses for:
e Damage e Corrosion e Wear e Leaks e Deformation e Bends
(b) Check all clamps for tightness and connections for leakage.
(c) Check that the hoses and lines are clear of sharp edges, moving parts and the exhaust system.
(d) Check that the lines installed in grommets, pass through the center of the grommets.
13. INSPECT FRONT AND REAR BRAKE PADS AND DISCS
(a) Check the thickness of the disc brake pads and check for irregular wear.
Minimum pad thickness: 3.0 mm (0.118 in.) NOTE: If a squealing or scraping noise occurs from the front or rear brakes during driving, check the pad wear indicator. If there are traces of the indicator contacting the disc rotor, the disc pad should be replaced.
(b) Check the disc for wear or runout.
Minimum disc thickness:
Maximum disc runout: 0.15 mm (0.0059 in.)
14. INSPECT PARKING BRAKE LININGS AND DRUMS (Sae page BR-26)
(a) Check the lining-to-drums contact condition and lining wear.
Minimum lining thickness: 1.0 mm <0.039 in.)
(b) Check the brake drums for scoring or wear. Maximum drum inside diameter: 168 mm (6.61 in.)
(c) Clean the brake parts with a damp cloth.
NOTE: Do not use compressed air to clean the brake parts.
(d) Bed down the parking brake shoes and drum. When performing the road test in item 24, do the following:
• Drive the vehicle at about 30 mph (50 km/h) on a safe, level and dry road.
• With the parking brake release button pushed in, pull on the lever with 20 lb (9 kg, 88 N) of force.
• Drive the vehicle for about 1/4 mile (400 meters) in this condition.
• Repeat this procedure 2 or 3 times.
• Check parking brake lever travel.
If necessary, adjust the parking brake.
Maximum 30 mm
Maximum 30 mm
15. INSPECT STEERING LINKAGE
(a) Check that the steering wheel freeplay.
Maximum steering wheel freeplay: 30 mm (1.18 in.)
With the vehicle stopped and pointed straight ahead, rock the steering wheel gently back and forth with light finger pressure.
(b) Check the steering linkage for looseness and damage. Check that:
• Tie rod ends so not have excessive play.
• Dust seals and boots are not damaged, a Boot clamps are not loose.
16. INSPECT STEERING GEAR HOUSING
Check the steering gear housing for oil leakage.
17. INSPECT BALL JOINTS AND DUST COVERS
(a) Inspect the ball joints for excessive looseness.
• Jack up the front of the vehicle and place wooden blocks with a height of 180 - 200 mm (7.09 -7.87 in.) under the front tires.
• Lower the jack until there is about half a load on the front coil springs. Place stands under the vehicle for safety.
• Make sure the front wheels are in a straightforward position, and block them with chocks.
• Using a lever, pry up the end of the lower arm, and check the amount of play.
Maximum ball joint vertical play: 23 mm (0.098 in.)
If excessive play is found, replace the ball joints.
(b) I nspect the dust cover for damage.
18. CHECK AUTOMATIC TRANSMISSION OR MANUAL TRANSMISSION AND DIFFERENTIAL OIL
Visually check the automatic transmission or manual transmission and differential for oil leakage.
If leakage is found, check for cause and repair.
19. REPLACE MANUAL TRANSMISSION AND DIFFERENTIAL OIL
(a) Remove the drain plug and drain the oil.
(b) Reinstall the drain plug.
(c) Add new oil until it begins to run out of the filler hole.
Transmission oil —
Oil grade: API GL-4 or GL-5 Viscosity: SAE 75W-90 or 80W-90 Capacity: 2.4 liters (2.5 US qts, 2.1 Imp. qts)
Differential oil —
Oil grade: API GL-5 hypoid gear oil or for LSD oil
OK if hot
OK if cool
OK if hot
OK if cool
Add .f cool
20. REPLACE AUTOMATIC TRANSMISSION FLUID
(a) Remove the drain plug and drain the fluid.
(b) Reinstall the drain plug securely.
(c) With the engine OFF, add new fluid through the dipstick tube.
Fluid: ATF DEXRON® U Drain and refill capacity:
Dry fill capacity:
(d) Start the engine and shift the selector into all positions from "P" through "L", and then shift into "P".
(e) With the engine idling, check the fluid level.
Add fluid up to the "COOL" level on the dipstick.
CAUTION: Do not overfill.
Add .f cool
21. REPACK FRONT AND REAR (IRS ONLY) WHEEL BEARINGS
(a) Change the front wheel bearing grease. (See pages FA-6 to 9)
Grease grade: Multipurpose grease (NLGI No. 2) •
Front wheel bearing friction preload (while turning): 0 - 1,050 g (0 - 2.3 lb, 0 - 10 N) In addition to oil seal fractional force
SEE PAGES RA-5 to 11
(b) IRS Type Rear Axle
Change the rear wheel bearing grease. (Seepages RA-5 toll)
22. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY
Tighten the following parts:
• Front seat mountings bolts
e Front suspension member-to-body mounting bolts and nuts
• Rear suspension member-to-body mounting bolts and nuts
• Strut bar bracket-to-body mounting bolts Torque: 425 kg-cm (31 ft-lb, 42 N m)
23. FINAL INSPECTION
(a) Check the operation of the body parts:
Auxiliary catch operates properly Hood locks securely when closed
• Front doors * Door locks operate properly Doors close properly
Door lock operates properly
Seat adjusts easily and locks securely at any position
Front seat back locks securely at any position Folding-down rear seat backs lock securely
• Check the engine and chassis for abnormal noises.
• Check that the vehicle does not wander or pull to one side
• Check that the brakes work properly and do not drag.
• Perform bedding down of the parking brake shoes and drum. (See page MA-8)
(c) Be sure to deliver a clean car and especially check:
e Steering wheel
• Shift lever knob
• All switch knobs
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