Toyota Celica Supra 1986 Installation and operating manual

Toyota Service and Repair Manual
1986 Celica Supra
Internal PDF links edited by MK2_Suprafan
© Toyota Motor Company
********NOT FOR SALE********

TABLE OF CONTENTS
SECTION PAGE
Introduction……………………..…………………………...……………… IN
Maintenance…………………………………………………..…………….. MA
Engine Mechanical…………………………………………………..……. EM
Emissions Control System…………………………...…………………. EC
EFI System……………………………………………………………………. FI
Cooling System………………………………………………..…………… CO
Lubrication System…………………………………………..…………… LU
Ignition System……………………………………………………………… IG
Starting System…………………………………………………………….. ST
Charging System…………………………………………………………… CH
Clutch………………………………………………………………..………... CL
Manual Transmission……………………………………………..……... MT
Automatic Transmission……………………………………..…………. AT
Front Axle and Suspension..…………………………………..………. FA
Rear Axle and Suspension..……………………………..…………….. RA
Brake System……………………………………………………..………… BR
Steering System…………………………………………………..……….. SR
Body Electrical System…………………………………………..……… BE
Body………………………………………………………………..…………… BO
Air Conditioning System……………………………..………………….. AC
Propeller Shaft System............................................................ PR
Appendix
Section Page
Service Specifications…………………………………………………….. A
Standard Bolt Torque Specifications………………………………… B
SST and SSM………………………………………………………………….. C
Automatic Transmission Hydraulic Circuit………………………… D
Electrical Wiring Diagrams………………………………………………. E

INTRODUCTION
p ...
HOW TO US E THIS MANUAL .............. .. ........... IN -2
ID ENTIFICATION IN FOR MA TION ............ .. ... ..... IN-4
GENERAL REPAIR INS TRUCTIONS .................. IN-4
PR ECAUTIONS FOR VE HICLES EOU IP PED W ITH
A CATALYTIC CO NVERTER ........ . ... ............. IN -7
VEHICLE LIFT
AND SUPPORT L OCA TIONS .... .. IN-8
ABBREVIATIONS
USED IN THIS MANUAL ........ IN-9
I
-
IN -1

IN·2 INTRODUCTION -How to Use This Manual
HOW TO USE THIS MANUAL
To assist in finding your way through the manual. the Section
Tit le and major heading are given at the top of every page.
An INDEX is provided on the first page of each section to guide
you
to the item to be repaired.
At the beginning of each section. PRECAUTIONS are given that
pertain to all repair operations contained in that section. Re¥1
theseprec/Wtions b8fors swting any rii{Jair task.
;TROUB LE SHOOTING tables are included for each system to
help you diagnooe the system problem and find the cause. The
repair for each possible cause is referenced in the remedy
column
to quickly lead you to the solution.
REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It
identifies the componentsand shows how the partsfit together.
Example:
AOI)USM!I Washer
Tt'lrust Washe r No. 1- - --'
Thrust Washtt No. 2 __ _ _..-
(j)-si<lo Sur i ng
*l...,"'· .. ,I e.,
Case eo ... , ·---- -'
'
'
~- ---- Ph,ion G..,
r--- Ciulc,Member RH
r- -- C: Iul•chMember LH
JCiutd't Member
1Thrutt Wash er
Th tust Whh er No. 2
~ ---- -+• Lock Plet•
( kg-em Ch ·lb. N· m•) : Specif*t<l torque
• NoMtuiablt ~tt
.. s (71. 11)
* Preeo.ttd pan
·-
•

INTRODU CTION - How 10 Use This Manual IN-3
Photograph or Illustration :
what to do andwhere
The procedures are presented in a step-by-step fo rmat:
• The photo or illustration shows what to do and where to do
it.
• The task heading tells what to do.
• The deta il ed text tells how to per form the task and gives
other informa tion such as spec i fications and warnings.
Example: / TIISk huding: what ro do
21. CHECK PISTON STROK E OF OVERDRIVE BRAKE
(a) Place SST and a dial in dicator onto the overdrive
broke piston as shown in the li!j ure.
SST 09,-30020 (09350~ 20)
Set p.rt No. ComponentP6ft No.
/ DstJJil text : how to do it
(b) Measure the stroke app l ying and re leasing the oom-
pressed
air (4- 8 k!j/cm' , 57 -114 psi or 392 -785
kPa) as shown in the figure.
Piston stroke: 1.40- 1.70 mm (0.0551 - 0.0669 in.)
-- Specifiedtlon
This format provides the exper i enced technician wi th a FAST
TRACK to the information needed. The upper case task head·
ing can be read at a glance and only when necessary, t he text
below it provides detailed i nformation. Important specifica·
tions end wamingsalways stand out in bo ld type.
REFERENCES
References have been kept to a minimum. However. when they
are required you are given the page to go to.
SPECIFICATIONS
Specifications are presented in bo ld type throughout the text
in the applicable step. You never have to leave the procedure
to look up your specs. All specifications are also fo und in
Appendex A, specifications, for quick reference.
WARNINGS , CAUTIONS, NOTES:
• WARNINGS are presen ted in bo ld type, and indicate there Is
a possibility of injury to you or other people.
• CAUTIONS are al so presented in bold type, and indica~ I
the possibility of damage 10 the components baing repaired.
• NOTES are separated from the te xt but do not appear in J
bold. They p ro vide addit ional informati on to help you
efficiently perform the repair .
1

I N-4 INTROD UC TI ON - ldentillcacion Informacion. General Repair lnslructions
IDENTIFICATION INFORMATION
VEHICLE I DENTIFI C AnON NUMBER
The whicle idencilicalion number is sumptd on the cow1 panel
of che engine compartmenl. This number is also sumped on cop
of the innrument panel ond th<l dri__.s door po$1.
ENGINE SERIAL NUMBER
The engine serial number is stamped on the right side of the
cylinder block.
GENERAL REPAIR INSTRUCTIONS
1. Use lender seal and floor covers to k eep tho vttlicle elton
and ptevenl dama91 .
2. During disouembly, keep parts in order to laciliute rt ·
assembly.
3. Obstrw che following:
(al Before perform
ing electrical work. dlsconnocc che
negative from the beuery terminal.
(b) If il is necessary to disconnect the battery for inspec.
tion or rep1ir, 1lway5 disconnect the cable from the
negative 1-1 terminol which is grounded to lhe
whic le body .
(c) To p.-nc damage to the bottery le<mi r\11 pon,
loosen the terminal nut and raise th e ~ l e straighl
up without tw isting It or prying it.
(d) Clean lhe bolterv termir\11 pons and cable ttfm ir\lls
with a shop rag. Do not ocrape lhem with a file or
other adrasive object.
(e) In st a ll t he cable terminal to the battery post with
the nut loose, and tighten the nut after installation.
Do not use a hammer to up the terminal onto the
pon.
(f) Be sure lhe cove< .10. lho positive (+) le<mi r\11 is
properly in place.
4. Check hose and wiring conn«tors to make sure th<lt they
are secu,.. and c.Otrec:t .

IN-6
WRONG
..
•
INTRODUCTION - G-ral Repair Instructions
CORRECT
-·
12. Obserw the following precauti ons to .vo id damage to the
parts:
(a) To disconnect vacuum hooes, pull on tht end, not the
middle of the hose .
(b) To pull opart elec:tricol connectors, pull on the con ·
nector itwlf.notthewi res.
(c) Be coreful not to drop elec:trieal components . such as
tentars or relays. If they are dropped on 1 herd floor,
they should be reploced ond not roused.
(d) When neam cleaning an engine, protect the diS ·
tributor. coil. air filter. e~rbu retor intake, air pump
and vcv from water.
(e) Never
uw an i mpact wrench to remove or innall
thermoswitches
or thermo sensors.
(f) When checking cont inuity at the wire connect or ,
insert
the tester probe corefully to prevent terminals
from bending.
(g) When using a vacuum fi'U90. never force the hose
onto a connector that is too large. U• 1 st~down
adapter i nste.d. Once the hose has been stretched, it
may l uk .
13. Tag hosts beforedisconnecting them :
(a) When disconnecting vacuum hoses. use tags
to identi·
fy how they should be reconnected.
(b) After completing a job, double check that the
\laCUUm hoses are propa<ly connected. A label under
the hood shows the proper l ayout .
/

IN -8
.. Front
•
IN TRODUCTION - Vth icle Lift and Support Locations
VEHICLE LIFT AND SUPPORT LOCATIONS
·- - ~
0
Se•m Notches
Se-am No tches
JACK POSITION ®
Front ·············· ·· ····· Center of crossmember
Rear ....................... Center of rear axle housing
PANTOGRAPH JACK POSITION - -
--
0
SUPPORT POSITION
Safety stand ......................... .. .................... ~

INTROOUCT IO N - Abbrevi ations Used in This Mlnuo l IN
-9
ABBREVIATIONS USED IN THIS MANUAL
•
A/C
ALA
AlT . ATM
ATF
8,
8,
B,
B,
BDC
BT DC
BVSV
c,
c,
fu8
DOHC
DP
DVV
ECT
ECU
EFI
EGA
ELR
EPA
ESA
ETA
EVAP
EX
Ex.
FL
Fo
IG
IN
IRS
ISC
LH
LHD
LSD
MP
M IT . MTM
OD
OPT
0/S
PCV
PS
RH
RL
RR
SED
SSM
SST
STD
S/W
T/C
TCCS
TOC
TWC
UIS
VSV
w/
w/o
AirConditioner
Automat ic Locl< l ng Retractor
Automatic TtaflJmiss i on
Automati c: Tr ansmiss ion Fl uid
OYOrdriYO Broke
No. 1 Brake
No.2 Brake
No.3 Brake
Bottom Dead Center
Be fore Top Dead Center
Birnatal Vacuum Switchi ng Val110
Overdri YO Direct Clutch
Front Clutch
Rear Cl utch
Circuit 8reak tr
Double Ovt< Hood Com
Dash Pot
Doub le Vacuum Vel \10
Electronic Contro iJed Transmission
Electronic Controlled Unit
Electronic Fuel Injection
Exhaust Gas Recirculation
Emergency Locking Ret rac tor
Evaporator Pressure Regulator
Electron ic Spark Advance
E lectronic Tuning Radio
Evaporat illl (Emission Control)
Exhaus t (man ifold, valve)
Ex cept
Front Left
F ront Right
Igniti on
Inta ke (man ifold, valve)
I
ndependent Raar Suspension
Idle Speed Control
Left- han d
Left- han d Drive
LimitedS li p Differential
Multipurpo ~
Manual Trtn smission
Overdrive
Option
Owrsize
Positive Ctankcase Ventilation
Power Steer i ng
Right ·h and
Rear Loft
Rear Ri ght
Sedan
Spec ial Service Materials
Spec ial Service Tools
Standard
Swit ch
Torque Conwntr
Toyoto Computer Controlled System
Top DN<f cantor
Three-Way catal yst
Und<mize
Vacuum Switch ing Va l ve
With
With out

•
MAINTENANCE
.....
M AI NTENANCE SCHE DULE . . • •. • . • • • • • • • • . • • MA ·2
MAIN TENANCEOPERATIONS • • • . . . . . . . • • • • •• MA-4
GE NE RA L MAINTENANCE ...... • .. .... . .. .. • MA ·12
GE NE RAL NOTES:
• Every se<Vice it em in me pe riodic m airm na nce list must be
performed.
• F1llure
to do ew n one item Cln ClUte the engine to Nn poor1y
•net incr ease ex haust emissions.
•

MA ·2
MAINT ENAN CE - Ma intenance Sc:hedule
MAINTENANCESCHEDULE
M:t in~ operations : A • ~ lt'IIJJ~ ad j ust i ll"'eCC!SSI'Y ;
R • RtCJIIOt. change or lubricate;
I • Inspect .wl correct or replece if necetJtry
NO RMAL CONDITION SCHEDULE
1\Service Interval
M1 lntenanoe services beyond 60,000 milts
(Odometer reading or months.
(08,000 km) should be performed tt the stmt
whlch.ver COf1'let rittt)
l nttr\llls st'lown In ead'l m.a ln tentnCI K:htdult.
See page
S';'Sttm M iltt )( 1.000 10
20 30
40
60
60 litem No.)
Mainttnanc::e ittms \ Km x 1,000 16 32 48 64
80 96
Months 12 24 36 48 60 72
ENGINE
OtM bttlJ UI I I r.tA-4 (i -2)
E nglnt otl and oil fitter• R R R R R R r.tA.S (itorn 61
E"9 ine eooltnt'»
R MA-6 lit em 71
Exh.wst pipes and mount ings 1 I MA-6 li- 1 11 _
--
FUEL Air filter• R R
MA ·S (i tem 41
F ue I II ne 1 nd connections I I MA-6 (i tem 101
Fue l fllt.er cap gls k et R MA -8 Utom 91
IGNITION Spark plugs (Pl atinum tipped) R MA ·6 (item 31
EVAP Charcoal canister I
MA-6 litem 81
BRAKES Brtkt Ii ning and drums I
I ~ I I
MA-6 (o ttm 14 1
Bub pads and di5CS (Front and,.., ) I I I MA -7 b tem 131
S... th li nt pi pes and hoM$ I I I MA ·7 (itom 121
CHASSIS Stetringlinkage I I I MA-6
lltt m 1 51
-
Boll jo l ntJ •nd du>t covtrs
I I I MA -9 (item 171
Automlt ic transmission, manuel trlnlm iu i on,
I I 1
MA ·9 (ittm 181
dl tf erentlal (eiC . LSO)end stetrint our housint oilt' l MA ·8 (hom 181
Li mited slip diffe r ent l ei (LSD I oil <•• I R I MA ·9 (item 191
Front and rear (IRSonly) wh eel bHrlngs grtaM(41 A MA · 10 (item 211
Botta and nuu on chlssls and body I I I
MA ·11 (item 221
Ml i nttn~t~« MN ices indi otil1ed by a stir t•• is reQui red un<ttr the terms of tht Emission Control SVstenu Wentnty . SN
Owner"s Gu l dt f or com ptftt wlll"'nty i nlotTN ti on .
NOTE:
(1) After IIO , OOOmiles (96,000 kml 0< 72montho. ; _, t<ery 10,000 mi lts (16,000 ltm ) or 12 month•
12 1 Afttr eo.ooo mi lts (96,000 k ml Of 72 months. repltce every 30 .000 milos ( 48 . 000 icml or 38 months.
(3) Inspect 1M fleering 9' *" housi ng for on ltlk'9t on l· y.
(4• Chllt!QIevery .CO , OOO miles (64.000 km ) or 48 months.

MAINTENANCE - Maintenan ce Schedu le
MA ·3
Fonowt ht MWrt conditi on sch e du le- if vehicle Is ope_rated m~ i nty under one or m ore of t he f ollo wing severe oond itions:
• Towing a tr ail ..-, uti "9a eamper or~ topQn it r.
•
Opttu ing on d un y, r ~. muddy or Silt tPtUd roads.
• RtPMt lhort tl i 9' leu than 5 mi'" (8 km) a nd cwtside ttmpe-ra w:r es r e~ i n below frwting..
• Extt n dve Idling weh as police, tu i or doo No-door Otliwfy uw..
SEVERE CO NDITION SCHEDULE
vrvi<t interval Imiles
Odometer reading
or months,
(96 , 000 km) should be performed It tht t~me
whichever corre first) In each
m1lnttntnce tchedule. s..-
System M
ll11 • 1. 000 5
~ ~
(item No .)
Ma in t-- n c:. items \ _Km X 1,000 8
6 ~
~
1bolt MA-4 (l" m 1)
I I
MA-4 fi-2 1
Ioil and oil IR R R R R R R R IR R R R
MA ·5 O t"" ~
R MA.S (
l"m _ 7)
t J> i pound I I ' I MA-6 (i- 11)
FUEl
. :~ ;N ne M~d oc>nnte t io ns
I • ' I I ' I R ' ' I I• I R MA-5 (l" m 4
o;e;J
I I MA-6 (item 10)
Fuet fille r R
MA.S(itcm ~
~
S 1>0rk 1)1 "91 R MA ·5 (i-3)
0\lre»aa canilttr I MA-6 litem 8)
Bt-t kt end drums ' ' ' I' I' II MA-8 (itom 14)
8r1h padland cr""'
lr Mt ) I ' II I I It II MA- 7 (i - 131
koh lint plpos--
• I
i1 II
MA .7
;; ...,.. 12
CHASSIS I ' ' ' It I MA-8 :i tom 16
llolllolnu and dust...,.,. I ' ' I I' '
MA -9 (i tem 11)
Automatic trtnsmiuion. manual transmission, MA·9 (i
tem 19)
di tftuntlal a nd tt t tr ing gn r housing oilI I) R R R
:: :~~ i ~~~ml~ )
' Front and rcor (IRS only ) w11 eol
IR MA-10 litem 211
I 8olu a nd nuts on ' 'I I II II
II II MA·11 (item
22)
Me inttnlnCI Mf"Y I CU ind.ieated by a star (* ) it: required under the ttmu of N Em l•tilon Control Systems Warran tY. SN
Owntr"s Guide fOt comple~ wanantv infOfml ti on.
NOTE:
(1I For the vthiclts frequently id l td fo r ext.mive .,.;oc,, and/or dri'l'tn for lono dintnet at klw speeds such as t«i . pol fce
and doot ·to-door dtl rv erv. it is recommended to ch .,ge at 60 . 000 mi les cee . ooo kml .
(2) After 1!0.000 miles ( 98 , 000 km ) or 12 montl>s. lns;>Kt ovory 10.000 milet 118 , 000 k m) or 12 months.
(3) Aftl r 60.000 milt s ( 96 , 000 km l Of 72 months, ,-.piece eve ry 30.000 mUn (48,000 km ) or 36 month$.
{4) Applicable wh en operatingm ai nly oo ctus cv rolds. II not. follow the normal condhlon schedule.
(5) Inspect tM •t.etring gur housing for oilltlk.tof ontv.
(6) Change tv try 40 . 000 miles ( 64 , 000 km) or •a montht .
(1} Ar>Pi i tibtt whtn Ol)tflti nt mainly on rough tf'ld/ Or Mu ddy ro.ds.. If not . fo ll ow the new-ma l collCf ition JC:htdule.

MA ·4 MAINTENANCE -Maintenance Operations
Nippondemo Borroughs
UOOOJ t(l(IOI;)ol laiOOI
CORRECT WRONG WRONG
CORRECT WRONG
-
MAINTENANCE OPERATIONS
ENGINE
Cold EI'!Jine Operations
1. REPLACE TIMING BELT
(a) Remove the timing belt.
(See pages EM ·1 1 to 13)
(b) Install the timing belt.
(See pages EM·15 to 17)
2. INSPECT V·RIBBED TYPE DRIVE BELT
(ALTERNATOR) AND CONVENTIONAL TYPE
DRIVE BELTS (PS PUMP AND A/C COMPRESSOR)
(a) Visually chock the bolt for separation of the adhesive
rubber above and below the core, core separat ion
from the belt side, S<!Vered core, separation of the rib
from the adhesive rubbe<, cracking
or separation of
the ribs , torn or worn ribs or cracks in the inner
ridges of the ri bs. Conventional typo only: Check
that the belt does not touch the bottom of the pulley
groove.
If necessary, replace thodrive belt.
(b) Using a belt tensi on gauge, check the drive belt
tension.
Belt tension gauge:
Nippondenso BTG·20 (95506.000201 or
Borroughs No. BT·33·73F
Drive belt temion:
V·ribbed type
Conventional type
Used bolt 135 • 20 lb
New belt 170 • 10 lb
Used bolt
80 t 20 lb
New bolt 125 t 261b
If necessary, adjust the drive belttension.
NOTE:
• "New belt" refers to a belt which has been used less
than 5 minutes on a running engine.
o "Used belt" refart to a belt which has been used on a
running engine for 5 minutes or more.
• After replacing the drive be l t, check that it fits properly
in the ribbed grooves, especially in the places difficult
to see.
o After installing a new belt, run the engine for about 5
minutes and then recheck the tension.

MAINTENANCE - Ma intenance Qp..-.tions MA-fi
-·
-·
3. REPLACE SPARK PLUGS (PLATINUM TIPPED)
(a) Dloconnect the sparl< plug wi re. at tht boot.
DO NOT pull on th e wires.
(b) Remove the spark plugs.
(c) Check the !liP on the new plugs.
Gap: 1.1 mm (0.()43 in.)
Reco"""'"'ndecl spark plugs:
NO P16R
NGK BPR 5EP 11
NOTE:
If adjusting the !liP of 1 new plug, bend on ly tho
btse of tho ground electrode. Do not touch tho tip. Never
attempt to adjust tho gap on a uood plug.
4. INSPECT AIR FILTER ~
(a) Vitua lly cheek that the air cleaner el ement Is not ex-
• cessivety di
rty, damaged or oil y.
(b) CI Nn the element with comprttled air.
F11'1t blow from the back side thoroughly. Then blow
off the f ront side of tho oloment.
5. REPLACE AIR FILTER
Replace the air ciNner element with anew one.
8. REPLACE ENGINE OIL AND OIL FILTER
I S.O pogt LU-3)
Engine oil grade:
API gradeS F or SF/CC , multigrade viscosity and fuel·
efficientoil
Engino oil oopeci
ty (Drain- r ef ill w ith oil filter chtngo ):
5.1 liters (5.4 US qts, 4 .5 Imp. qts)
7. REPLACE ENGINE COOLANT
(a) Drain the coo l ant from the rediator a nd engine droin
coc ks . (Engine drain is at ri ght rear of engine block.)
(b) Close the dre ln cocks .
(c) Fill systemwi th coolant.
Coollnt copecity (w/ hoator or air condit i oner) :
MIT 8.0 lltors (8.5 US qu , 7.0 Imp . qts)
AfT 7.9.1itors ( 8.3 US qu , 7.0 Imp . qu )
Usa o good brand of ethy'-1!1y<o l base ooolent, mixed
1.... ------------'-=• !!l accord i ng to the manufecturtr's instrUctions.

MA-6
MAINTENANCE -Maintenance Operations
-I
A!js
•
!!
;;
:.
-c
Air shou ld flow th rough freely and
no charCoal should come out. -
~Gaskot
-
8. INSPECT CHARCOAL CAN ISTER
9.
(a) Disconne<:t the hoses to the charcoal canister located
near
the rear exhaust manifold. Label the hoses for
co rrect installation.
(b) Plug pi pe A with your finger and blow compressed
air (3 kg/em'.
43 psi or 294 kPe) through pipe B (fuel
tank side).
• Check that air comes out of the bottom pipe C
without resistance.
• Check that no activated charcoal comes out.
If necessary. replace the charcoal canister.
NOTE: Do not attempt to wash the cha rcoal.
(c) Connect the hoses to the charcoalcanister.
REPLACE GASKET IN FUEL FILLER CAP .
(a) Remove the old gasket (O·ring) from the fuel _' fi ll e
cap. Do not damage the cap. i
•
(b) Insta ll the newgasket by hand. j
(c) Inspect the cap for damage or cracks. i
(d) Insta ll thecap and check the torque limiter.
10. INSPECT FUEL LI NES AND CONNECTIONS
(See page fl.57)
Visually inspect the fuel lines for cracks. leakage. loose
connections. deformation or tank band looseness.
11. INSPECT EXHAUST PIPES AND MOUN TINGS
Visually inspect the pipes, hangers,
and connections for
severe corrosion. le aks or damage.

MA IN TE NA NCE -MaintenanceOperations
MA ·7
......
BRAKES
12 . INSPECT BRAKE LI NE PIPES AN D HOSES
NOTE: lmpect in a we
ll lighted area. Inspect the tnt i ,.
circumference and le"9th of the brake 00.. ...... t mir·
ror as required. Turn the front wheels fully right or left be-
fore Inspecting the front brake.
(a) Check all brake lines end hotH for:
• Damage • Corrosion
• W ear • Leaks
• Deformation • Benck
• Cracks • Twists
lb) Cheek all clamps for tightness and oonneetions for
leakage.
(c) Cheek that the hoses end li nes are cl ea r of sharp
edges, moving parts end the .. r.aust system.
(d) Cheek that the lines installed in grommets, pm
through thecenter of thegrommets.
13 . IN SPECT FRONT AND REAR BRAKE PADS A ~
DISCS
(Front: See- BR· 14 , RMf: S. -BR·20) i
(a ) Cheek m. th i cknns of the discbrakepads and cheek
for irregul ar wea r.
Minimum peel thickneu: 3.0 mm 10.118 in.)
NOTE: If a squealing or scraping noise occurs from the
front or rear brakes duri"9 driving, cheek the pad wear in·
dicator. If th e re are traoes of the indicator contacting the
disc rotor, thedisc
pad should be replaced.
(b) Check the disc for wear or runout.
Minimum disc
thick.- :
Front 19.0 mm 10. 748 in.)
RMf 17.0 mm (0.ee9 in.)
••
M u:imum disc runout: 0.16 mm (0. 006 9 in.)

MA·8 MAINTENANCE
-Maintenance Operations
w.ool1 MAOI ..
Freeplay
-++-·...1.
.T
Max imu m
30mm
.......
14. INSPECT PARKING BRAKE LININGS AND DRUMS
(See pego BR·26)
(a) Check the lining-to-drums contact condition and lin·
ing wear .
Minimum lining thidu,..: 1.0 mm (0.039 in.)
(b) Check
tha brakedrums for ICOring or wear.
Maximum drum inside diameter: 188 mm (6.81 in.)
(c) Clean
the brake partswith adamp cloth.
NOTE: Do
not use compressed air to clean the brake
parts.
(d) Sed down the parking brake shoes and drum. When
performing the road ten 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 motors\
in thiscondition. .
• Repeat thisprocedure2 or 3 times. ,
• Check parking brake lever travel. 1
If necessary, adjust the parking brake. I
•
CHASSIS
15 . INSPECT STEERING LINKAGE
(a) Check that the steering wheelfreeplay.
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 pr...ure .
(b) Check the steering linkage for looseness anddamage.
Check
that:
• Tie rod ends so not have e•oessive play.
• Oust seals and boots are
not damaged.
• Bootclampsare
not loooe.
16. INSPECT STEERING GEAR HOUSING
Check
the steering gear housing foroil leakage.

ftb~t. Pl .ay: 2.5 mm
usa 14 c:
MAINTENANCE -MaintenanceOperations
Oust Cover
......
Drain Plug
17. INSPECT BALL JOINTS AND OUST COVERS
(a) Inspect the ball joints for exc~ive 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 vehi-
cle for seftty.
• Make sure the front wtleels are in a straightfor·
ward position, and block them with chocks.
• Using a lever, p ry up the end of the lowerarm, and
check theamount of play.
Maximum ball joint -'ical play: 2.5 mm (0.098 in.)
If excessive play is found, replace the ball joints.
(b) Inspect thedust cover for damage .
18. CHECK AUTOMATIC TRANSMISSION OR MANUAL
TRANSMISSION AND DIFFERENTIAL OIL
Visually check the automatic transmission or manual tr an5-
miaion and differential for o il leakage.
If leakage is found, check for cause and repair.
19. REPLACE MANUAL TRANSMISSION AND
DIFFERENTIAL OIL
(a) Remove thedrain plug and drein the oil.
(b) Re install the drain plug.
•
(c) Add new oil until it begins to run out of the filler
hole.
Transmis.ston 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.qtsl
Differential oil -
Oll grade: AP I GL-5 hypoid gear oil or for LSD oil
(LSD only)
Viscosity: Above -18'C to •F) SAE 90
Below - 18'C (00 F) SAE 80W·90
or80W
Capacity: 1.2 liters (1 .3 US qts, 1.1 Imp.qts)

MA·10
MAINTENANCE- Maintenance Operations
Or•in Pl ug
Add ;rhot
Add if coo l -
SEE PAGES FA-6 to 9
SEE PAGES RA·6to 11
20. REPLACE AUTOMATIC TRANSMISSION FLUID
(a) Remove thedrain plug and drain the fluid.
(b) Reinstall the drain plug securely.
(c) With the engine OFF, edd new fluid through the dip·
stick tube.
fluid: ATF DEXRON® D
Drain andrefill capacity:
2.4 liters (2.5 US qts , 2.1 Imp. qu)
Dry fill capacity:
6.51iters (6.9 US qts , 5.7 Imp. qts)
{d) Start the engine and shift the selector into all posi·
ti ons from "P" through "L", and thenshift into "P" .
{e) Wi th the engine idling, check the fluid level.
Add f lu id up to the "COOL" level on tile dipstick.
CAUTION: Do not overfill.
21. REPACK FRONT AND REAR (IRS ONL V) WHEEL
BEARINGS
{a} Change tile front wheel bearing grease.
(See pages FA·6 to 9)
Groese grade: Multipurpo• groese {NLGI No. 21 •
Front wheel b-ing friction praloed (while turning ):
0 - 1,()50g {0 -2.31b,0 - 10 N)
In eddition to oil saar frictional force
fbi IRS Type Rear Axle
Change tho roar wheel bearing grease.
{See pages RA ·5 to111

MAIN TE NAN CE - MaintenanceOperations MA ·11
22 . TIGHTEN BOLTS AN D NUTS ON CHASSIS AND
BODY
Tighten the following p¥ts:
• Front soot mountings bolts
Torque:
375 k ...., (27 ft · ll, 37 N· m)
• Front suspension membaHo.body mounting bolts and
nuts
To rqut : 800 kg-em (&8 ft· lb , 78N·ml
• Roar
SUSPension mtmbtr-to.body mounting bolts and
nuts
Torque: 1 .200 k...., ( 87 ft ·l b, 118 N·ml
Front~ • Strut bar bnleket-to.bodymounting bolts
Torque: 4 25 k...., (31 ft·ll , 42 N- ml
-~~~ ..
'
•
•
~.,,
.......
......
23 . FINAL INSPECTION
(a) Check the operation of the body parts:
• Hood
Auxiliary catch ope<ltes properly
Hood lockssecurely wtlen closed
• Frontdoors
Door lod<s operateproperly
Doors close properly
• L
ilt back door
Doorlock operettt properly
• Seats
•
Seat ad justs .. lily and locks securely at any posi·
tion
Front sut back locks tteurely at anyposition
Foklin9-<lown rear seat b.cks lock IICUrtly
(bl Road test
• Check
the engine and chHils for ebnom~~ l noltes.
• Check
that the ,.h lcr. does not wander or pull to
one side
• Check thlt the brakes w ort< properly and do not
drag.
• Perform baddino down of the parking broke shoes
and drum . (See page MA-8)
(c) Be sure to delivtr1 cletn car and eopeciolly check:
• Steeringwheel
• Shift lever knob
• A ll switchknobs
• Doorhandles
• Seats