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Brake caliper housing with integral parking brake on the rear axle. To ensure that the parking brake works perfectly, when a new brake caliper is fitted, and every time the brake pads are replaced the piston must be adjusted as described below: Removal: Release / unclip the handbrake cable Remove screw plug (a) – see Fig. 1 Slacken the hexagon socket screw (Fig. 2). Withdraw the piston until it stops moving. Installation: Screw in the hexagon socket screw in a clockwise direction (Figure 3) until the brake shoes touch the brake disc and the brake disc becomes difficult to turn. Then slacken the adjuster screw by one third to half of a turn (Brake disc will turn easily – see Fig. 4). Screw in and tighten screw plug (1) – Fig. 5. Attach brake cable and adjust it in accordance with the manufacturer’s instructions.

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NOTE: Samurai & Sidekick 1) Remove rocker cover. Rotate crankshaft until zero degree (TDC) timing mark of timing belt cover is in line with timing mark on crankshaft pulley. 2) Cylinder No. 1 should be at TDC on compression stroke. Remove distributor cap, and ensure rotor is pointed upward at distributor hold-down bolt and to No. 1 terminal of distributor cap. If not as described, rotate crankshaft 360 degrees. 3) Measure valve clearance between adjustment screw and valve stem using thickness gauge. Check intake valve clearance of cylinders No. 1 and 2 and exhaust valve clearance of cylinders No. 1 and 3. 4) Turn crankshaft one complete revolution (360 degrees). Check intake valve clearance of cylinders No. 3 and 4 and exhaust valve clearance of cylinders No. 2 and 4. Ensure clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS table. 5) If clearance adjustment is necessary, loosen lock nut and turn adjusting screw. After adjusting clearance, tighten adjusting Swift DOHC uses hydraulic lifters. Adjustment is not required. screw lock nut to 11-14 ft. lbs. (15-19 N.m) on Samurai or 90-108 INCH lbs. (10-13 N.m) on Sidekick. On all models, recheck clearance. VALVE CLEARANCE SPECIFICATIONS TABLE ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡ Application SOHC Engines Samurai, Sidekick 8-Valve TBI & Swift (1) Engine Cold Exhaust ……………………. .006-.008 (.15-.20) Intake …………………….. .005-.007 (.13-.17) Engine Hot Exhaust ……………………. .010-.012 (.25-.30) Intake …………………….. .009-.011 (.23-.27) Sidekick 16-Valve PFI Engine Cold Exhaust & Intake ………….. .0031-.0047 (.08-.12) Engine Hot Exhaust & Intake ………….. .0047-.0063 (.12-.16) DOHC Engine Swift (1) …………………………………. (2) (1) – Swift is available with 1.3L DOHC and SOHC engines. (2) – Hydraulic valve lash adjusters are used. Adjustment is not required. ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡ Swift SOHC 1) Remove rocker cover. Remove right side inner fender apron extension to enable timing marks to be seen. Align crankshaft pulley timing mark with TDC mark on timing belt cover. 2) Remove distributor cap. Ensure rotor is pointing upward toward distributor hold-down bolt and to No. 1 terminal of distributor cap. If not as described, rotate crankshaft 360 degrees. 3) Measure valve clearance between adjustment screw and valve stem using thickness gauge. Check intake valve clearance of cylinders No. 1 and 2 and exhaust valve clearance of cylinders No. 1 and 3. Turn crankshaft one complete revolution (360 degrees). Check intake valve clearance of cylinders No. 3 and 4 and exhaust valve clearance of cylinders No. 2 and 4. 4) Ensure clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS table. If clearance adjustment is necessary, loosen lock nut and turn adjusting screw. Hold adjusting screw while tightening lock nut to 11-14 ft. lbs. (15-19 N.m). Recheck clearance. In. (mm)

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NOTE: Before starting the adjustment process, inspect the top for damage, make sure that the door window glass and rear quarter glass are correctly adjusted then completely lower all window glass. NOTE: After each adjustment make sure the convertible top operates correctly. The Convertible Top Dowel Pins Fall Forward (Overshoot) or Rearward (Undershoot). The Receiver Cups — Cam Bolt Adjustment. 1. Remove the quarter trim panel. For additional information, refer to Section 501-05. 2. Close the convertible top and examine the position of the dowel pins relative to the receiver cups. 3. Move the convertible top to the half-open position to access the cam bolt. 4. NOTE: Rotating the top of the cam bolt toward the front of the vehicle will lengthen the top, increase the tension on the top and increase pull-down effort. Rotating the cam bolt in the opposite direction will have the opposite effect. NOTE: Turn the adjusting cam one notch at a time. Adjust the adjusting cam as needed. 1. Remove the cam stop set screw. 2. Rotate the adjusting cam. 3. Install the cam stop set screw. 5. Make sure the convertible top operate correctly. 6. Install the quarter trim panel. For additional information, refer to Section 501-05. 7. Close the convertible top. Convertible Top Lifts Up Unevenly — Lift Cylinder and C-pivot Inspection 8. Remove the quarter trim panel. For additional information, refer to Section 501-05. 9. NOTE: This step applies to vehicles equipped with the Mach sound system. Remove the screws and disconnect the electrical connectors. 10. Remove the screws. 11. Remove the speakers. For additional information, refer to Section 415-03. 12. Move the convertible top to the half-open position and support the convertible top in that position. 13. Remove the lift cylinder rod mounting bolts. 14. Remove the nuts and support the lift cylinders. 15. Using the convertible top switch, retract the lift cylinder rods and check for bent or binding rods. If one rod bottoms out 25mm (1 inch) or more before the other, the lagging lift cylinder may be bent and will need to be replaced. 16. With the lift cylinder rods retracted, manually lower the convertible top. 17. Manually lift each side rail 7.5-10 cm (3-4 inches) to check for obvious binding. Side arms should have equal resistance, side-to-side. If the resistance is noted, loosen the clamp load of the c-pivot rivet with using a center pinch. If a dramatic resistance is still noted replace the c-pivot rivet with shoulder bolt kit (F5ZZ- 76539A04-A). 18. Position the lift cylinders and install the nuts. 19. Install the two cylinder rod mounting bolts. 20. Install the speakers. For additional information, refer to Section 415-03. 21. Install the screws. NOTE: This step applies to vehicles equipped with the Mach sound system. 22. Install the screws and connect the electrical connectors.

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1. Adjust rear brakes. Release parking brake. Raise and support vehicle. Check parking brake cables for free movement. See Fig. 7 . Lower vehicle. Move front seats forward. Pry off plastic caps that cover access holes to parking brake console hood-to-tunnel bracket screws. Unfasten screws that secure parking brake console hood to tunnel brackets. Raise console hood to expose parking brake lever assembly and adjustment nut. See Fig. 8 . 2. Partially raise and support vehicle. Turn adjustment nut on lever assembly until wheels are difficult to turn. Loosen nut until rear wheels are just free to turn. Lower vehicle, position parking brake console hood and fasten it to tunnel brackets with screws. Tighten parking brake console hood-to-tunnel bracket screws to 2.5 N.m (22 INCH lbs.). Snap in plastic caps that cover access holes to parking brake console hood-to-tunnel bracket screws. Adjust front seats to their previous position.

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Test Requirements Special tools, testers and auxiliary items required Head light adjusting unit VAS 5046 or Headlight adjuster VAS 5047 Test- and adjustment requirements: Tire pressure must be OK. Lenses must not be damaged or dirty. Reflectors and bulbs OK. Vehicle must be properly loaded. Move vehicle back and forth for 1 meter (3 to 4 feet) or bounce front and rear of vehicle several times up and down to settle suspension. Vehicle and headlight adjuster must be on a level surface. Operating instructions of headlight adjuster VAS 5046 or Operating instructions of headlight adjuster VAS 5047 Inclination must be set. If the vehicle is equipped with separate low beams and high beams, high beam must be adjusted extra. Note that the adjuster must be set to 0% when adjusting the high beams. In the trim above the headlight, inclination measurements are stamped in “%” . The headlamps must be adjusted according to these measurements. Percentage information is based on a projection distance of 10 meters. For example: inclination of 1.0 % converts to approx. 10 cm. For vehicles with halogen headlamps and manual headlamp range control Note: For certain markets, no manual headlamp range control is offered in conjunction with halogen headlamps. The headlight range adjuster thumb wheel, if present, must be in basic setting – 0 – . Load: Vehicle must be loaded with one person on the drivers seat, weighing 165 lbs (75 kg), otherwise vehicle must be empty (curb weight). The curb weight is the weight of the vehicle ready to be operated with filled fuel tank (at least 90% filled), including the weight of all equipment usually carried in the car such as spare wheel, tools, car jack, fire extinguisher, etc. If the fuel tank is not at least 90% full, adjust the weight as follows: Read fuel level from fuel gauge. Calculate additional weight needed using the following table. Place extra weight in luggage compartment. Tank filling table