a–1 service specifications
TRANSCRIPT
Front and rear brakePad thicknessDisc thicknessDisc runoutParking brakeLining thicknessDrum inside diameterFront axle and suspensionBall joint vertical playSteering wheel freeplayTorque specificationsFront seat mount boltsStrut/stabilizer bar bracket x BodyEngine mounting center member x BodyFront suspension lower crossmember x BodyRear suspension lower crossmember x Body
MAINTENANCEEngine
Engine oil capacity (Drain and refill with oil fitter change)
GapFiring orderValve clearance
Coolant capacity 1w/ Heater)
Drive belt tensionAlternator
Spark plugType
Chassis
PS pump
–SERVICE SPECIFICATIONS MaintenanceA–2
ENGINE MECHANICAL (3S–FE)Specifications
Intake manifoldvacuum
Camshaft andgear
Compressionpressure
Valve guidebushing
Cylinder head
Valve spring
Valve lifter
Idle speed
Manifold
Valve
–SERVICE SPECIFICATIONS Engine Mechanical (3S–FE)A–3
Specifications (Cont’d)
Idler pulleytension spring
Camshaft andgear (cont’d)
Piston andpiston ring
Connecting rod
Cylinder block
Crankshaft
–SERVICE SPECIFICATIONS Engine Mechanical (3S–FE)A–4
Spark plug tube x Cylinder headCamshaft bearing cap x Cylinder headCylinder head cover x Cylinder headIntake manifold x Cylinder headIntake manifold stay x Cylinder headIntake manifold stay x Cylinder blockEGR valve x Intake manifoldEGR pipe x Cylinder headWater outlet x Cylinder headExhaust manifold x Catalytic converterExhaust manifold x Cylinder headEngine hanger x Cylinder headAlternator bracket x Cylinder head
Oil pump pulley x Oil pump drive shaftNo. 1 idler pulley x Cylinder headNo. 2 idler pulley x Cylinder blockCamshaft timing pulley x CamshaftCrankshaft pulley x CrankshaftCylinder head x Cylinder block
Specifications (Cont’d)
Torque Specifications
Crankshaft(cont’d)
Part tightened
–SERVICE SPECIFICATIONS Engine Mechanical (3S–FE)A–5
Engine RH mounting bracket x Cylinder blockEngine RH mounting insulator x Engine mounting bracketEngine RH mounting insulator x Body (2WD)Engine RH mounting insulator x Body (4WD)Engine RH mounting stay x Engine mounting insulatorEngine RH mounting stay x Alternator bracketEngine LH mounting bracket x TransaxleEngine LH mounting insulator x Engine mounting insulatorEngine LH mounting insulator x BodyEngine LH mounting stay x Engine mounting insulator (4/T)Engine LH mounting stay x Transaxle (A/T)Engine front mounting bracket x TransaxleEngine front mounting insulator x Engine mounting bracketEngine center mounting bracket x Cylinder block (2WD)Engine rear mounting x TransaxleEngine rear mounting insulator x Engine mounting bracketEngine front pipe x Catalytic converterExhaust front pipe x Exhaust center pipe
Main bearing cap X Cylinder blockConnecting rod cap x Connecting rodRear oil seal retainer x Cylinder blockRear end plate X Cylinder blockFlywheel x Crankshaft (M/T)Drive plate x Crankshaft (A/T)Suspension lower crossmember x BodySuspension lower crossmember x Engine mounting center memberEngine mounting center member x BodyEngine mounting center member x Engine mounting insulator
Torque Specifications (Cont’d)
Part tightened
–SERVICE SPECIFICATIONS Engine Mechanical (3S–FE)A–6
ENGINE MECHANICAL (2VZ–FE)Specifications
Intake manifoldvacuum
Compressionpressure
Valve guidebushing
Air intakechamber
Cylinder head
Valve spring
Valve lifter
Idle speed
Manifold
Camshaft
Valve
–SERVICE SPECIFICATIONS Engine Mechanical (2VZ–FE)A–7
Specifications (Cont’d)
Connecting rod
Timing belttensioner
Piston andpiston ring
Camshaft(cont’d)
Cylinder block
Crankshaft
–SERVICE SPECIFICATIONS Engine Mechanical (2VZ––FE)A–8
Recessed head boltLH engine hanger x LH Cylinder headCamshaft bearing cap x Cylinder headCylinder head cover x Cylinder headNo. 3 timing belt cover x Cylinder headNo. 3 timing belt cover x Cylinder blockExhaust manifold x Cylinder headIntake manifold x Cylinder headNo. 2 idler pulley bracket stay x Cylinder headNo. 2 idler pulley bracket stay x No. 2 idler pulley bracketWater by–pass outlet x Cylinder headWater outlet x Cylinder headAir intake chamber x Intake manifoldAir intake chamber stay x Air intake chamberAir intake chamber stay x Cylinder headCrossover pipe x Exhaust manifoldCrossover pipe x Cylinder headCrossover pipe x Cylinder blockEGR valve x Air intake chamber
No. 1 idler pulley x Cylinder blockNo. 2 idler pulley x No. 2 idler pulley bracket .Camshaft tinning pulley x CamshaftCrankshaft pulley x CrankshaftTinning belt tensioner x Oil pumpEngine RH mounting bracket x Cylinder blockCylinder head x Cylinder block 12–sided bolt
Circle runoutMain journal taper and out–of–roundCrank pin taper and out–of–round
Torque Specifications
Specifications (Cont’d)
Main bearing center wall thickness
Main journal oil clearance
Main journal diameter
Crank pin diameter
Crankshaft(cont’d)
Part tightened
–SERVICE SPECIFICATIONS Engine Mechanical (2VZ–FE)A–9
Connecting rod cap x Connecting rodRear oil seal retainer x Cylinder blockNo. 2 idler pulley bracket x Cylinder blockWater by–pass pipe x Cylinder blockRear end plate x Cylinder blockFlywheel x CrankshaftDrive plate x CrankshaftEngine RH mounting insulator x Engine mounting bracketEngine RH mounting insulator x Body BoltNutEngine LH mounting insulator x Engine mounting bracketEngine LH mounting insulator x BodyNo. 1 engine RH mounting stay x Air intake chamberNo. 1 engine RH mounting stay x Engine RH mounting insu-latorNo. 2 engine RH mounting stay x AlternatorNo. 2 engine RH mounting stay x Engine RH mounting insu-latorEngine LH mounting stay x Transaxle M/T
Engine LH mounting stay x Engine mounting insulatorEngine front mounting insulator x Cylinder blockEngine front mounting insulator x TransaxleEngine front mounting insulator x Engine mounting bracketEngine center mounting bracket x Cylinder blockEngine rear mounting insulator x TransaxleEngine rear mounting insulator x Engine mounting bracketEngine mounting center member x BodyEngine mounting center member x Engine front mountinginsulatorEngine mounting center member x Engine center mountinginsulatorEngine mounting center member x Engine rear mountinginsulatorExhaust front pipe x Exhaust manifoldExhaust front pipe x Catalytic converterSuspension lower crossmember x BodySuspension lower crossmember x Engine mounting centermember
EGR pipe x EGR valveEGR pipe x RH exhaust manifoldMain bearing cap x Cylinder block
Torque Specifications (Cont’d)
Part tightened
A/T
–SERVICE SPECIFICATIONS Engine Mechanical (2112–FE)A–10
ResistanceInjection volumeDifference between each injectorFuel leakage
EFI SYSTEM (3S–FE)Specifications
No continuityNo continuityContinuityNo continuityContinuityNo continuity
ContinuityNo continuityNo continuityNo continuityNo continuityContinuity
Throttle opening angle(from Vertical)
Clearance betweenstop screw and fever
Clearance betweenstop screw and lever
Throttlepositionsensor(w/o ECT)
Throttle body fully closed angle
Cold startinjector timeswitch
Throttlepositionsensor(W/ECT)
Fuel pressureregulator
ResistanceFuel leakage
Water temp.sensor
Between terminals
Cold startinjector
Air flow meter
Fuel pressure
Throttle body
at No vacuum
Resistance
PS1N – E 1
ISC valve
lDL – E1
Injector
–SERVICE SPECIFICATIONS EFI System (3S–FE)A–11
HINT• Perform all voltage and resistance measurements with the ECU connected.• Verify that the battery voltage is 11 V or above with the ignition switch is ON.
Stop light SW ON (Brake pedal depressed) or defoggerSW ON
No trouble (”CHECK” engine warning light off) andengine running
Check connector TE 1 – E 1 not connected
Specifications (Cont’d)
Check connector TE1 – E1 connected
*1 W/O ECT *2 W/ EGT *3A/C
EGR gas temp.sensor(CALIF.. only)
Ex. shift position P or N range
Intake air temp. 20 °C (68°F)
Measuring plate fully closed
Coolant temp. 80 °C (176°F)
Shift position P or N range
Measuring plate fully open
Throttle valve fully closed
Throttle valve fully closed
Heater blower SW ON
Air conditioning ON
Throttle valve open
Throttle valve open
Throttle valve open
Cranking or idling
STD voltage (V)
3,000 rpm
EG SW ON
IG SW ON
IG SW ON
IG SW ON
IG SW ON
IG SW ON
Cranking
Terminals Condition
Voltage
Idling
ECU
–SERVICE SPECIFICATIONS EFI System (3S–FE)A–12
Fuel tank band x BodyCold start injector x Air intake chamberCold start injector pipe x Cold start injectorCold start injector pipe x Delivery pipeFuel pressure regulator X Delivery pipeFuel return pipe x Fuel pressure regulatorDelivery pipe x Cylinder headThrottle body x Air intake chamber
Fuel evaporation vent tube x Fuel tank 4WDFuel inlet pipe x Fuel tank
Fuel sender gaugeFuel pump X Fuel tank
Specifications (Cont’d)
Torque Specifications
Coolant temp. 80 °C (176°F)
Intake air temp. 20 °C (68°F)
Measuring plate fully closed
Measuring plate fully open
Throttle valve fully closed
Throttle valve fully closed
Throttle valve fully closed
Throttle valve fully closed
Throttle valve fully open
Throttle valve fully open
* 1 w/o ECT *2 w/ ECT
Throttle valve open
Throttle valve open
Part tightened
ECU (cont’d) Resistance
Condition
Fuel line
–SERVICE SPECIFICATIONS EFI System (3S–FE)A–13
Engine coolant x Drain plugWater pump x Water pump coverWater pump x Cylinder headWater by–pass pipe X Water pumpWater inlet housing x Water pumpOil cooler x Radiator tower tank
Cylinder block x Drain plugWater pump x Cylinder blockWater inlet x Water pumpWater inlet pipe x Alternator belt adjusting bar
LUBRICATION SYSTEM (3S–FE)Specifications
Torque Specifi cations (3S–FE)
COOLING SYSTEMSpecifications
Torque Specifications (2VZ–FE)
Valve opening temperatureValve lift at 95 °C (203°F)
Relief valve opening pressure
Engine coolant capacity
Engine coolant capacity
at Idlingat 3,040 rpm
STDLimitSTDLimit
Body clearance .
See page A–20
STDLimit
Part tightened
Part tightened
See page A–2
Tip clearance
3S–FE2VZ–FE
Oil pressure
Thermostat
Oil pump
Radiator
–SERVICE SPECIFICATIONS Cooling SystemA–17
EFI SYSTEM (2VZ–FE)Specifications
Clearance between stopscrew and lover
EGR gastemp. sensor(CALIF. only)
Cold startInjector timeswitch
Fuel pressureregulator
Fuel pressureVSV
Water temp.sensor
Throttlepositionsensor
Between terminals
Cold startinjector
Air flowmeter
Resistance
ISC valve
Injector
–SERVICE SPECIFICATIONS EFI System (2VZ–FE)A–14
HINT:• Perform all voltage and resistance measurements with the ECU connected.• Verify that the battery voltage is 11 V or above with the ignition switch is ON.
No trouble (”CHECK”’ engine warning light off) andengine running
Specifications (Cont’d)
Stop light SW ON (Brake pedal depressed)
Check connector TE1 – E1 not connected
Check connector TE1 – Et connected
Shift position P or N range
Ex shift position P or N range
Intake air temp. 20 °C (68°F)
Measuring plate fully closed
Coolant temp. 60 °C (176°F)
Measuring plate fully open
Throttle valve fully closed
Heater blower SW ON
Air conditioning ON
Throttle valve open
Throttle valve open
Cranking or idling
Heater resistance
STD voltage (V)
Oxygensensor
IG SW ON
IG SW ON
IG SW ON
IG SW ON
IG SW ON
IG SW ON
Cranking
Terminals Condition
Voltage
Idling
*1 w/
rpm
ECU
–SERVICE SPECIFICATIONS EFI System (2VZ–FE)A–15
Fuel pump x Fuel tankFuel inlet pipe x Fuel tankFuel tank band x BodyCold start injector x Air intake chamberCold start injector tube x Cold start injectorCold start injector tube x Delivery pipeFuel pressure regulator x Delivery pipeDelivery pipe x Intake manifoldNo. 2 fuel pipe x Delivery pipeAir intake chamber x Intake manifoldEGR pipe nutNo. 1 engine hangerAir intake chamber stayNo. 1 RH engine mounting stay x Air intake chamberNo. 1 RH engine mounting stay x RH engine mounting insulatorThrottle body x Air intake chamberISC valve x Air intake chamber
Specifications (Cont’d)
Torque Specifications
Intake air temp. 20 °C (68°F)
Measuring plate fully closed
Coolant temp. 60 °C (176°F)
Union bolt typeFlare nut type
Measuring plate fully open
Throttle valve fully dosed
Throttle valve fully closed
Throttle valve fully open
Throttle valve open
STD resistance (fl)
Part tightened
ECU (cont’d) Resistance
Terminals Condition
Fuel line
–SERVICE SPECIFICATIONS EFI System (2VZ–FE)A–16
Engine coolant x Drain plugWater pump x Water pump coverWater pump x Cylinder headWater by–pass pipe X Water pumpWater inlet housing x Water pumpOil cooler x Radiator tower tank
Cylinder block x Drain plugWater pump x Cylinder blockWater inlet x Water pumpWater inlet pipe x Alternator belt adjusting bar
LUBRICATION SYSTEM (3S–FE)Specifications
Torque Specifi cations (3S–FE)
COOLING SYSTEMSpecifications
Torque Specifications (2VZ–FE)
Valve opening temperatureValve lift at 95 °C (203°F)
Relief valve opening pressure
Engine coolant capacity
Engine coolant capacity
at Idlingat 3,040 rpm
STDLimitSTDLimit
Body clearance .
See page A–20
STDLimit
Part tightened
Part tightened
See page A–2
Tip clearance
3S–FE2VZ–FE
Oil pressure
Thermostat
Oil pump
Radiator
–SERVICE SPECIFICATIONS Lubrication System (3S–FE)A–17
Engine oil drain plugOil pump body cover x Oil pump bodyOil pump x Cylinder blockOil strainer x Cylinder blockOil strainer x Oil pumpOil pan x Cylinder blockOil pan x Oil pumpStiffener plate x Cylinder blockStiffener plate x Transaxle case
Oil pan x Drain plugOil pump. x Cylinder blockOil strainer x Main bearing capOil strainer x Oil pumpOil pan x Cylinder blockOil pan x Oil pumpOil pan X Rear oil seal retainerStiffener plate x Cylinder blockStiffener plate x Transaxle case
LUBRICATION SYSTEM (2VZ–FE)Specifications
Torque Specifications
Torque Specifications
Engine coolant capacity
Body clearance
See page A–20
Part tightened
Side clearance
Part tightened
Tip clearance
Oil pressure
Oil pump
–SERVICE SPECIFICATIONS Lubrication System (3S–FE)A–18
Engine oil drain plugOil pump body cover x Oil pump bodyOil pump x Cylinder blockOil strainer x Cylinder blockOil strainer x Oil pumpOil pan x Cylinder blockOil pan x Oil pumpStiffener plate x Cylinder blockStiffener plate x Transaxle case
Oil pan x Drain plugOil pump. x Cylinder blockOil strainer x Main bearing capOil strainer x Oil pumpOil pan x Cylinder blockOil pan x Oil pumpOil pan X Rear oil seal retainerStiffener plate x Cylinder blockStiffener plate x Transaxle case
LUBRICATION SYSTEM (2VZ–FE)Specifications
Torque Specifications
Torque Specifications
Engine coolant capacity
Body clearance
See page A–20
Part tightened
Side clearance
Part tightened
Tip clearance
Oil pressure
Oil pump
–SERVICE SPECIFICATIONS Lubrication System (2VZ–FE)A–18
Air gapSignal generator (pickup coil) resistance
STARTING SYSTEMRated voltage and output powerNo–toad characteristic
Rated outputRotor coil resistanceSlip ring diameter
IGNITION SYSTEM
Circle runoutSpring installed load
CommutatorOuter diameter
CHARGING SYSTEM
Secondary coil resistance
Alternator regu-lator (ICS
Battery specific gravity
Primary coil resistance
Brush exposed length
High–tensioncord
Regulating voltage
Drive belt tension
Undercut depth
Ignition timing
See page A–2
Bruch length
Ignition coil
Firing order
Spark plug
Resistance
Distributor
Alternator
Starter
–SERVICE SPECIFICATIONS Ignition SystemA–19
Air gapSignal generator (pickup coil) resistance
STARTING SYSTEMRated voltage and output powerNo–toad characteristic
Rated outputRotor coil resistanceSlip ring diameter
IGNITION SYSTEM
Circle runoutSpring installed load
CommutatorOuter diameter
CHARGING SYSTEM
Secondary coil resistance
Alternator regu-lator (ICS
Battery specific gravity
Primary coil resistance
Brush exposed length
High–tensioncord
Regulating voltage
Drive belt tension
Undercut depth
Ignition timing
See page A–2
Bruch length
Ignition coil
Firing order
Spark plug
Resistance
Distributor
Alternator
Starter
–SERVICE SPECIFICATIONS Starting SystemA–19
Air gapSignal generator (pickup coil) resistance
STARTING SYSTEMRated voltage and output powerNo–toad characteristic
Rated outputRotor coil resistanceSlip ring diameter
IGNITION SYSTEM
Circle runoutSpring installed load
CommutatorOuter diameter
CHARGING SYSTEM
Secondary coil resistance
Alternator regu-lator (ICS
Battery specific gravity
Primary coil resistance
Brush exposed length
High–tensioncord
Regulating voltage
Drive belt tension
Undercut depth
Ignition timing
See page A–2
Bruch length
Ignition coil
Firing order
Spark plug
Resistance
Distributor
Alternator
Starter
–SERVICE SPECIFICATIONS Charging SystemA–19
Dry fill 3S–FE2VZ– FE
Drain and refillw/ Oil filter change
API grade SG, multigrade,recommended viscosity and fuel–efficient oil
w/o Oil filter change
Engine oil
LUBRICANT
ClassificationCa pa city
Imp. qtsUS qtsLitersItem
–SERVICE SPECIFICATIONS LubricantA–20
Input shaftRoller bearing journal diameter3rd gear journal diameter4th gear journal diameter5th gear journal diameterRunoutOutput shaftRoller bearing journal diameter1 st gear journal diameter2nd gear journal diameterRunoutGear thrust clearance
Pedal height (from asphalt sheet)Push rod play at pedal topPedal freepiayClutch release point (from pedal stroke end)Disc rivet head depthDisc runoutDiaphragm spring out of alignmentDiaphragm spring finger wear Depth WidthFlywheel runout
Clutch cover x FlywheelMaster cylinder set nutRelease cylinder set boltReservoir tank x Master cylinderClutch line unionBleeder plugRelease fork support
MANUAL TRANSAXLE (S51)Specifications
CLUTCHSpecifications
Torque SpecificationsPart tightened
–SERVICE SPECIFICATIONS ClutchA–2
Input shaftRoller bearing journal diameter3rd gear journal diameter4th gear journal diameter5th gear journal diameterRunoutOutput shaftRoller bearing journal diameter1 st gear journal diameter2nd gear journal diameterRunoutGear thrust clearance
Pedal height (from asphalt sheet)Push rod play at pedal topPedal freepiayClutch release point (from pedal stroke end)Disc rivet head depthDisc runoutDiaphragm spring out of alignmentDiaphragm spring finger wear Depth WidthFlywheel runout
Clutch cover x FlywheelMaster cylinder set nutRelease cylinder set boltReservoir tank x Master cylinderClutch line unionBleeder plugRelease fork support
MANUAL TRANSAXLE (S51)Specifications
CLUTCHSpecifications
Torque SpecificationsPart tightened
–SERVICE SPECIFICATIONS Manual Transaxle (S51)A–2
Shift fork to hub sleeve clearanceSynchronizer ring to gear clearanceInput shaft snap ring thicknessNo.2 clutch hub
Gear oil clearance1 st, 2nd, 3rd & 4th
Output shaft snap ring thicknessNo.1 clutch hub
Specifications (Cont’d)
No.3 clutch hub
Rear bearing
5th
–SERVICE SPECIFICATIONS Manual Transaxle (S51)A–3
Transmission case x Transaxle caseTransmission case x Case coverTransmission case protectorRear bearing retainerOutput shaft front bearing lock plateInput shaft oil receiver5th driven gear lock nutReverse idler shaft lock boltControl shaft coverReverse shift arm bracketNo.3 shift fork x Shift fork shaft
Side bearing preioad (at starting)Side bearing adjusting shim thickness
Shift lever preloadShift lever seat shim thickness
Specifications (Cont’d)
Torque SpecificationsPart tightened
–SERVICE SPECIFICATIONS Manual Transaxle (S51)A–4
No. 1 lock ball assembly lock nutNo. 2 lock ball assemblyFiller plugDrain plugBack–up light switchSide bearing retainerClutch release bearing retainerStraight screw plug (Shit fork shaft)(Reverse restrict pinyTransaxle x Engine (10 mm bolt)(12 mm bolt)Left engine mountingDrive shaft center bearing bracketDrive shaft X Side gear shaftSteering knuckle x Lower armEngine mounting center member x BodyEngine mounting center member x Engine MountingEngine mounting center member x Lower crossmemberLower cross member x Body
Torque Specifications (Cont’d)
Part tightened
–SERVICE SPECIFICATIONS Manual Transaxle (S51)A–5
TRANSMISSION ASSEMBLYInput shaftRoller bearing journal diameter3rd gear journal diameter4th gear journal diameterRunoutOutput shaft1 st gear journal diameter2nd gear bushing diameterRunoutGear thrust clearance
Shift fork to hub sleeve clearanceSynchronizer ring to gear clearanceOil pump assemblyRotor body clearance
MANUAL TRANSAXLE (E56F5)Specifications
Input shaft snap ring thicknessNo.2 clutch hub
Gear oil clearance1 st and 4th gear
Rotor tip clearance
2nd and 3rd gear
Side clearance
5th gear
–SERVICE SPECIFICATIONS Manual Transaxle (E56F5)A–6
DIFFERENTIAL ASSEMBLYDifferential side bearing preload (at starting) New bearing Reused bearingNo. 1 case bushing inner diameter
Differential No. 1 case backlashFront differential case backlashDifferential No.2 case thrust clearanceFront differential case thrust clearanceThrust washer thicknessFor No. 1 case side gear
Input shaft snap ring thickness (cont’d)4th gear and rear bearing
Conical spring washer heightFor No. 1 case
Front case outer diameterNo. 1 case side
Specifications (Cont’d)
No–2 case bushing inner diameter
No.2 case side
For No.2 case
–SERVICE SPECIFICATIONS Manual Transaxle (E56F5)A–7
Shim thicknessFor differential side bearing preload
Thrust washer thickness (cont’d)For front case side gear
Specifications (Cont’d)
For No. 2 case and front case
For No–2 case side gear
–SERVICE SPECIFICATIONS Manual Transaxle (E56F5)A–8
TRANSFER ASSEMBLYRing gear runoutRing gear mounting case runoutRing gear backlashDriven pinion preload (at starting)
Shim thickness (cont’d)For differential side bearing preload (cont’d)
Transfer total prreload (at starting)(Add driven pinion preload)
Specifications (Cont’d)
Adjusting shim thicknessFor ring gear backlash
–SERVICE SPECIFICATIONS Manual Transaxle (E56F5)A–9
Oil pump x CoverRing gear x Differential caseRing bearing retainer x Transmission caseTransmission case x Transaxfe caseOil pump assembly x Transaxle caseShift fork x ShaftOil pipe X HousingTransmission case x Transmission case coverShift and select lever shaft assembly xTransmission caseBelicrank x Transmission caseBack–up light switch X Transmission caseDriven pinion x Bearing cageRing gear x Ring gear mounting caseDriven pinion cage x Transfer caseTransfer left case x Transfer right caseTransfer left case x Inspection hole coverDifferential lock sleeve x Shift forkTransfer right case x Transfer case coverDriven pinion cage x Extension housingExtension housing x Dynamic damperTransaxle assembly x Transfer assemblyDifferential lock indicator switch X Transfer left caseOutput shaft assembly x Lock nutTransfer left case x Plug (Large)Transfer left case x Plug (Small)Transmission case x PlugTransfer left case X Drain plugReverse idler gear retaining boltOil cooler pipe elbow X TransaxleOil cooler pipe x Elbow
Specifications (Cont’d)
Adjusting shim thickness (cont’d) For tooth contact
Torque Specifications
Part tightened
–SERVICE SPECIFICATIONS Manual Transaxie (E56F5)A–10
Shift and select lever X Transmission caseLock bolt x Transmission caseEngine front mounting X TransaxleStiffener plateEngine rear end plateEngine mounting left bracket x TransaxleTransfer right case x Actuator bracketTransaxle assembly x Engine
Input shaft _3rd and 4th gear journal diameter5th gear journal diameterRunoutOutput shaftRoller bearing journal diameter1 st and 2nd gear journal diameterRunoutGear thrust clearance
MANUAL TRANSAXLE (E52)Specifications
Shift fork to hub sleeve clearanceSynchronizer ring to gear clearaneOutput shaft bearing preload (at starting)
Torque Specifications (Cont’d)
Gear oil clearance1 st and 4th
Part tightened
Reverse idler
2nd and 3rd
5th
–SERVICE SPECIFICATIONS Manual Transaxle (E56F5)A–11
Shift and select lever X Transmission caseLock bolt x Transmission caseEngine front mounting X TransaxleStiffener plateEngine rear end plateEngine mounting left bracket x TransaxleTransfer right case x Actuator bracketTransaxle assembly x Engine
Input shaft _3rd and 4th gear journal diameter5th gear journal diameterRunoutOutput shaftRoller bearing journal diameter1 st and 2nd gear journal diameterRunoutGear thrust clearance
MANUAL TRANSAXLE (E52)Specifications
Shift fork to hub sleeve clearanceSynchronizer ring to gear clearaneOutput shaft bearing preload (at starting)
Torque Specifications (Cont’d)
Gear oil clearance1 st and 4th
Part tightened
Reverse idler
2nd and 3rd
5th
–SERVICE SPECIFICATIONS Manual Transaxle (E52)A–11
Tight plug drive in depthControl shaft cover oil seal drive on depthInput shaft snap ring thicknessNo. 2 clutch hub
Speedometer driven gear oil seal drive in depthOil pumpBody clearance
Output shaft snap ring thicknessNo. 1 clutch hub
Specifications (Cont’d)Side bearing preload (at starting)
Input rear bearing
Side clearance
Tip clearance
–SERVICE SPECIFICATIONS Manual Transaxle (E52)A–12
Differential pinion to side gear backlashDifferential runoutDifferential side gear thrust washer thickness
Output shaft snap ring thickness (cont’d)No. 3 clutch hub
Output shaft rear bearing adjusting shim thickness
Specifications (Cont’d)
–SERVICE SPECIFICATIONS Manual Transaxle (E52)A–13
Transaxle case X Transaxle case receiverTransaxle case x Transmission caseTransaxle case x Case coverTransaxle case x Oil pumpTransmission case x Case coverTransmission case x Rear bearing retainerOil pump x CoverShift and select lever lock boltReverse shift arm bracketStraight screw plugReverse restrict pin holderRing gear X Differential caseDifferential case No. 1 X No. 25th driven gear lock nutReserse idler shaft lock boltControl shaft x Lock boltShift fork X Lock boltBack–up light switchFiller plugDrain plugElbow X Transaxie
Differential side bearing adjusting shim thickness
Specifications (Cont’d)
Torque Specifications
Part tightened
–SERVICE SPECIFICATIONS Manual Transaxle (E52)A–14
Transaxle X Engine 12 mm bolt10 mm bolt
Transaxle X Engine front mountingInsulator x Engine front mountingTransaxle X Stiffener plateTransaxle X Engine mounting left stayEngine left mounting x Left stayEngine mounting bracket X Body bracketTransaxle x Rear end plateTransaxle x Case protectorLower arm x BodyStabilizer bar x BodyDrive shaft X Side gear shaftBall joint X Steering knuckleTie rod end x Steering knuckleDrive shaft x Axle hubCenter member x BodyCenter member X Engine mountingLower crossmember X BodyClutch release cylinder x Transaxle
oil cooler tube x ElbowSelecting bellcrank set boltTransaxle X Engine
Specifications (Cont’d)
Part tightened
–SERVICE SPECIFICATIONS Manual Transaxle (E52)A–15
Line pressure (wheel locked)Engine idling
At stall (Throttle valve fully opened)Engine stall revolution
Time lagEngine idle speed (A/C OFF)Throttle cable adjustment (Throttle valve fully opened)
* O/D main switch OFFNOTE:(1) In the 2 and L ranges, all stages lock–up is OFF.(2) In the following cases, the lock–up will be released regardless of the lock–up pattern.• When the throttle is completely closed.
• When the brake light switch is ON.
Body clearanceTip clearanceSide clearancePump body bushing inside diameterStator shaft bushing inside diameter
AUTOMATIC TRANSAXLE (A140E)Specifications
Throttle valve fully open [ ] Fully closed
Piston strokePiston rod length
Throttle valve opening 5 %
Secondcoast brake
km/h (mph)Shiftschedule
Lock–uppoint Lock–up OFF
km/h (mph)
Lock–up ON
NORMP’WR
NORMPWR
Oil pump
D range
D range
2 range
L range
NORM
NORM
O/DO/D
PWR
PWR
2nd 3rd 2nd 3rd
–SERVICE SPECIFICATIONS Automatic Tiransaxle Al 40E)A–16
(Upper valve body)Throttle modulator valveAccumulator control valveLow coast modulator valveDown shift plug2nd coast modulator valveThrottle valveCut–back valveLock–up relay valve
(Lower valve body)Primary regulator valve1–2 shift valve2–3 shift valve3–4 shift valveLock–up signal valveSecondary regulator valvePressure relief valveCooler by–pass valve
Planetary pinion gear thrust clearance
Ring gear flange bushing inside diameter
Piston strokeDrum bushing inside diamaterFlange thickness
Direct clutch piston strokeDirect clutch bushing inside diameter
Planetary pinion gear thrust clearance
Planetary pinion gear thrust clearance
Specifications (Cont’d)
Piston strokeFlange thickness
Counter drive gear preload
Coil outerdiametermm (in.)
Rear plane-tary gear
Front plane-tary gear
Free lengthmm (in.)
Valve bodyspring
Overdriveunit
TotalNo. ofcoifs
Forwardclutch
Direct clutch
Spring Color
–SERVICE SPECIFICATIONS Automatic Transaxle (Al 40E)A–17
(Lower valve body)Primary regualtor valve2–3 shift valve1–2 shift valve3–4 shift valveSecondary regulator valveLock–up signal valve
(Upper valve body)Throttle modulator valveAccumulator control valveCut–back valveLock–up relay valve2nd coast modulator valve
Pinion to side gear backlashSide gear thrust washer thickness
Side bearing adjusting shim thickness
Specifications (Cont’d)
Drive pinion preload (at starting)
Total preload (at starting)
Coil outerdiameter mm(in.)
Accumulatorspring
Free lengthmm (in.)
Valve bodyRetainer
Thickness(mm (in.)
TotalNo. ofcoils
Height mm(in.)
Widthmm (in.)
Differential
Retainer
Spring Color
–SERVICE SPECIFICATIONS Automatic Transaxle (A140E)A–18
Drive plate x Crank shaftTorque converter X Drive plateOil pump x Transaxle caseOil pump body X Stator shaftSecond coast brake band guideUpper valve body x Lower valve bodyValve bodyAccumulator coverOil strainerOil panOil pan drain plugCooler pipe union nutTesting plugParking lock pawl bracketOverdrive case x Transaxle caseNeutral start switch boltNeutral start switch nut
Side bearing adjusting shim thickness(cont’d)
Specifications (Cont’d)
Torque Specifications
Transaxle case x Engine
Differential(cont’d)
Part tightened
–SERVICE SPECIFICATIONS Automatic Transaxle (Al 40E)A–19
At stall(Throttle valve fully opened)Engine stall revolutionTime lag N range –N range –Engine idling speed (A/C OFF)Throttle cable adjustment (Throttle valve fully opened)
*1 3 – O/D up–shift point with closed accelerator pedal is at 32 – 45 km/h (20 – 28 mph).*2 Lock–up ”ON” point with closed accelerator pedal is at 64 – 73 km/h (40 – 45 mph).*3 Lock–up ”OFF” point with closed accelerator pedal is at 60 – 68 km/h (37 – 42 mph).*4 O/D – 3 down–shift is possible up to maximum speed.
Governor pressureDrive pinion rpm1,0001,8003,500Line pressure (wheel locked)Engine idling
AUTOMATIC TRANSAXLE (A140L)Specifications
Same the A140E automatic transaxle specifications (seepage A–16)
Same the A140E automatic trransaxle specifications (see page A– 17)
D range (throttle valve fully open)
(Vehicle speed reference)
Rear plane-tary gear
Frontplanetarygear
Differentialgear ratio
Second coastbrake
Overdriveunit
Shiftschedule
Forwardclutch
km/h (mph)
Directclutch
Oil pump
L range
3.736
–SERVICE SPECIFICATIONS Automatic Transaxle (A140L)A–20
(Lower valve body)Secondary regulator valveLow coast shift valveO/D sequence valveIntermediate shift valve3–4 coast shift valve3–4 shift valve2–3 shift valve.Detent regulator valve1–2 shift lower valvePrimary regulator valve
(Lower valve body)Primary regulator valve1–2 shift valveDetent regulator valve2–3 shift valve3–4 coast shift valveLock–up signal valveO/D sequence valveSecondary regulator valvePressure relief valveCooler by–pass valve
(Upper valve body)Throttle modulator valveAccumulator control valveLow coast modulator valveDown shift plug2nd coast modulator valveThrottle valveLock–up relay valve
(Upper valve body)Throttle modulator valveAccumulator control valveCut–back valveLock–back relay valve2nd coast modulator valve
Torque SpecificationsSame the A140E automatic transaxle. (See page A–19)
Same the A140E automatic transaxle (See page A–18)
Specifications (Cont’d)Coil outerdiametermm (in.)
Accumulatorspring
Free lengthmm (in.)
Valve bodyspring
Thicknessmm (in.)
Valve bodyretainer
TotalNo. ofcoils
Height mm(in.)
Widthmm (in.)
Differential
Color
Retainer
Spring
–SERVICE SPECIFICATIONS Automatic Transaxle (A140L)A–21
Line pressure (wheel locked)Engine idling
At stallEngine stall revolutionTime lag N range –
N range –Engine idle speed (A/C OFF)Throttle cable adjustment (Throttle valve fully opened)
Body clearanceTip clearanceSide clearancePump body bushing inside diameterStator shaft bushing inside diameterFront sideRear side
AUTOMATIC TRANSAXLE (A540E)Specifications
Between boot end face and inner cable stopper
Throttle valve fully open [Fu lly closed]
Piston strokePiston rod length
Throttle valve opening 5%
Secondcoast brake
* O/D switch OFF
Shiftschedule
Lock–uppoint
km/h (mph)
Lock–up OFF
km/h (mph)
Lock–up ON
NORMPWR
NORMPWR
Oil pump
D range
D range
2 range
L range
NORM
NORM
PW R
PWR
–SERVICE SPECIFICATIONS Automatic Transaxle (A540E)A–22
(Lower valve body)Pressure relief valveCheck valveSecondary regulator valveNo. 2 accumulator control valveSecond lock valve3–4 shift valveLow coast modulator valve1–2 shift valve2–3 shift valvePrimary regulator valve
(Upper valve body)Second coast modulator valveB, orifice control valveDown–shift plugThrottle valveThrottle modulator valveCut–back vaIveNo. 1 accumulator control valveLock–up relay valve
Piston strokeDrum bushing inside diamaterrFlange thickness
Sun gear bushing inside diameterRing gear flange bushing inside diameter
Counter drive gear preloadPlanetary pinion gear thrust clearance
Direct clutch piston strokeDirect clutch bushing inside diameter
Planetary pinion gear thrust clearance
Planetary pinion gear thrust clearance
Specifications (Cont’d)
Piston strokeFlange thickness
Coil outerdiameter mm(in.)
Rearplanetarygear
Frontplanetarygear
Forwardclutch
First and reversebrake
Free lengthmm (in.)
Valve bodyspring
Overdriveunit
TotalNo. ofcoils
Pack clearance
Direct clutch
Spring Color
–SERVICE SPECIFICATIONS Automatic Transaxle (A540E)A–23
(Lower valve body)Primary regulator valveSecondary regulator valveNo. 2 accumulator control valveSecond lock valveLow coast modulator valve1–2 shift valve2–3 shift valve3–4 shift valve
(Upper valve body)Lock–up relay valveThrottle modulator valveSecond coast modulator valveCut–back valveNo. 1 accumulator control valveB, orifice contron valve
Pinion to side gear backlashSide gear thrust washer thickness
Specifications (Cont’d)
Side bearing adjusting shim thickness
Drive pinion preload (at startin )
Total preload (at starting)
Coil outerdiameter mm(in.)
Accumulatorspring
Free lengthmm (in.)
Valve bodyretainer
Thickness(mm (in.)
TotalNo. ofcoils
Widthmm (in.)
Height mm(in.)
Differential
Retainer
Spring Color
–SERVICE SPECIFICATIONS Automatic Transaxle (A540E)A–24
Oil cooler pipe unionOil panValve body x Transaxte caseAccumulator x CoverOil pump x Transaxle caseO/D case X Transaxle caseDifferential LH side bearing retainerDifferential RH retainerDifferential carrier coverOil pump body x Stator shaftUpper valve body x Lower valve bodyDifferential left case x Right caseRing gear x Differential case
Specifications (Cont’d)
Torque Specifications
Side bearing adjusting shimthickness (cont’d)
Differential(cont’d)
Part tightened
–SERVICE SPECIFICATIONS Automatic Transaxte (A540E)A–25
Line pressure (wheel locked)Engine idling
At stall
Engine stall revolutionTime lag
Engine idle speed (A/C OFF)Throttle cable adjustment (Throttle valve fully opened)
AUTOMATIC TRANSAXLE (A540H)Specifications
Center differential control pressure (D range)
Throttle valve fully open [Fully closed]
Throttle valve opening 5%
* O/D switch OFF
Shiftschedule
Engine R.P.M.
Lock–uppoint
Solenoid valve
km/h (mph)
Lock–up OFF
km/h (mph)
Lock–up ON
PressureNo. 2No. 1
–SERVICE SPECIFICATIONS Automatic Transaxle (A540H)A–26
Drive pinion preload (at staring)New bearingReused bearingTotal preload (at starting)New bearingReused bearingPinion to side gear backlashSide gear thrust washer thickness
Piston strokeDrum bushing inside diameter MaximumFlange thinkness
Same the A540E automatic transaxle (See page A–22)
Same the A540E automatic transaxie (See page A–24)
Same the A540E automatic transaxle (See page A–23)
Same the A540E automatic transaxle (See page A–23)
Specifications (Cont’d)
Side bearing adjusting shim thickness
Accumulatorspring
First and reversebrake
Front planetarygear
Second coastbrake
Rear planetarygear
Valve bodyspring
Valve bodyretainer
Over driveunit
Pack clearance
Forwardclutch
Direct clutch
Differential
Oil pump
–SERVICE SPECIFICATIONS Automatic Transaxle (A540H)A–27
Driven pinion preload (at starting)Total preload (at starting)Ring gear backlashDriven pinion bearing cageDriven pinion preload (at starting)New bearingReused bearingCenter differential side gear backlashCenter differential left side gearthrust washer thickness
Center differential side gear thrustclearanceCenter differential right side gearthrust washer thickness
Transfer clutch modulator valveNo. 2 low–high shift valveNo. 1 low–high shift valve
Side bearing adjusting shimthickness leont’dy
Specifi cations (Cont’d)
Transfer lower valve body springCoil outerdiameter mm(in.)
Differential end play
Free lengthmm (in.)
Differential(cont’d)
TotalNo. ofcoils
Transfer
Color
–SERVICE SPECIFICATIONS Automatic Transaxle (A540H)A–28
Oil cooler pipe union and elbowOil panValve body x Transaxle caseAccumulator x Cover
Transfer clutch modulator valveNo. 2 low–high shift valveNo. 1 low–high shift valve
Specifications (Cont’d)
Torque Specifications
Transfer lower valve body retainer
Center differential plate washer
Ring gear adjusting shim
Thicknessmm (in.)
Transfer(cont’d)
Heightmm (in.)
Widthmm (in.)
Part tightened
–SERVICE SPECIFICATIONS Automatic Transaxle (A540H)A–29
Oil pump X Transaxle caseO/D case x Transaxle caseDifferential LH side bearing retainerDifferential carrier coverOil pump body x Stator shaftUpper valve body x Lower valve bodyFront differential right case x Front differential left caseRing gear X Ring gear mounting caseTransfer right case retainer x Transfer right caseTransfer right case X Adjusting nut lock plate lock boltTransfer right case x Transfer left caseTransfer right case x Mode select lever and rodTransfer right case x Oil strainerTransfer left case X Rear wheel speed sensorTransfer left case X Transfer inspection hole coverTransfer left case x Drain plugTransfer left case x Driven pinion bearing cageDriven pinion bearing cage x Transfer extension housingTransfer extension housing X Dynamic damperTransfer right case x Oil pump coverTransfer ring gear X Ring gear mounting caseCenter differential control solenoid x Transfer valve bodyTransfer valve body x Transfer left caseNeutral start switch boltNeutral start switch nutTransfer assembly X Transaxle case
Propeller shaft x DifferentialIntermediate shaft x Propeller shaftCenter support bearing x BodyIntermediate shaft x Center bearing x Joint flange
Bearing axial playFront propeller shaft runoutIntermediate shaft runoutRear propeller shaft runoutIntermediate shaft flange runout
PROPELLER SHAFTSpecifications
Torque Specifications (Cont’d)
Torque Specifications
Cross groove joint set bolt
Part tightened
Part tightened
–SERVICE SPECIFICATIONS Automatic Transaxle (A540H)A–30
Oil pump X Transaxle caseO/D case x Transaxle caseDifferential LH side bearing retainerDifferential carrier coverOil pump body x Stator shaftUpper valve body x Lower valve bodyFront differential right case x Front differential left caseRing gear X Ring gear mounting caseTransfer right case retainer x Transfer right caseTransfer right case X Adjusting nut lock plate lock boltTransfer right case x Transfer left caseTransfer right case x Mode select lever and rodTransfer right case x Oil strainerTransfer left case X Rear wheel speed sensorTransfer left case X Transfer inspection hole coverTransfer left case x Drain plugTransfer left case x Driven pinion bearing cageDriven pinion bearing cage x Transfer extension housingTransfer extension housing X Dynamic damperTransfer right case x Oil pump coverTransfer ring gear X Ring gear mounting caseCenter differential control solenoid x Transfer valve bodyTransfer valve body x Transfer left caseNeutral start switch boltNeutral start switch nutTransfer assembly X Transaxle case
Propeller shaft x DifferentialIntermediate shaft x Propeller shaftCenter support bearing x BodyIntermediate shaft x Center bearing x Joint flange
Bearing axial playFront propeller shaft runoutIntermediate shaft runoutRear propeller shaft runoutIntermediate shaft flange runout
PROPELLER SHAFTSpecifications
Torque Specifications (Cont’d)
Torque Specifications
Cross groove joint set bolt
Part tightened
Part tightened
–SERVICE SPECIFICATIONS Propeller ShaftA–30
Wheel lateral runoutTie rod end left–right errorHub bearing axial direction playBall joint vertial playBall joint rotation conditionDrive shaft standard length(FWD/SV21 /TOYOTA type/LH)(FWD/SV21 /TOYOTA type/RH)(FWD/SV21 /GKN type/LH)(FWD/SV21 /GKN type/RH)( FVIJD/VZV21)(4WD/M/T/LH)(4WD/A/T/LH)(4WD/M/T/RH)
FRONT AXLE AND SUSPENSIONSpecifications
Wheel angle(FWD/SV21 and 4WD)(FWD/VZV21)
(FWD/SV21 and 4WD)( FWD/VZV21)
Less than 3.0 mm/m (0.118 in./3.3 ft)
(FWD/SV21 )(4WD)(F1ND/VZV21 )
Front axleand suspension
Chassis groungclearance
Steering axis inclination
Cold tireinflationpressure
Front wheelalignment
Outside wheel (Max.)Inside wheel (Max.)
Adjustment STDInspection STD
Side slip
Camber
Caster
Toe–in
–SERVICE SPECIFICATIONS Front Axle and SuspensionA–31
Tie rod end lock nutShock absorber X Steering knuckle Tie rod end x Steering knuckleBall joint x Lower suspension armDisc brake caliper X Steering knuckleHub bearing lock nutCenter drive shaft bearing lock nutBall joint x Steering knuckleDrive shaft x Side gear shaft (FWD/VZV21 and 4WD)Drive shaft x Center drive shaft (FWD/VZV21) ,Center drive shaft bearing bracket installation bolt(FWD 1)Drive shaft bearing bracket bolt (GKN)(TOYOTA)Drive shaft bearing bracket x Bracket stayPiston rod x Suspension supportSuspension support x BodyDisc brake hose union boltSuspension lower crossmember x BodyStabilizer bar x Lower suspension armLower arm shaft x Lower suspension armLower arm shaft x BodyStabilizer bar bracket x BodyEngine center mounting member X BodyEngine center mounting member x Engine mountings
Torque SpecificationsPart tightened
–SERVICE SPECIFICATIONS Front Axle and SuspensionA–32
Limit Lateral runout Radial runoutRing gear installing temperatureDrive pinion oil seal drive in depthSide gear oil seal drive in depthSide gear thrust washer thickness
Drive pinion bearing preload at StartingNew bearingReused bearing
Drive pinion to ring gear backlashPinion gear to side gear backlashRing gear runoutCompanion flange runout
REAR AXLE AND SUSPENSIONSpecifications
Camber (FWD /Sedan)(FWD/Wagon)(4WD)Left–right error
Wheel lateral runoutHub bearing axial direction
(FWD/SV21 and 4WD)(FWD/VZV21)
(FWD SV21)(4WD)(FIND/¿¿V21)
(FWD/SV21)(FWD/VZV21)(4WD)
Rear axleand suspension
Chassis groundclearance
Cold tireinflationpressure
Rear wheelalignment
Adjustment STDInspection STD
Total preloacf at Starting
Differential
Wagon
Toe–in
Sedan
–SERVICE SPECIFICATIONS Rear Axle and SuspensionA–33
Specifications (Cont’d)
Drive pinion adjusting plate washer thickness
Side bearing adjusting plate. thickness
Differential(cont’d)
–SERVICE SPECIFICATIONS Rear Axle and SuspensionA–34
Axle bearing lock nutAxle carrier x Shock AbsorberAxle hub x Axle carrierStrut rod X Axle carrierNo. 1 and No. 2 suspension arm x Axle carrierDrive shaft x ’Side gear shaftPiston rod X Suspension supportSuspension support x BodyNo. 1 suspension Arm x BodyNo. 2 suspension arm x BodyStrut rod X BodyStabilizer bar X Stabilizer bar linkShock absorber X Stabilizer bar linkStabilizer bar bracket x BodyFuel tank band X BodyHub nut
Carrier x Carrier coverCarrier X Drain plugCarrier x Filler plugCarrier x Side bearing capRing gear x Differential caseDrive pinion x Companion flageCompanion flange x Propeller shaft
(4WD)Differential x Support member
Torque Specifications
Part tightened
–SERVICE SPECIFICATIONS Rear Axle and SuspensionA–35
Pedal height (from asphalt sheet)Pedal freeplayPedal reserve distance at 50 kg (110.2 lb, 490 N
Lever travel at 20 kg 144.1 Ib, 196 N)Clearance between rear shoe and leverParking brake shoe lever shim thickness
Lever travel at 20 kg (44.1 Ib, 196 N)Shoe to parking brake shoe lever clearanceParking brake shoe lever shim thickness
BRAKE SYSTEMSpecifications
Booster push rod to piston clearance w/SST
Disc runoutPad thickness
Parking brake(Drum)
Parking brake(Disc)
Rear disc inner diameter
Drum to shoe clearance
Drum inside diameter
Rear brake(Disc)
Rear brake(Drum)
Lining thickness
Brake booster
Limit thickness
Disc thickness
Disc thickness
Pad thickness
Brake pedal
Discrrunout
Front brake
–SERVICE SPECIFICATIONS Brake SystemA–36
Master cylinder X Piston stopper boltMaster cylinder x ReservoirMaster cylinder x Brake boosterBrake tube union nutBrake booster clevis lock nutBrake booster x Pedal bracketFront disc brake cylinder installation boltFront disc brake torque plate X Steering knuckleFront disc brake cylinder x Flexible hoseRear drum brake wheel cylinder x Backing plateParking brake cable bracket x Backing plateBleeder plugRear disc brake cylinder installation boltRear disc brake torque plate X Dust coverRear disc brake cylinder X Flexible hoseRear disc brake main pin x Torque plateRear disc brake torque plate x Rear axle carrierA.B.S. actuator x Proportioning valve bracket (w/o LSPV)A.B.S. actuator x 3–way union (w/ LSPV)Proportioning valve installation bolt (w/o LSPV)A.B.S. actuator x 3–way unmionA.B.S. actuator bracket x Body
Rear axle hub installation boltDeceleration sensor x Computer bracketA.B.S. computer x Computer bracketA.B.S. computer bracket x Body
Front speed sensor installation boltFront sensor rotor x Axle hubRear speed sensor installation bolt
Torque Specifications
Part tightened
–SERVICE SPECIFICATIONS Brake SystemA–37
PS pump rotating torqueSteering rack runoutControl valve bearing preload
STEERINGSpecifications
Steering effortRotor shaft bushing oil clearance
Steering wheel freeplayCollar No. 1 outer diameter
Vane plate length Rotor and cam ring mark
Maximum rise of oil levelOil pressure at idle speed
Vane plate to rotor groove clearance
Flow control valve spring length
Collar No. 2 outer diameter
Support shim thickness
Drive belt tension
Steeringcolumn
Power steering
Total preload
Vane plate
–SERVICE SPECIFICATIONS SteeringA–38
Tie rod end x Knuckle armLower crossmemberPressure port union X Front housingSuction port union X Front housingPS pump shaft x Drive pulleyControl valve housing X Cylinder housingBearing guide lock nutRack guide spring cap lock nutRack x Rack endTurn pressure tube x Gear housingGear housing X Pressure and return lineUniversal jointGear housing X BodyEngine rear mount bracket
Upper tube x Upper bracketTilt lever retainer x Breakaway bracketSerration boltUpper bracket x Column cover supportColumn tube x Breakaway bracketMain shaft X Intermediate shaftColumn tube X Thrust stopperBreakaway bracket x BodyColumn tube x BodyColumn support bolt .Universal jointSteering wheel x Main shaft
PS pump x Pressure tubeControl valve housing X Cylinder housingBearing guide lock nutRack guide spring cap lock nutRack x Rack endTurn pressure tube x Gear housingGear housing x BodyPressure tube x Gear housingReturn tube x Gear housingTie rod end X Knuckle armTie rod end lock nut
Pressure port union X Front housingSuction port union x Front housingAir control valve x Front housingPS pump shaft x Drive pulleyPS pump x Pump bracket
PS pump x Pressure hosePressure hose x Flexible nutPS pump x Bracket
Torque Specifications
Power steering(2WD/SV21 )
Power steering(2WD/VZV21)
Steeringcolumn
Part tightened
–SERVICE SPECIFICATIONS SteeringA–39
Rear pump stay X Pump bracketLower crossmemberPressure hose X Pressure tubeControl valve housing X Cylinder housingBearing guide lock nutRack –guide spring cap lock nutRack X Rack endTurn pressure tube x Gear housingGear housing X BodyEngine rear mount bracketGear housing X Return lineGear housing X Pressure lineCenter member x BodyUniversal jointTie rod end lock nutPropeller shaft x Intermediate shaftFront exhaust pipe
Pressure port union x Front housingSuction port union x Front housingPS pump shaft X Drive pulleyPS pump x Pressure hosePS pump x Bracket
Torque Specifications (Cont’d)Power steering(2WD/VZV21 )(cont’d)
Power steering(4WD)
Front exhaust pipe
Center member
Part tightened
–SERVICE SPECIFICATIONS SteeringA–40
Front SeatSeat back x Seat adjusterSeat cushion x Seat– adjusterSeat adjuster x BodyRear Seat (Sedan Fixed Type)Seat back x Body .Rear Seat (Sedan Separate Type)Seat back side hinge x Seat backSeat back side hinge x BodySeat back center hinge x Seat backSeat back center hinge x BodySide seat back x Body Rear Seat (Station Wagon)Seat back side hinge x Seat backSeat back side hinge x BodySeat back center hinge x Seat backSeat back center hinge x BodySide seat back x BodySeat cushion x BodyFront Seat Belt (w/Automatic Shoulder Belt)Guide rail x BodyShoulder belt x Guide railELR x Parking brake bracketInner lap belt x BracketOuter lap belt x BodyBracket x SeatSlide anchor plate x Belt anchor baseBelt anchor base x BodyFront Seat Belt (w/o Automatic Shoulder Belt)Shoulder belt anchor x BodyShoulder belt lower side x BodyELR upper side x BodyInner belt x BracketBracket x SeatSlide anchor plate x Belt anchor baseBelt anchor base x BodyRear Seat BeltShoulder belt anchor x BodyShoulder belt lower side x BodyELR x Body (Sedan)ELR upper side x Body (Station Wagon)ELR lower side x Body jStation Wagon)Inner seat belt x BodyCRS tether anchor x Body
BODYTorque Specifications
Part tightened
–SERVICE SPECIFICATIONS BodyA–41
Transaxle oil E50 (08885–80206) orequivalentRecommended oilOil grade: AN GL–5Viscosity : SAE 75W–90 or 80W–90SA E 90W[above –18°C (0°F)]SAE 80W[below –18°C (0°F)]
Transaxle oil E50 (08885–80206) orequivalentRecommended oilOil grade: API GL–5Viscosity : SAE 75W–90 or 80W–90SAE 90W[above –18°C (0°F)]SAE 80W[below –18°C (0°F)]
API grade GL–5Hypoid gear oilViscosity: Above –18°C (0°F) SAE 90Below –18°C (0°F) SAE 80W–90
Differential oil(w/ Automatic transaxle)SV21 seriesVZV21 series
Molybdenum disulphide lithium base,NLGI No. 2
Automatic transaxlefluid(w/o Differential oil)
ATF type T (08886–00405) or equivalent
Al 40EDry fillDrain and refill
Al 40LDry fillDrain and refill
A540HDry fillDrain and refill
A540EDry fillDrain and refill
E56F5(w/ Differential andtransfer)
API GL–4 or GL–5SAE 75W–90 or 80W–90
Lithium base multipurpose, NLGI No. 2
SAE J 1703 or FMVSS No. 116, DQT3
S51(w/ Differential oil)
Steering gear housing grease
Manualtransaxle oil
Wheel bearing grease
Transfer oil (A540H)
Power steering fluid
LUBRICANT
800cc 48.8 cu in.
Rear differential oil
ATF DEXRON II
ATF DEXRON 11
Classification
Brake fluid
Capacity
Imp. qtsUS qtsLitersItem
E52
ATF DEXRON II
ATF DEXRON II
–SERVICE SPECIFICATIONS LubricantA–42