Diesel Data: Automotive Repair
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Installation








REAR SUSPENSION: REAR AXLE BEAM: INSTALLATION

INSTALLATION

1. INSTALL REAR AXLE CARRIER BUSHING LH





(a) Align the arrow mark on a new rear axle carrier bushing LH with the matchmark on the rear axle beam assembly and temporarily install the rear axle carrier bushing LH to the rear axle beam assembly. (Perform this procedure when reusing the rear axle beam assembly.)
NOTE: Install the rear axle carrier bushing LH in the same direction as the removed bushing.

(b) Temporarily install a new rear axle carrier bushing LH to the position shown in the illustration. (Perform this procedure when replacing with a new rear axle beam assembly.)
(A):
0°53' +/- 3° (0.88° +/- 3°)
NOTE: Install the rear axle carrier bushing LH in the same direction as the removed bushing.





(c) Using SST, install the rear axle carrier bushing LH to the rear axle beam assembly.
SST: 09710-04101
SST: 09950-40011
09951-04020
09952-04010
09953-04030
09954-04020
09955-04051
09957-04010
09958-04011
SST: 09950-60010
09951-00620

NOTICE:
- Hang the claws of SST to the bushing deeply and firmly.
- Do not scratch the rubber portion (A) of the bushing.
- Do not deform the bushing rib.

2. INSTALL REAR AXLE CARRIER BUSHING RH
HINT: Perform the same procedure as the LH side.

3. TEMPORARILY TIGHTEN REAR AXLE BEAM ASSEMBLY





(a) Support the rear axle beam assembly using 2 jacks and 2 wooden blocks.





(b) Temporarily install the rear axle beam assembly with the 2 bolts and 2 nuts.
(c) Temporarily tighten the 2 bolts.
NOTE: Since stopper nuts are used, temporarily tighten the bolts.

4. TEMPORARILY TIGHTEN REAR SHOCK ABSORBER WITH COIL SPRING LH





(a) Temporarily install the rear shock absorber with coil spring LH and the rear No. 1 shock absorber cushion retainer with the nut.
5. TEMPORARILY TIGHTEN REAR SHOCK ABSORBER WITH COIL SPRING RH
HINT: Perform the same procedure as the LH side.

6. INSTALL REAR STABILIZER BAR (for TMC Made) Installation
7. INSTALL REAR STABILIZER BAR (except TMC Made) Installation
8. INSTALL REAR AXLE BEAM DAMPER Installation
9. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY LH (for Rear Drum Brake) Installation
10. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY RH (for Rear Drum Brake)
HINT: Perform the same procedure as the LH side.

11. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY LH (for Rear Disc Brake) Installation
12. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY RH (for Rear Disc Brake)
HINT: Perform the same procedure as the LH side.

13. TEMPORARILY TIGHTEN NO. 4 REAR BRAKE TUBE (for Rear Drum Brake)





(a) Using a union nut wrench (10 mm), temporarily install the No. 4 rear brake tube to the rear brake wheel cylinder assembly LH.

NOTICE:
- Do not bend or damage the brake line.
- Do not allow any foreign matter such as dirt and dust to enter the brake line.

14. TEMPORARILY TIGHTEN NO. 3 REAR BRAKE TUBE (for Rear Drum Brake)
HINT: Perform the same procedure as the No. 4 rear brake tube.

15. INSTALL REAR FLEXIBLE HOSE LH (for Rear Drum Brake)
(a) Install the rear flexible hose LH with a new clip.
NOTE: Install the new clip as far as it will go.





(b) Using a union nut wrench (10 mm), connect the No. 4 rear brake tube to the rear flexible hose while holding the rear flexible hose LH with a wrench.
without union nut wrench - Torque: 15 Nm (155 kgf-cm, 11 ft-lbf)
with union nut wrench - Torque: 14 Nm (143 kgf-cm, 10 ft-lbf)

NOTICE:
- Do not bend or damage the brake line.
- Do not allow any foreign matter such as dirt and dust to enter the brake line.
- Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
- This torque value is effective when the union nut wrench is parallel to the torque wrench.

16. INSTALL REAR FLEXIBLE HOSE RH (for Rear Drum Brake)
HINT: Perform the same procedure as the LH side.

17. FULLY TIGHTEN NO. 4 REAR BRAKE TUBE (for Rear Drum Brake)





(a) Using a union nut wrench (10 mm), fully tighten the No. 4 rear brake tube.
without union nut wrench - Torque: 15 Nm (155 kgf-cm, 11 ft-lbf)
with union nut wrench - Torque: 14 Nm (143 kgf-cm, 10 ft-lbf)

NOTICE:
- Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
- This torque value is effective when the union nut wrench is parallel to the torque wrench.

18. FULLY TIGHTEN NO. 3 REAR BRAKE TUBE (for Rear Drum Brake)
HINT: Perform the same procedure as the No. 4 rear brake tube.

19. INSTALL REAR DISC LH (for Rear Disc Brake) Installation
20. INSTALL REAR DISC RH (for Rear Disc Brake)
HINT: Perform the same procedure as the LH side.

21. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY LH (for Rear Disc Brake) Replacement
22. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY RH (for Rear Disc Brake)
HINT: Perform the same procedure as the LH side.

23. INSTALL REAR FLEXIBLE HOSE LH (for Rear Disc Brake)





(a) Install the rear flexible hose LH to the rear axle beam with the bolt.
Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)
NOTE: Do not twist the rear flexible hose LH.

24. INSTALL REAR FLEXIBLE HOSE RH (for Rear Disc Brake)
HINT: Perform the same procedure as the LH side.

25. CONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY (for Rear Disc Brake)





(a) Install the No. 3 parking brake cable assembly to the rear disc brake cylinder assembly LH.
HINT: Be sure to engage the No. 3 parking cable assembly clip onto the rear disc brake cylinder assembly LH as shown in the illustration.





(b) Connect the No. 3 parking brake cable assembly to the rear disc brake cylinder assembly LH.
26. CONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY (for Rear Disc Brake)
HINT: Perform the same procedure as the No. 3 parking brake cable assembly side.

27. INSTALL PARKING BRAKE LEVER PROTECTOR LH (for Rear Disc Brake) Installation
28. INSTALL PARKING BRAKE LEVER PROTECTOR RH (for Rear Disc Brake)
HINT: Perform the same procedure as the LH side.

29. INSTALL REAR BRAKE DRUM LH (for Rear Drum Brake) Installation
30. INSTALL REAR BRAKE DRUM RH (for Rear Drum Brake)
HINT: Perform the same procedure as the LH side.

31. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY





(a) Install the No. 3 parking brake cable assembly with the bolt.
Torque: 6.0 Nm (61 kgf-cm, 53 in-lbf)
32. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY
HINT: Perform the same procedure as the No. 3 parking brake cable assembly.

33. INSTALL REAR SPEED SENSOR WIRE LH





(a) Install the rear speed sensor wire LH with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
NOTE: Do not twist the rear speed sensor wire LH.

(b) Engage the clamp.
NOTE: Do not twist the rear speed sensor wire LH.

34. INSTALL REAR SPEED SENSOR WIRE RH
HINT: Perform the same procedure as the LH side.

35. CONNECT REAR SPEED SENSOR WIRE LH (for Rear Drum Brake) Installation
36. CONNECT REAR SPEED SENSOR WIRE RH (for Rear Drum Brake)
HINT: Perform the same procedure as the LH side.

37. CONNECT REAR SPEED SENSOR WIRE LH (for Rear Disc Brake) Installation
38. CONNECT REAR SPEED SENSOR WIRE RH (for Rear Disc Brake)
HINT: Perform the same procedure as the LH side.

39. ADJUST PARKING BRAKE LEVER TRAVEL (for Rear Disc Brake) Adjustments
40. INSPECT REAR DISC BRAKE CYLINDER OPERATION LEVER AND STOPPER CLEARANCE (for Rear Disc Brake) Adjustments
41. ADJUST REAR DRUM BRAKE SHOE CLEARANCE (for Rear Drum Brake) Installation
42. FILL BRAKE FLUID RESERVOIR (for Rear Drum Brake) Service and Repair
43. BLEED BRAKE LINE (for Rear Drum Brake) Service and Repair
44. INSPECT FOR BRAKE FLUID LEAK (for Rear Drum Brake)
45. INSPECT BRAKE FLUID LEVEL (for Rear Drum Brake) Testing and Inspection
46. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
47. INSTALL REAR WHEELS
Torque: 103 Nm (1050 kgf-cm, 76 ft-lbf)
48. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for Rear Disc Brake) Installation
49. INSTALL CENTER NO. 1 INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (for Rear Disc Brake)
HINT:
- for Manual Transaxle Installation
- for Automatic Transaxle Installation

50. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Rear Disc Brake)
HINT:
- for Manual Transaxle Installation
- for Automatic Transaxle Installation

51. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for Rear Disc Brake) Installation
52. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL RH (for Rear Disc Brake) Installation
53. STABILIZE SUSPENSION Installation
54. FULLY TIGHTEN REAR AXLE BEAM ASSEMBLY





(a) Fully tighten the 2 bolts on the rear axle beam assembly.
Torque: 85 Nm (867 kgf-cm, 63 ft-lbf)

NOTICE:
- Since stopper nuts are used, tighten the bolts.
- The final torque must be applied under standard vehicle height conditions.

55. FULLY TIGHTEN REAR SHOCK ABSORBER WITH COIL SPRING LH





(a) Fully tighten the nut on the rear shock absorber with coil spring LH (lower side).
Torque: 80 Nm (816 kgf-cm, 59 ft-lbf)
CAUTION: The final torque must be applied under standard vehicle height conditions.

56. FULLY TIGHTEN REAR SHOCK ABSORBER WITH COIL SPRING RH
HINT: Perform the same procedure as the LH side.

57. INSPECT REAR WHEEL ALIGNMENT
Service and Repair.
58. PLACE FRONT WHEELS FACING STRAIGHT AHEAD (w/ VSC)
59. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (w/ VSC)
NOTE: Disconnect the cable from the negative (-) battery terminal for more than 2 seconds.

60. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (w/ VSC)
61. PERFORM YAW RATE SENSOR ZERO POINT CALIBRATION (w/ VSC) Programming and Relearning.
62. CHECK STEERING ANGLE SENSOR ZERO POINT CALIBRATION (w/ VSC) C1290.
63. CHECK FOR SPEED SENSOR SIGNAL (w/ ABS) Test Mode Procedure.
64. CHECK FOR SPEED SENSOR SIGNAL (w/ VSC) Test Mode Procedure.
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