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Service Specification

The document provides service specifications for standard bolts, vehicle maintenance, engine torque values, and engine component measurements for a Toyota 5S-FE engine. It includes specifications for bolt torque values, compression pressures, valve clearances, piston and bearing sizes, crankshaft clearances, and other engine part dimensions and tolerances. The specifications are intended to guide maintenance and repair of the vehicle and engine.

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Loc Truong

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0% found this document useful (0 votes)

263 views

Service Specification

Uploaded by

Loc Truong

Available Formats

Download as PDF, TXT or read online on Scribd

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SS1

SERVICE SPECIFICATIONS STANDARD BOLT

STANDARD BOLT
SS0ZS01

HOW TO DETERMINE BOLT STRENGTH

Bolt Type Hexagon Head Bolt Normal Recess Bolt Deep Recess Bolt Stud Bolt Weld Bolt Class

4
No Mark No Mark No Mark

6
w/ Washer w/ Washer

10T

11T

B06431

Author :

Date :

164

SS2
SERVICE SPECIFICATIONS STANDARD BOLT
SS0ZT01

SPECIFIED TORQUE FOR STANDARD BOLTS

Specified torque Class Diameter mm 6 8 10 12 14 16 6 8 10 12 14 16 6 8 10 12 14 16 6 8 10 12 14 16 8 10 12 8 10 12 8 10 12 8 10 12 Pitch mm Nm 1 1.25 1.25 1.25 1.5 1.5 1 1.25 1.25 1.25 1.5 1.5 1 1.25 1.25 1.25 1.5 1.5 1 1.25 1.25 1.25 1.5 1.5 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 5 12.5 26 47 74 115 6.5 15.5 32 59 91 140 8 19 39 71 110 170 10.5 25 52 95 145 230 29 61 110 34 70 125 38 78 140 42 87 155 Hexagon head bolt kgfcm 55 130 260 480 760 1,150 65 160 330 600 930 1,400 80 195 400 730 1,100 1,750 110 260 530 970 1,500 2,300 300 620 1,100 340 710 1,300 390 800 1,450 430 890 1,600 ftlbf 48 in.lbf 9 19 35 55 83 56 in.lbf 12 24 43 67 101 69 in.lbf 14 29 53 80 127 8 19 38 70 108 166 22 45 80 25 51 94 28 58 105 31 64 116 Nm 6 14 29 53 84 7.5 17.5 36 65 100 9 21 44 80 125 12 28 58 105 165 33 68 120 37 78 140 42 88 155 47 97 175 Hexagon flange bolt kgfcm 60 145 290 540 850 75 175 360 670 1,050 90 210 440 810 1,250 120 290 590 1,050 1,700 330 690 1,250 380 790 1,450 430 890 1,600 480 990 1,800 ftlbf 52 in.lbf 10 21 39 61 65 in.lbf 13 26 48 76 78 in.lbf 15 32 59 90 9 21 43 76 123 24 50 90 27 57 105 31 64 116 35 72 130

10T

11T

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165

SS3
SERVICE SPECIFICATIONS STANDARD BOLT
SS0ZU01

HOW TO DETERMINE NUT STRENGTH

Nut Type Present Standard Hexagon Nut Old Standard Hexagon Nut Cold Forging Nut Cutting Processed Nut Class

4N
No Mark

5N (4T)
No Mark (w/ Washer) No Mark (w/ Washer) No Mark

6N
6N

7N (5T) *

8N
8N

10N (7T)
10N

No Mark

11N
11N

12N
12N

*: Nut with 1 or more marks on one side surface of the nut.

HINT: Use the nut with the same number of the nut strength classification or the greater than the bolt strength classification number when tightening parts with a bolt and nut. Example: Bolt = 4T Nut = 4N or more
Author : Date : 166

B06432

SS4
SERVICE SPECIFICATIONS MAINTENANCE

MAINTENANCE
SS07401

SERVICE DATA
Front axle and suspension Ball joint vertical play Maximum 0 mm (0 in.)

Author :

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167

SS5
SERVICE SPECIFICATIONS MAINTENANCE
SS07501

TORQUE SPECIFICATION
Part tightened Front seat mount bolts Front suspension member x Body Rear suspension member x Body Nm 37 181 51 kgfcm 375 1,850 520 ftlbf 27 134 38

Author :

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168

SS6
SERVICE SPECIFICATIONS ENGINE MECHANICAL (5SFE)

ENGINE MECHANICAL (5SFE)

SS0AD03

SERVICE DATA
Compression pressure at 250 rpm STD 1,226 kPa (12.5 kgf/cm2, 178 psi) or more Minimum 981 kPa (10.0 kgf/cm2, 142 psi) Difference of pressure between each cylinder 98 kPa (1.0 kgf/cm2, 14 psi) or less at cold Intake Exhaust Mark 2.500 Mark 2.550 Mark 2.600 Mark 2.650 Mark 2.700 Mark 2.750 Mark 2.800 Mark 2.850 Mark 2.900 Mark 2.950 Mark 3.000 Mark 3.050 Mark 3.100 Mark 3.150 Mark 3.200 Mark 3.250 Mark 3.300 0.19 0.29 mm (0.007 0.011 in.) 0.28 0.38 mm (0.011 0.015 in.) 2.500 mm (0.0984 in.) 2.550 mm (0.1004 in.) 2.600 mm (0.1024 in.) 2.650 mm (0.1043 in.) 2.700 mm (0.1063 in.) 2.750 mm (0.1083 in.) 2.800 mm (0.1102 in.) 2.850 mm (0.1122 in.) 2.900 mm (0.1142 in.) 2.950 mm (0.1161 in.) 3.000 mm (0.1181 in.) 3.050 mm (0.1201 in.) 3.100 mm (0.1220 in.) 3.150 mm (0.1240 in.) 3.200 mm (0.1260 in.) 3.250 mm (0.1280 in.) 3.300 mm (0.1299 in.) 8 12 BTDC @ idle 700 50 rpm 42.0 mm (1.654 in.) 32 37 N (3.25 3.75 kgf, 7.2 8.3 lbf)

Valve clearance Adjusting shim (for repair part)

Ignition timing Idle speed Idler pulley tension spring Cylinder head

w/ Terminals TE1 and E1 connected of DLC1 Free length Installed load at 50.5 mm (1.988 in.) Warpage Cylinder block side Manifold side Valve seat Refacing angle Contacting angle Contacting width Inside diameter Outside diameter (for repair part)

Maximum 0.05 mm (0.0020 in.) Maximum 0.08 mm (0.0031 in.) 30, 45, 75 45 1.0 1.4 mm (0.039 0.055 in.) 6.010 6.030 mm (0.2366 0.2374 in.) 11.048 11.059 mm (0.4331 0.4342 in.) 11.050 11.077 mm (0.4350 0.4361 in.)

Valve guide bushing

STD O/S 0.05 STD Intake Exhaust Minimum Intake Exhaust

Valve

Valve overall length

Vale face angle Stem diameter Stem oil clearance

Margin thickness Valve spring Deviation Free length Installed tension at 34.7 mm (1.366 in.)

97.40 97.80 mm (3.8346 3.8504 in.) 98.25 98.65 mm (3.8681 3.8839 in.) 97.1 mm (3.823 in.) 98.0 mm (3.858 in.) 44.5 Intake 5.970 5.985 mm (0.2350 0.2356 in.) E h Exhaust 5 965 5.980 mm (0.2348 0.2354 in.) t 5.965 5 980 (0 2348 0 2354 i ) STD Intake 0.025 0.060 mm (0.0010 0.0024 in.) Exhaust 0.030 0.065 mm (0.0012 0.0026 in.) Maximum Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) STD 0.8 1.2 mm (0.031 0.047 in.) Minimum 0.5 mm (0.020 in.) Maximum 2.0 mm (0.079 in.) 40.95 42.80 mm (1.6122 1.6850 in.) 164 189 N (16.7 19.3 kgf, 36.8 42.5 lbf)

Author :

Date :

169

SS7
SERVICE SPECIFICATIONS Valve lifter Lifter diameter Lifter bore diameter Oil clearance ENGINE MECHANICAL (5SFE)

30.966 30.976 mm (1.2191 1.2195 in.) 31.000 31.018 mm (1.2205 1.2212 in.) STD 0.024 0.052 mm (0.0009 0.0020 in.) Maximum 0.07 mm (0.0028 in.) Maximum 0.30 mm (0.0118 in.) STD Intake Exhaust Maximum Intake Exhaust STD Maximum 0.045 0.100 mm (0.0018 0.0039 in.) 0.030 0.085 mm (0.0012 0.0033 in.) 0.12 mm (0.0047 in.) 0.10 mm (0.0039 in.) 0.025 0.062 mm (0.0010 0.0024 in.) 0.10 mm (0.0039 in.) 26.959 26.975 mm (1.0614 1.0620 in.) Maximum 0.04 mm (0.0016 in.) STD Intake 42.01 42.11 mm (1.6539 1.6579 in.) Exhaust 40.06 40.16 mm (1.5772 1.5811 in.) Minimum Intake 41.90 mm (1.6496 in.) Exhaust 39.95 mm (1.5728 in.) STD 0.020 0.200 mm (0.0008 0.0079 in.) Maximum 0.30 mm (0.0188 in.) 22.5 22.9 mm (0.886 0.902 in.) Maximum STD Mark 1 Mark 2 Mark 3 Maximum STD O/S 0.50 STD Mark 1 Mark 2 Mark 3 O/S 0.50 STD Maximum No.1, No.2 STD No.1 No.2 Oil (side rail) Maximum No.1 No.2 Oil (side rail) 0.05 mm (0.0020 in.) 87.000 87.010 mm (3.4252 3.4256 in.) 87.010 87.020 mm (3.4256 3.4260 in.) 87.020 87.030 mm (3.4260 3.4264 in.) 87.23 mm (3.4342 in.) 87.73 mm (3.4350 in.) 86.815 86.825 mm (3.4179 3.4183 in.) 86.825 86.835 mm (3.4183 3.4186 in.) 86.835 86.845 mm (3.4201 3.4205 in.) 87.350 87.380 mm (3.4375 3.4387 in.) 0.175 0.195 mm (0.0068 0.0076 in.) 0.215 mm (0.0085 in.) 0.030 0.070 mm (0.0012 0.0028 in.) 0.270 0.490 mm (0.0106 0.0192 in.) 0.450 0.670 mm (0.0177 0.0263 in.) 0.100 0.470 mm (0.0039 0.0185 in.) 1.09 mm (0.0429 in.) 1.27 mm (0.0499 in.) 1.07 mm (0.0421in.)

Manifold Camshaft

Warpage Thrust clearance

Journal oil clearance Journal diameter Circle runout Cam lobe height

Camshaft gear backlash Camshaft gear spring end free distance Cylinder block Cylinder head surface warpage Cylinder bore diameter

Piston and piston ring

Piston diameter

Piston oil clearance Piston ring groove clearance Piston ring end gap

Connecting rod

Thrust clearance

STD 0.160 0.312 mm (0.0063 0.0123 inb.) Maximum 0.35 mm (0.0138 in.) 1.484 1.488 mm (0.0584 0.0586 in.) 1.488 1.492 mm (0.0586 0.0587 in.) 1.492 1.496 mm (0.0587 0.0589 in.) 0.024 0.055 mm (0.0009 0.0022 in.) 0.023 0.069 mm (0.0009 0.0027 in.) 0.08 mm (0.0031 in.) 0.05 mm (0.0020 in.) 0.15 mm (0.0059 in.) 22.005 22.017 mm (0.8663 0.8668 in.) 21.997 22.009 mm (0.8660 0.8665 in.) 0.005 0.011 mm (0.0002 0.0004 in.) 0.05 mm (0.0020 in.) 7.860 8.000 mm (0.3094 0.3150 in.) 7.60 mm (0.2992 in.)

Connecting rod bearing center wall thickness Reference STD Mark 1 Mark 2 Mark 3 Connecting rod oil clearance STD STD U/S 0.25 Maximum Rod bend Maximum per 100 mm (3.94 in.) Rod twist Maximum per 100 mm (3.94 in.) Bushing inside diameter Piston pin diameter Piston pin oil clearance STD Maximum Connecting rod bolt outside diameter STD Minimum

Author :

Date :

170

SS8
SERVICE SPECIFICATIONS Crankshaft Thrust clearance ENGINE MECHANICAL (5SFE)

STD 0.020 0.220 mm (0.0008 0.0087 in.) Maximum 0.30 mm (0.0118 in.) Thrust washer thickness 2.440 2.490 mm (0.0961 0.0980 in.) Main journal oil clearance STD No.3 STD 0.025 0.044 mm (0.0010 0.0017 in.) U/S 0.25 0.027 0.067 mm (0.0011 0.0026 in.) Others STD 0.015 0.034 mm (0.0006 0.0013 in.) U/S 0.25 0.019 0.059 mm (0.0007 0.0023 in.) Maximum 0.08 mm (0.0031 in.) Main journal diameter STD 54.988 55.003 mm (2.1653 2.1655 in.) U/S 0.25 54.745 54.755 mm (2.1553 2.1557 in.) Main bearing center wall thickness (Reference) STD No.3 Mark 1 1.992 1.995 mm (0.0784 0.0785 in.) Mark 2 1.995 1.998 mm (0.0785 0.0787 in.) Mark 3 1.998 2.001 mm (0.0787 0.0788 in.) Mark 4 2.001 2.004 mm (0.0788 0.0789 in.) Mark 5 2.004 2.007 mm (0.0789 0.0790 in.) Others Mark 1 1.997 2.000 mm (0.0786 0.0787 in.) Mark 2 2.000 2.003 mm (0.0787 0.0789 in.) Mark 3 2.003 2.006 mm (0.0789 0.0790 in.) Mark 4 2.006 2.009 mm (0.0790 0.0791 in.) Mark 5 2.009 2.012 mm (0.0791 0.0792 in.) Crank pin diameter STD 51.985 52.000 mm (2.0466 2.0472 in.) U/S 0.25 51.745 51.755 mm (2.0372 2.0376 in.) Circle runout Maximum 0.06 mm (0.0024 in.) Main journal taper and outofround Maximum 0.02 mm (0.0008 in.) Crank pin taper and outofround Maximum 0.02 mm (0.0008 in.) Thrust clearance Backlash Crankshaft to No.1 Balance shaft Offvehicle Onvehicle Adjusting spacer thickness STD 0.060 0.110 mm (0.0024 0.0043 in.) Maximum 0.11 mm (0.0043 in.)

Balance shaft

STD at punch mark A at punch mark B STD at punch mark A at punch mark B No.01 No.03 No.05 No.07 No.09 No.11 No.13 No.15 No.17 No.19 No.21 No.23 No.25 No.27 No.29 No.31 No.33 No.35 No.37 No.39

0.005 0.040 mm (0.002 0.0016 in.) 0.005 0.060 mm (0.002 0.0024 in.) 0.025 0.065 mm (0.0010 0.0026 in.) 0.025 0.085 mm (0.0010 0.0033 in.) 1.74 mm (0.0685 in.) 1.76 mm (0.0693 in.) 1.78 mm (0.0701 in.) 1.80 mm (0.0709 in.) 1.82 mm (0.0717 in.) 1.84 mm (0.0724 in.) 1.86 mm (0.0732 in.) 1.88 mm (0.0740 in.) 1.90 mm (0.0748 in.) 1.92 mm (0.0756 in.) 1.94 mm (0.0764 in.) 1.96 mm (0.0772 in.) 1.98 mm (0.0780 in.) 2.00 mm (0.0787 in.) 2.02 mm (0.0795 in.) 2.04 mm (0.0803 in.) 2.06 mm (0.0811 in.) 2.08 mm (0.0819 in.) 2.10 mm (0.0827 in.) 2.12 mm (0.0835 in.)

Author :

Date :

171

SS9
SERVICE SPECIFICATIONS ENGINE MECHANICAL (5SFE)
SS0AE03

TORQUE SPECIFICATION
Part tightened Oil pump pulley x Oil pump drive shaft No.2 idler pulley x Oil pump Crankshaft pulley x Crankshaft Camshaft timing pulley x Camshaft for use with SST No.1 idler pulley x Cylinder head Cylinder head x Cylinder block 1st 2nd Nm 24 42 108 54 37 42 49 Turn 90 19 49 19 44 25 42 25 7.8 13 19 for use with SST EGR valve x intake manifold EGR pipe x Cylinder head Intake manifold stay x Intake manifold Intake manifold stay x Stiffening plate Water outlet x Cylinder head No.2 intake manifold stay x Cylinder head No.2 intake manifold stay x Intake manifold Exhaust manifold x Cylinder head No.1 exhaust manifold stay x Exhaust manifold No.1 exhaust manifold stay x Transaxle No.2 exhaust manifold stay x Exhaust manifold No.2 exhaust manifold stay, LH stiffener plate x Cylinder block TMC made TMMK made 34 29 13.3 61.2 39 39 15 21 42 49 42 42 42 58 42 9.3 88 83 14 mm head 17 mm head 46 64 66 27 9.3 19 39 39 kgfcm 245 425 1,100 550 380 425 500 Turn 90 195 500 190 450 250 425 250 80 130 195 350 300 130 600 398 398 150 214 428 500 425 425 425 591 425 95 900 850 470 650 670 280 95 195 398 398 ftlbf 18 31 80 40 27 31 36 Turn 90 14 36 14 33 18 31 18 69 in.lbf 9 14 25 21 10 45 29 29 11 15 31 36 31 31 31 43 31 82 in.lbf 65 61 34 47 48 20 82 in.lbf 14 29 29

Water bypass pipe x Cylinder head Spark plug tube x Cylinder head Camshaft bearing cap x Cylinder head Cylinder head cover x Cylinder head RH engine hanger x Generator bracket Generator bracket x Cylinder head LH engine hanger x Cylinder head No.3 timing belt cover x Cylinder head Delivery pipe x Cylinder head Intake manifold x Cylinder head Fuel inlet hose x Delivery pipe

No.1 rear end plate x Cylinder block Flywheel (M/T) x Crankshaft Drive plate (A/T) x Crankshaft Transaxle (M/T) x Cylinder block

Transaxle (A/T) x Cylinder block Drive plate x Torque converter clutch No.2 rear end plate x Cylinder block Exhaust pipe bracket, No.2 rear end plate x Transaxle RH stiffener plate x Cylinder block RH stiffener plate x Transaxle

Author :

Date :

172

SS10
SERVICE SPECIFICATIONS LH stiffener plate x Transaxle ENGINE MECHANICAL (5SFE) 37 42 52 52 64 64 64 64 TMC made TMMK made for silver color for green color 80 44 66 66 80 64 43 25.5 29 59 1st 2nd 25 Turn 90 49 13 8.8 22 43 62 56 56 33 33 33 19 33 380 430 530 530 650 650 650 650 820 450 670 670 820 650 440 260 300 600 250 Turn 90 500 130 90 224 440 630 570 570 330 330 330 195 330 27 31 38 38 47 47 47 47 59 32 49 49 59 47 32 19 21 43 18 Turn 90 36 9 78 in.lbf 16 32 46 41 41 24 24 24 14 24

M/T A/T

No.2 RH engine mounting bracket x Cylinder block No.2 RH engine mounting bracket x Generator bracket Rear engine mounting insulator x Cylinder block Front engine mounting insulator x Cylinder block Engine moving control rod x No.2 RH engine mounting bracket Engine moving control rod x Body Front engine mounting insulator x Front frame

Rear engine mounting insulator x Front frame LH engine mounting insulator x Frount frame LH engine mounting insulator x Transaxle PS pump x PS pump bracket A/C compressor x Cylinder block Fuel inlet hose x Fuel filter Main bearing cap x Cylinder block Connecting rod cap x Connecting rod

Engine balancer x Cylinder block Rear oil seal retainer x Cylinder block Water pump x Cylinder block Generator drive belt adjusting bar x Cylinder block PS pump bracket x Cylinder block Front exhaust pipe x Exhaust manifold Front exhaust pipe x Center pipe Center exhaust pipe x Tailpipe Support bracket for front exhaust pipe x Exhaust pipe bracket on No.2 rear end plate Support stay for front exhaust pipe x Support bracket Support bracket for front exhaust pipe x Front frame Support bracket for center exhaust pipe x Body Support bracket for tailpipe x Body

Author :

Date :

173

SS11
SERVICE SPECIFICATIONS ENGINE MECHANICAL (1MZFE)

ENGINE MECHANICAL (1MZFE)

SS07602

SERVICE DATA
Compression pressure at 250 rpm STD 1,500 kPa (15.3 kgf/cm2, 218 psi) Minimum 1,000 kPa (10.2 kgf/cm2, 145 psi) Difference of pressure between each cylinder 100 kPa (1.0 kgf/cm2, 15 psi) or less at cold Intake Exhaust Mark 2.500 Mark 2.550 Mark 2.600 Mark 2.650 Mark 2.700 Mark 2.750 Mark 2.800 Mark 2.850 Mark 2.900 Mark 2.950 Mark 3.000 Mark 3.050 Mark 3.100 Mark 3.150 Mark 3.200 Mark 3.250 Mark 3.300 0.15 0.25 mm (0.006 0.010 in.) 0.25 0.35 mm (0.010 0.014 in.) 2.500 mm (0.0984 in.) 2.550 mm (0.1004 in.) 2.600 mm (0.1024 in.) 2.650 mm (0.1043 in.) 2.700 mm (0.1063 in.) 2.750 mm (0.1083 in.) 2.800 mm (0.1102 in.) 2.850 mm (0.1122 in.) 2.900 mm (0.1142 in.) 2.950 mm (0.1161 in.) 3.000 mm (0.1181 in.) 3.050 mm (0.1201 in.) 3.100 mm (0.1220 in.) 3.150 mm (0.1240 in.) 3.200 mm (0.1260 in.) 3.250 mm (0.1280 in.) 3.300 mm (0.1299 in.) 8 12 BTDC @ idle 700 50 rpm 10.0 10.8 mm (0.394 0.425 in.)

Valve clearance Adjusting shim for repair part

Ignition timing Idle speed Timing belt tensioner Cylinder head

w/ Terminals TE1 and E1 connected of DLC1 Protrusion from housing side

Warpage Valve seat Refacing angle Contacting angle Contacting width Valve guide bushing bore diameter

Maximum 0.10 mm (0.039 in.) 30, 45, 75 45 1.0 1.4 mm (0.039 0.055 in.) 10.295 10.313 mm (0.4053 0.4080 in.) 10.345 10.363 mm (0.4073 0.4080 in.)

STD O/S 0.05

12 pointed head cylinder head bolt diameter at tension portion STD 8.95 9.05 mm (0.3524 0.3563 in.) Minimum 8.75 mm (0.3445 in.) Valve guide bushing Inside diameter Outside diameter for repair part 5.510 5.530 mm (0.2169 0.2177 in.) 10.333 10.344 mm (0.4068 0.4072 in.) 10.383 10.394 mm (0.4088 0.4092 in.)

STD O/S 0.05 STD Intake Exhaust Minimum Intake Exhaust

Valve

Valve overall length

Valve face angle Stem diameter Stem oil clearance

Margin thickness

95.45 mm (3.5779 in.) 95.40 mm (3.7559 in.) 94.95 mm (3.7382 in.) 94.90 mm (3.7362 in.) 44.5 Intake 5.470 5.485 mm (0.2154 0.2159 in.) Exhaust 5.465 5.480 mm (0.2152 0.2157 in.) STD Intake 0.025 0.060 mm (0.0010 0.0024 in.) Exhaust 0.030 0.065 mm (0.0012 0.0026 in.) Maximum Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) STD 1.0 mm (0.039 in.) Maximum 0.5 mm (0.020 in.)

Author :

Date :

174

SS12
SERVICE SPECIFICATIONS Valve spring Deviation Free length Installed tension at 33.8 mm (1.331 in.) Lifter diameter Lifter bore diameter Oil clearance ENGINE MECHANICAL (1MZFE)

Maximum 2.0 mm (0.079 in.) 45.50 mm (1.7913 in.) 186 206 N (19.0 21.0 kgf, 41.9 46.3 lbf) 30.966 30.976 mm (1.2191 2.2195 in.) 31.000 31.016 mm (1.2205 1.2211 in.) STD 0.024 0.050 mm (0.0009 0.0020 in.) Maximum 0.07 mm (0.0028 in.) STD Maximum STD Intake Exhaust Maximum Intake Exhaust 0.040 0.090 mm (0.0016 0.0035 in.) 0.12 mm (0.0047 in.) 0.035 0.072 mm (0.0014 0.0028 in.) 0.025 0.062 mm (0.0010 0.0024 in.) 0.10 mm (0.0039 in.) 0.09 mm (0.0035 in.) 26.959 26.975 mm (1.0613 1.0620 in.) Maximum 0.06 mm (0.0024 in.) STD Intake 42.11 42.21 mm (1.6579 1.6618 in.) Exhaust 41.96 42.06 mm (1.6520 1.6559 in.) Minimum Intake 41.96 mm (1.6520 in.) Exhaust 41.81 mm (1.6461 in.) STD 0.020 0.200 mm (0.0008 0.0079 in.) Maximum 0.30 mm (0.0188 in.) 18.2 18.8 mm (0.712 0.740 in.) Maximum 0.10 mm (0.0039 in.)

Valve lifter

Camshaft

Thrust clearance Journal oil clearance

Journal diameter Circle runout Cam lobe height

Camshaft gear backlash Camshaft gear spring end free distance Air intake chamber Intake manifold Warpage

Warpage Air intake chamber side Cylinder head side Warpage

Maximum 0.15 mm (0.0059 in.) Maximum 0.08 mm (0.0031 in.) Maximum 0.50 mm (0.0196 in.)

Exhaust manifold Cylinder block

Cylinder head surface warpage Cylinder bore diameter

Maximum 0.07 mm (0.0028 in.) 87.500 87.512 mm (3.4449 3.4453 in.) Maximum 87.52 mm (3.4457 in.)

12 pointed head main bearing cap bolt diameter at tension portion STD 7.500 7.600 mm (0.2953 0.2992 in.) Minimum 7.20 mm (0.2835 in.) Piston and piston ring Piston diameter AISIN made at 23.2 mm (0.913 in.) from the piston head MAHLE made at 41.2 mm (1.622 in.) from the piston head Piston oil clearance AISIN made STD Maximum MAHLE made STD Maximum Piston ring groove clearance No.1 No.2 Piston ring end gap STD No.1 No.2 Oil Maximum No.1 No.2 Oil 87.453 87.467 mm (3.4430 3.4436 in.) 0.084 0.106 mm (0.0033 0.0042) 0.13 mm (0.0051 in.) 0.033 0.059 mm (0.0013 0.0023) 0.08 mm (0.0031 in.) 0.020 0.070 mm (0.0008 0.0028 in.) 0.020 0.060 mm (0.0008 0.0024 in.) 0.25 0.35 mm (0.0098 0.0138 in.) 0.35 0.45 mm (0.0138 0.0177 in.) 0.15 0.40 mm (0.0059 0.0157 in.) 0.95 mm (0.0374 in.) 1.05 mm (0.0413 in.) 1.00 mm (0.0394 in.) 87.406 87.416 mm (3.4412 3.4416 in.)

Author :

Date :

175

SS13
SERVICE SPECIFICATIONS Connecting rod Thrust clearance Connecting rod thickness Connecting rod bearing center wall thickness Reference ENGINE MECHANICAL (1MZFE)

STD 0.15 0.30 mm (0.0059 0.0118 in.) Maximum 0.35 mm (0.0138 in.) 20.80 20.85 mm (0.8189 0.8209 in.) 1.484 1.487 mm (0.0584 0.0585 in.) 1.487 1.490 mm (0.0585 0.0587 in.) 1.490 1.493 mm (0.0587 0.0588 in.) 1.493 1.496 mm (0.0588 0.0589 in.) 0.038 0.064 mm (0.0015 0.0025 in.) 0.08 mm (0.0031 in.) 0.05 mm (0.0020 in.) 0.15 mm (0.0059 in.) 22.005 22.014 mm (0.8663 0.8667 in.) 21.997 22.006 mm (0.8660 0.8664 in.) 0.005 0.011 mm (0.0002 0.0004 in) 0.05 mm (0.0020 in.) 7.2 7.3 mm (0.284 0.287 in.) 7.0 mm (0.276 in.)

Mark 1 Mark 2 Mark 3 Mark 4 Connecting rod oil clearance STD Maximum Rod outofalignment Maximum per 100 mm (3.94 in.) Rod twist Maximum per 100 mm (3.94 in.) Bushing inside diameter Piston pin diameter Bushing oil clearance STD Maximum Connecting rod bolt diameter at tension portion STD Minimum Crankshaft Thrust clearance

STD 0.04 0.24 mm (0.0016 0.0095 in.) Maximum 0.30 mm (0.0118 in.) Thrust washer thickness 1.930 1.980 mm (0.0760 0.0780 in.) Main journal oil clearance STD No.1 and No.4 0.014 0.036 mm (0.0006 0.0014 in.) No.2 and No.3 0.026 0.048 mm (0.0010 0.0019 in.) Maximum No.1 and No.4 0.05 mm (0.0020 in.) No.2 and No.3 0.06 mm (0.0024 in.) Main journal diameter 60.988 61.000 mm (2.4011 2.4016 in.) Main bearing center wall thickness Reference (TMC made) Mark 1 2.486 2.489 mm (0.0979 0.0980 in.) Mark 2 2.489 2.492 mm (0.0980 0.0981 in.) Mark 3 2.492 2.495 mm (0.0981 0.0982 in.) Mark 4 2.495 2.498 mm (0.0982 0.0983 in.) Mark M k 5 2 498 2 501 mm (0 0983 0 0985 i ) 2.498 2.501 (0.0983 0.0985 in.) Mark 6 2.501 2.504 mm (0.0985 0.0986 in.) Mark 7 2.504 2.507 mm (0.0986 0.0987 in.) Reference (TMMK made) Mark 1 2.485 2.488 mm (0.0978 0.0980 in.) Mark 2 2.488 2.491 mm (0.0980 0.0981 in.) Mark 3 2.491 2.494 mm (0.0981 0.0982 in.) Mark 4 2.494 2.497 mm (0.0982 0.0983 in.) Mark 5 2.497 2.500 mm (0.0983 0.0984 in.) Mark 6 2.500 2.503 mm (0.0984 0.0985 in.) Mark 7 2.503 2.506 mm (0.0985 0.0987 in.) Crank pin diameter 52.992 53.000 mm (2.0863 2.0866 in.) Circle runout Maximum 0.06 mm (0.0024 in.) Main journal taper and outofround Maximum 0.02 mm (0.0008 in.) Crank pin taper and outofround Maximum 0.02 mm (0.0008 in.)

Author :

Date :

176

SS14
SERVICE SPECIFICATIONS ENGINE MECHANICAL (1MZFE)
SS07703

TORQUE SPECIFICATION
Part tightened Timing belt plate x Oil pump No.1 idler pulley x Oil pump No.2 idler pulley x No.2 idler pulley bracket Camshaft timing pulley x Camshaft for SST Timing belt tensioner x Oil pump RH engine mounting bracket x Cylinder block No.2 timing belt cover x No.3 timing belt cover No.1 timing belt cover x Oil pump Crankshaft pulley x Crankshaft No.2 generator bracket x Engine RH mounting bracket Cylinder head x Cylinder block 12 pointed head bolt 1st 2nd Recessed head bolt Nm 8 34 43 125 88 27 28 8.5 8.5 215 28 54 Turn 90 18.5 16 8 49 kgfcm 80 350 440 1,300 900 280 290 85 85 2,200 290 550 Turn 90 185 160 80 500 ftlbf 69 in.lbf 25 32 94 65 20 21 74 in.lbf 74 in.lbf 159 21 40 Turn 90 13 12 69 in.lbf 36

Camshaft bearing cap x Cylinder head Cylinder head cover x Cylinder head Exhaust manifold x Cylinder head Exhaust manifold stay x Exhaust manifold Except California A/T and all M/T California A/T and all M/T Exhaust manifold stay x Transmission housing Except California A/T California A/T No.1 EGR pipe x RH exhaust manifold No.1 EGR pipe x EGR cooler PS pump bracket x RH cylinder head Oil dipstick guide x LH cylinder head Water inlet pipe x LH cylinder head Cylinder head rear plate x LH cylinder head No.3 timing belt cover x Cylinder head Water outlet x Intake manifold Fuel inlet hose x Fuel filter Intake manifold x Cylinder head Air intake chamber x Intake manifold No.2 EGR pipe x Air intake chamber No.2 EGR pipe x EGR cooler No.1 engine hanger x Air intake chamber No.1 engine hanger x RH cylinder head Air intake chamber stay x Air intake chamber Air intake chamber stay x RH cylinder head Rear engine mounting insulator x Cylinder block Front engine mounting insulator x Cylinder block Engine moving control rod x RH engine mounting bracket Engine moving control rod x RH fender apron No.2 RH engine mounting stay x No.2 RH engine mounting bracket

20 34

200 350

15 25

20 34 12 12 43 8 19.5 8 8.5 15 29 15 43 12 12 39 39 19.5 19.5 64 64 64 64 64

200 350 120 120 440 80 200 80 85 150 300 150 440 120 120 400 400 200 200 650 650 650 650 650

15 25 9 9 32 69 in.lbf 14 69 in.lbf 74 in.lbf 11 21 11 32 9 9 29 29 14 14 47 47 47 47 47

Author :

Date :

177

SS15
SERVICE SPECIFICATIONS No.2 RH engine mounting stay x No.2 Generator bracket RH engine mounting stay x Water outlet RH engine mounting stay x Engine moving control rod RH engine mounting stay x No.2 RH engine mounting bracket Front engine mounting insulator x Front frame TMC made TMMK made ENGINE MECHANICAL (1MZFE) 64 32 32 32 650 320 320 320 47 23 23 23

Silver color bolt Green color bolt

80 44 66 48 48 66 64 43 25 25 18 22 Turn 90 27 24.5 Turn 90 8 9 39 18 30 8 39 28 25 43 83 83 21 62 56 56 33 33 44

820 450 670 490 490 670 650 440 250 250 185 225 Turn 90 275 250 Turn 90 80 90 400 180 310 80 400 290 250 440 850 850 210 630 570 570 330 330 450

59 32 48 35 35 48 47 31 18 18 13 16 Turn 90 20 18 Turn 90 69 in.lbf 78 in.lbf 29 13 22 69 in.lbf 29 21 18 32 61 61 15 46 41 41 24 24 33

Engine mounting absorber x Front frame Engine mounting absorber x Transaxle Rear engine mounting insulator x Front frame LH engine mounting insulator x Transaxle PS pump x PS pump bracket A/C compressor x Housing bracket A/C compressor x No.1 oil pan Generator adjusting bar x Drive belt adjusting bar bracket Main bearing cap x Cylinder block 12 pointed head bolt 1st 2nd 6 pointed head bolt 1st 2nd

Connecting rod cap x Connecting rod

Rear oil seal retainer x Cylinder block EGR cooler x Cylinder block Engine coolant drain union x Cylinder block Water seal plate x Cylinder block Oil filter union x Cylinder block Water inlet housing x Cylinder block Knock sensor x Cylinder block No.2 idler pulley bracket x Cylinder block A/C compressor housing bracket x Cylinder block Generator bracket x Cylinder block Drive plate x Crankshaft Flywheel x Crankshaft Front exhaust pipe support bracket x No.1 oil pan Front exhaust pipe x Exhaust manifold Front exhaust pipe x Center exhaust pipe Center exhaust pipe x Tailpipe Front exhaust pipe bracket x Sub frame Front exhaust pipe support bracket x Front exhaust pipe stay Heated oxygen sensor x Center exhaust pipe

Author :

Date :

178

SS16
SERVICE SPECIFICATIONS EMISSION CONTROL (5SFE)

EMISSION CONTROL (5SFE)

SS0AF03

TORQUE SPECIFICATION
Part tightened EGR valve x Intake manifold EGR valve x EGR pipe Exhaust manifold x Cylinder head Front exhaust pipe x Exhaust manifold Front exhaust pipe x Center exhaust pipe Nm 13.3 10 49 62 56 kgfcm 136 102 500 630 570 ftlbf 10 7 36 46 41

Author :

Date :

179

SS17
SERVICE SPECIFICATIONS EMISSION CONTROL (1MZFE)

EMISSION CONTROL (1MZFE)

SS07801

SERVICE DATA
EGR valve position sensor Resistance (VC E2) Power source voltage (VC E2) Power output voltage (EGLS E2) at vacuum (17.3 kPa, 130 mmHg, 5.1 in.Hg) at no vacuum 1.5 4.3 k 4.5 5.5 V 3.2 5.1 V 0.4 1.6 V

Author :

Date :

180

SS18
SERVICE SPECIFICATIONS EMISSION CONTROL (1MZFE)
SS07902

TORQUE SPECIFICATION
Part tightened EGR valve position sensor x EGR valve EGR pipe x EGR valve EGR pipe x EGR cooler EGR valve x Air intake chamber EGR gas temperature sensor x EGR valve Front exhaust pipe x Exhaust manifold Front exhaust pipe x Center exhaust pipe Front exhaust pipe bracket x Sub frame Front exhaust pipe support bracket x Front exhaust pipe stay Nm 2 12 12 12 20 62 56 33 33 kgfcm 20 120 120 120 200 630 570 330 330 ftlbf 17 in.lbf 9 9 9 14 46 41 24 24

Author :

Date :

181

SS19
SERVICE SPECIFICATIONS SFI (5SFE)

SFI (5SFE)
SS0AG03

SERVICE DATA
Fuel pressure regulator Fuel pump Injector Fuel pressure at no vacuum 301 347 kPa (3.1 3.5 kgf/cm2, 44 50 psi) 0.2 3.0 13.4 14.2 54 69 cm3 (3.3 4.2 cu in.) per 15 seconds 7 cm3 (0.4 cu in.) or less One drop or less per minute 6 1,300 1,500 rpm (w/ Cooling fan OFF) Resistance Resistance at 20C (68F) at 20C (68F) Injection volume Difference between each cylinder Fuel leakage Throttle body fully closed angle Throttle opener setting speed Clearance between stop screw and lever 0 mm (0 in.) Throttle valve fully open Resistance (+B ISCC or ISCO)

Throttle body

Throttle position sensor

VTA E2 VTA E2 VC E2 at cold at hot at 20C (68F) at 20C (68F)

0.2 5.7 k 2.0 10.2 k 2.5 5.9 k 17.0 24.5 21.5 28.5 30 34 33 39

IAC valve

VSV for EVAP VSV for vapor pressure sensor VSV for EGR ECT sensor

Resistance Resistance

at 20C (68F) at 20C (4F) at 0C (32F) at 20C (68F) at 40C (104F) at 60C (140F) at 80C (176F) at 20C (4F) at 0C (32F) at 20C (68F) at 40C (104F) at 60C (140F) at 80C (176F)

33 39 10 20 k 4 7 k 2 3 k 0.9 1.3 k 0.4 0.7 k 0.2 0.4 k 10 20 k 4 7 k 2 3 k 0.9 1.3 k 0.4 0.7 k 0.2 0.4 k 4.5 5.5 V 4.5 5.5 V 0.8 1.4 11 16 1,500 rpm

IAT sensor

Resistance

MAP sensor Vapor Pressure Sensor A/F sensor Heated oxygen sensor Fuel cut rpm

Power source voltage Power sorce voltage

Resistance Resistance

at 20C (68F) at 20C (68F)

Fuel return rpm

Author :

Date :

182

SS9
SERVICE SPECIFICATIONS ENGINE MECHANICAL (5SFE)
SS0AE03

No.1 rear end plate x Cylinder block Flywheel (M/T) x Crankshaft Drive plate (A/T) x Crankshaft Transaxle (M/T) x Cylinder block

Author :

Date :

172

M/T A/T

Author :

Date :

173

SS11
SERVICE SPECIFICATIONS ENGINE MECHANICAL (1MZFE)

ENGINE MECHANICAL (1MZFE)

SS07602

Valve clearance Adjusting shim for repair part

Ignition timing Idle speed Timing belt tensioner Cylinder head

w/ Terminals TE1 and E1 connected of DLC1 Protrusion from housing side

Warpage Valve seat Refacing angle Contacting angle Contacting width Valve guide bushing bore diameter

Maximum 0.10 mm (0.039 in.) 30, 45, 75 45 1.0 1.4 mm (0.039 0.055 in.) 10.295 10.313 mm (0.4053 0.4080 in.) 10.345 10.363 mm (0.4073 0.4080 in.)

STD O/S 0.05

STD O/S 0.05 STD Intake Exhaust Minimum Intake Exhaust

Valve

Valve overall length

Valve face angle Stem diameter Stem oil clearance

Margin thickness

Author :

Date :

174

SS12
SERVICE SPECIFICATIONS Valve spring Deviation Free length Installed tension at 33.8 mm (1.331 in.) Lifter diameter Lifter bore diameter Oil clearance ENGINE MECHANICAL (1MZFE)

Valve lifter

Camshaft

Thrust clearance Journal oil clearance

Journal diameter Circle runout Cam lobe height

Camshaft gear backlash Camshaft gear spring end free distance Air intake chamber Intake manifold Warpage

Warpage Air intake chamber side Cylinder head side Warpage

Maximum 0.15 mm (0.0059 in.) Maximum 0.08 mm (0.0031 in.) Maximum 0.50 mm (0.0196 in.)

Exhaust manifold Cylinder block

Cylinder head surface warpage Cylinder bore diameter

Maximum 0.07 mm (0.0028 in.) 87.500 87.512 mm (3.4449 3.4453 in.) Maximum 87.52 mm (3.4457 in.)

Author :

Date :

175

SS13
SERVICE SPECIFICATIONS Connecting rod Thrust clearance Connecting rod thickness Connecting rod bearing center wall thickness Reference ENGINE MECHANICAL (1MZFE)

Author :

Date :

176

SS14
SERVICE SPECIFICATIONS ENGINE MECHANICAL (1MZFE)
SS07703

20 34

200 350

15 25

20 34 12 12 43 8 19.5 8 8.5 15 29 15 43 12 12 39 39 19.5 19.5 64 64 64 64 64

200 350 120 120 440 80 200 80 85 150 300 150 440 120 120 400 400 200 200 650 650 650 650 650

15 25 9 9 32 69 in.lbf 14 69 in.lbf 74 in.lbf 11 21 11 32 9 9 29 29 14 14 47 47 47 47 47

Author :

Date :

177

Silver color bolt Green color bolt

80 44 66 48 48 66 64 43 25 25 18 22 Turn 90 27 24.5 Turn 90 8 9 39 18 30 8 39 28 25 43 83 83 21 62 56 56 33 33 44

820 450 670 490 490 670 650 440 250 250 185 225 Turn 90 275 250 Turn 90 80 90 400 180 310 80 400 290 250 440 850 850 210 630 570 570 330 330 450

59 32 48 35 35 48 47 31 18 18 13 16 Turn 90 20 18 Turn 90 69 in.lbf 78 in.lbf 29 13 22 69 in.lbf 29 21 18 32 61 61 15 46 41 41 24 24 33

Connecting rod cap x Connecting rod

Author :

Date :

178

SS16
SERVICE SPECIFICATIONS EMISSION CONTROL (5SFE)

EMISSION CONTROL (5SFE)

SS0AF03

Author :

Date :

179

SS17
SERVICE SPECIFICATIONS EMISSION CONTROL (1MZFE)

EMISSION CONTROL (1MZFE)

SS07801

Author :

Date :

180

SS18
SERVICE SPECIFICATIONS EMISSION CONTROL (1MZFE)
SS07902

Author :

Date :

181

SS19
SERVICE SPECIFICATIONS SFI (5SFE)

SFI (5SFE)
SS0AG03

Throttle body

Throttle position sensor

VTA E2 VTA E2 VC E2 at cold at hot at 20C (68F) at 20C (68F)

0.2 5.7 k 2.0 10.2 k 2.5 5.9 k 17.0 24.5 21.5 28.5 30 34 33 39

IAC valve

VSV for EVAP VSV for vapor pressure sensor VSV for EGR ECT sensor

Resistance Resistance

at 20C (68F) at 20C (4F) at 0C (32F) at 20C (68F) at 40C (104F) at 60C (140F) at 80C (176F) at 20C (4F) at 0C (32F) at 20C (68F) at 40C (104F) at 60C (140F) at 80C (176F)

33 39 10 20 k 4 7 k 2 3 k 0.9 1.3 k 0.4 0.7 k 0.2 0.4 k 10 20 k 4 7 k 2 3 k 0.9 1.3 k 0.4 0.7 k 0.2 0.4 k 4.5 5.5 V 4.5 5.5 V 0.8 1.4 11 16 1,500 rpm

IAT sensor

Resistance

MAP sensor Vapor Pressure Sensor A/F sensor Heated oxygen sensor Fuel cut rpm

Power source voltage Power sorce voltage

Resistance Resistance

at 20C (68F) at 20C (68F)

Fuel return rpm

Author :

Date :

182

SS20
SERVICE SPECIFICATIONS SFI (5SFE)
SS0AH03

TORQUE SPECIFICATION
Part tightened Fuel line Union bolt type Flare nut type Fuel pump assembly x Fuel tank Fuel filter x Fuel pump bracket Fuel pressure regulator x Fuel pump bracket Delivery pipe x Cylinder head Fuel tank band x Body Throttle body x Intake manifold Knock sensor 1 x Cylinder block A/F sensor x Exhaust manifold Oxygen sensor (bank 1 sensor 1) x Exhaust manifold Oxygen sensor (bank 1 sensor 2) x Front exhaust pipe Nm kgfcm ftlbf 29 28 4 2 2 13 39 19 44 44 44 44 300 285 40 20 20 130 400 195 450 450 450 450 21 21 35 in.lbf 17 in.lbf 17 in.lbf 9 29 14 32 32 32 32

for use with SST

Author :

Date :

183

SS21
SERVICE SPECIFICATIONS SFI (1MZFE)

SFI (1MZFE)
SS10902

SERVICE DATA
Fuel pressure regulator Fuel pump Injector Fuel pressure at no vacuum 301 347 kPa (3.1 3.5 kgf/cm2, 44 50 psi) 0.2 3.0 13.4 14.2 60 73 cm3 (3.4 4.5 cu in.) per 15 sec. 13 cm3 (0.8 cu in.) or less 1 drop or less per 12 minute at 20C (4F) at 20C (68F) at 60C (140F) 14.6 17.8 k 2.21 2.69 k 0.29 0.35 k 900 1,950 rpm Resistance Resistance Injection volume Difference between each cylinder Fuel leakage Resistance (THA E2) at 20C (68F)

MAF meter

Throttle body Throttle position sensor

Throttle opener setting speed Resistance Throttle valve fully closed Throttle valve fully open Resistance (+B RSO or RSC)

VTA E2 VTA E2 VC E2 at cold at hot at 20C (68F) at 20C (68F) at 20C (68F) at 20C (68F)

0.2 6.3 k 2.0 10.2 k 2.5 5.9 k 17.0 25.0 21.5 29.5 27 33 27 33 33 39 33 39

IAC valve

VSV for EGR VSV for EVAP VSV for ACIS VSV for Vapor Pressure Sensor Vapor Pressure Sensor ECT sensor

Resistance Resistance Resistance Resistance

Power source voltage

4.5 5.5 V

Resistance

at 20C (4F) at 0C (32F) at 20C (68F) at 40C (104F) at 60C (140F) at 80C (176F) at 50C (122F) at 100C (212F) at 150C (302F) at 20C (68F) at 800C (1472F) at 20C (68F) at 800C (1472F)

10 20 k 4 7 k 2 3 k 0.9 1.3 k 0.4 0.7 k 0.2 0.4 k 64 97 k 11 16 k 2 4 k 0.8 1.4 1.8 3.2 11 16 23 32 1,200 rpm

EGR gas temperature sensor A/F sensor

Resistance

Heater coil resistance

Heated oxygen sensor Fuel cut rpm

Heater coil resistance

Fuel return rpm

Author :

Date :

184

SS22
SERVICE SPECIFICATIONS SFI (1MZFE)
SS10A01

TORQUE SPECIFICATION
Part tightened Fuel line (Union bolt type) Fuel line (Flare nut type) Fuel pump assembly x Fuel tank Fuel filter x Fuel pump bracket Fuel pressure regulator x Fuel pump bracket Delivery pipe x Intake manifold No.1 fuel pipe x Intake manifold Fuel tank band x Body Throttle body x Air intake chamber Intake air control valve x Air intake chamber ECT sensor x Water outlet Knock sensor x Cylinder block A/F sensor x Exhaust manifold Heated oxygen sensor (Bank 1, 2 sensor 1) x Exhaust manifold Heated oxygen sensor (Bank 1 sensor 2) x Exhaust pipe using SST Nm 29 28 4 2 2 10 19.5 39 19.5 14.5 20 39 44 44 44 kgfcm 300 285 40 20 20 100 200 400 200 145 200 400 450 450 450 ftlbf 21 21 35 in.lbf 17 in.lbf 17 in.lbf 7 14 29 14 10 14 29 32 32 32

Author :

Date :

185

SS23
SERVICE SPECIFICATIONS COOLING (5SFE)

COOLING (5SFE)
SS0AI03

SERVICE DATA
Thermostat Valve opening temperature Valve lift Relief valve opening pressure at 95C (203F) 80 84C (176 183F) 8 mm (0.31 in.) or more Radiator cap STD 74 103 kPa (0.75 1.05 kgf/cm2, 10.7 14.9 psi) Minimum 59 kPa (0.6 kgf/cm2, 8.5 psi) 4.9 8.5 A

Electric cooling fan

Rotating amperage

Author :

Date :

186

SS24
SERVICE SPECIFICATIONS COOLING (5SFE)
SS0AJ03

TORQUE SPECIFICATION
Part tightened Cylinder block x Drain plug Water pump x Water pump cover, Cylinder block Water bypass pipe x Water pump cover Generator drive belt adjusting bar x Cylinder block Water inlet x Water pump cover Oil cooler x Radiator lower tank Oil cooler pipe x Oil cooler Upper radiator support x Body Electric cooling fan x Radiator Nm 25 8.8 9.3 22 8.8 8.3 14.7 12.8 5.0 kgfcm 250 90 95 224 90 85 150 130 50 ftlbf 18 78 in.lbf 82 in.lbf 16 78 in.lbf 74 in.lbf 11 9 44 in.lbf

Author :

Date :

187

SS25
SERVICE SPECIFICATIONS COOLING (1MZFE)

COOLING (1MZFE)
SS07C01

SERVICE DATA
Thermostat Valve opening pressure Valve lift Relief valve opening pressure at 95C (203F) 80 84C (176 183F) 10.0 mm (0.394 in.) or more Radiator cap STD 83 113 kPa (0.85 1.15 kgf/cm2, 12.1 16.4 psi) Minimum 69 kPa (0.7 kgf/cm2, 10.0 psi) 7.4 7.8 mm (0.2959 0.3119 in.) at 20C (68F) No.1 No.2 8.3 11.3 A 8.3 11.3 A

Radiator Cooling fan

Plate height Rotating amperage

Author :

Date :

188

SS26
SERVICE SPECIFICATIONS COOLING (1MZFE)
SS07D02

TORQUE SPECIFICATION
Part tightened RH engine drain plug x EGR cooler LH engine drain plug x Union on cylinder block Water pump x Cylinder block Water inlet x Water inlet housing Water inlet pipe x LH cylinder head Radiator support x Body No.1 cooling fan shroud x Radiator No.2 cooling fan shroud x Radiator Radiator oil cooler x Radiator lower tank Radiator inlet pipe x Radiator lower tank Nm 7 13 8 8 19.5 12.8 5.0 5.0 8.3 14.7 kgfcm 70 130 80 80 200 130 50 50 85 150 ftlbf 61 in.lbf 9 69 in.lbf 69 in.lbf 14 9 44 in.lbf 44 in.lbf 74 in.lbf 11

Author :

Date :

189

SS27
SERVICE SPECIFICATIONS LUBRICATION (5SFE)

LUBRICATION (5SFE)
SS0AK03

SERVICE DATA
Oil pressure at idle speed at 3,000 rpm Body clearance Tip clearance STD Maximum STD Maximum 29 kPa (0.3 kgf/cm2, 4.3 psi) or more 245 490 kPa (2.5 5.0 kgf/cm2, 36 71 psi) 0.10 0.16 mm (0.0039 0.0063 in.) 0.20 mm (0.0079 in.) 0.04 0.16 mm (0.0016 0.0063 in.) 0.20 mm (0.0079 in.) Oil pump

Author :

Date :

190

SS28
SERVICE SPECIFICATIONS LUBRICATION (5SFE)
SS0AL03

TORQUE SPECIFICATION
Part tightened Oil pan x Drain plug Oil pump body cover x Oil pump body Oil pump x Cylinder block Oil strainer x Engine balancer Oil strainer x Oil pump Oil pan x Cylinder block Oil pan x Oil pump Oil cooler x Cylinder block Union bolt Nut Nm 37 8.8 8.8 5.4 5.4 5.4 5.4 78.5 9.0 kgfcm 375 90 90 55 55 55 55 800 92 ftlbf 27 78 in.lbf 78 in.lbf 48 in.lbf 48 in.lbf 48 in.lbf 48 in.lbf 58 80 in.lbf

Author :

Date :

191

SS29
SERVICE SPECIFICATIONS LUBRICATION (1MZFE)

LUBRICATION (1MZFE)
SS07E01

SERVICE DATA
Oil pressure at idle speed at 3,000 rpm Side clearance Body clearance Tip clearance STD Maximum STD Maximum STD Maximum 29 kPa (0.3 kgf/cm2, 43 psi) or more 294 539 kPa (3.0 5.5 kgf/cm2, 43 78 psi) 0.030 0.090 mm (0.0012 0.0035 in.) 0.15 mm (0.0059 in.) 0.100 0.175 mm (0.0039 0.0069 in.) 0.30 mm (0.0118 in.) 0.110 0.240 mm (0.0043 0.0094 in.) 0.35 mm (0.0138 in.) Oil pump

Author :

Date :

192

SS30
SERVICE SPECIFICATIONS LUBRICATION (1MZFE)
SS07F03

TORQUE SPECIFICATION
Part tightened Oil pressure switch x Cylinder block No.2 oil pan x Drain plug Oil pump x Relief valve plug Oil pump x Cylinder block 10 mm head 12 mm head Nm 13 45 36.8 8 19.5 8 8 19.5 10 mm head 12 mm head 8 19.5 8 37.2 8 8 8 7.8 25 43 43 43 21 kgfcm 130 460 375 80 200 80 80 200 80 200 80 380 80 80 80 80 250 440 440 440 210 ftlbf 9 33 37 69 in.lbf 14 69 in.lbf 69 in.lbf 14 69 in.lbf 14 69 in.lbf 27 69 in.lbf 69 in.lbf 69 in.lbf 69 in.lbf 18 32 32 32 15

Crankshaft position sensor x Oil pump Oil pan baffle plate x No.1 oil pan No.1 oil pan x Cylinder block No.1 oil pan x Oil pump

No.1 oil pan x Rear oil seal retainer No.1 oil pan x Transaxle Oil strainer x Main bearing cap Oil strainer x Oil pump No.2 oil pan x No.1 oil pan Flywheel housing under cover x Transaxle A/C compressor x A/C compressor housing bracket PS pump x PS pump bracket PS pump drive belt adjusting strut x PS pump PS pump drive belt adjusting strut x Oil pump Exhaust pipe bracket x No.1 oil pan

Author :

Date :

193

SS31
SERVICE SPECIFICATIONS IGNITION (5SFE)

IGNITION (5SFE)
SS0AM03

SERVICE DATA
Firing order Hightension cord Spark plug Resistance 1342 Maximum 25 k per cord

Recommended spark plug Correct electrode gap for new spark plug Maximum electrode gap for used spark plug

DENSO made NGK made

PK20TR11 BKR6EKPB11 1.1 mm (0.043 in.) 1.3 mm (0.051 in.) 9.7 16.7 k 12.4 19.6 k 835 1,400 1,060 1,645 985 1,600 1,265 1,890

Ignition coil

Secondary coil resistance

at cold at hot at cold at hot

Camshaft position sensor Crankshaft position sensor

Resistance

at cold at hot

Author :

Date :

194

SS32
SERVICE SPECIFICATIONS IGNITION (5SFE)
SS0AN03

TORQUE SPECIFICATION
Part tightened Spark plug x Cylinder head Ignition coil x No.2 intake manifold stay No.2 intake manifold stay x Cylinder head No.2 intake manifold stay x Intake manifold Camshaft position sensor assembly x Cylinder head Crankshaft position sensor x Oil pump Nm 18 9.8 21 42 9.5 9.5 kgfcm 180 100 214 428 97 97 ftlbf 13 87 in.lbf 15 31 84 in.lbf 84 in.lbf

Author :

Date :

195

SS33
SERVICE SPECIFICATIONS IGNITION (1MZFE)

IGNITION (1MZFE)
SS07G02

SERVICE DATA
Firing order Hightension cord Spark plug Resistance 123456 Maximum 25 k per cord

Recommended spark plug Correct electrode gap for new plug Maximum electrode gap for used plug

DENSO made NGK made

PK20TR11 BKR6EKPB11 1.1 mm (0.043 in.) 1.3 mm (0.051 in.) 0.70 0.94 0.85 1.10 10.8 14.9 k 13.1 17.5 k 6.8 11.7 k 8.6 13.7 k 835 1,400 1,060 1,645 1,690 2,560 2,145 3,010 1,630 2,740 2,065 3,225

Ignition coil

Primary coil resistance Secondary coil resistance AISAN made Diamond made

at cold at hot at cold at hot at cold at hot

Camshaft position sensor

Resistance DENSO made Wabash made

at cold at hot at cold at hot at cold at hot

Crankshaft position sensor

Resistance

Author :

Date :

196

SS34
SERVICE SPECIFICATIONS IGNITION (1MZFE)
SS07H01

TORQUE SPECIFICATION
Part tightened Spark plug x Cylinder head Ignition coil x Cylinder head Camshaft position sensor x Cylinder head Crankshaft position sensor x Oil pump Nm 18 8 8 8 kgfcm 180 80 80 80 ftlbf 13 69 in.lbf 69 in.lbf 69 in.lbf

Author :

Date :

197

SS35
SERVICE SPECIFICATIONS STARTING (5SFE)

STARTING(5SFE)
SS0AO01

SERVICE DATA
Starter Rated voltage and output power Noload characteristics Brush length Spring installed load Current rpm STD Minimum STD 1.2 kW 1.4 kW Minimum 1.2 kW 1.4 kW STD Minimum STD Minimum Maximum 12 V 1.2 kW, 1.4 kW 90 A or less at 11.5 V 3,000 rpm or more 15.5 mm (0.610 in.) 10.0 mm (0.394 in.) 13.7 19.6 N (1.4 2.0 kgf, 3.0 4.4 lbf) 17.6 23.5 N (1.8 2.4 kgf, 3.9 5.3 lbf) 9.8 N (1.0 kgf, 2.2 lbf) 11.8 N (1.2 kgf, 2.6 lbf) 30.0 mm (1.181 in.) 29.0 mm (1.142 in.) 0.6 mm (0.024 in.) 0.2 mm (0.008 in.) 0.05 mm (0.0020 in.)

Commutator Diameter Undercut depth Circle runout Magnetic switch Contact plate for wear

Maximum 0.9 mm (0.035 in.)

Author :

Date :

198

SS36
SERVICE SPECIFICATIONS STARTING (5SFE)
SS0AP01

TORQUE SPECIFICATION
Part tightened Starter mounting bolt End cover x Field frame Starter housing x Magnetic switch Field frame x Armature assembly Lead wire x Terminal C of starter Terminal nut x Terminal C of starter Terminal nut x Terminal 30 of starter Magnetic switch end cover x Magnetic switch housing Nm 37 1.5 5.9 5.9 5.9 17 17 2.5 kgfcm 380 15 60 60 60 173 173 26 ftlbf 27 13 in.lbf 52 in.lbf 52 in.lbf 52 in.lbf 13 13 23 in.lbf

Author :

Date :

199

SS37
SERVICE SPECIFICATIONS STARTING (1MZFE)

STARTING (1MZFE)
SS07I01

SERVICE DATA
Starter Rated voltage and output power Noload characteristics Brush length Spring installed load Commutator Diameter Undercut depth Circle runout Magnetic switch Contact plate for wear Current rpm STD Minimum STD Minimum STD Minimum STD Minimum Maximum 12 V 1.4 kW 90 A or less at 11.5 V 3,000 rpm or more 15.5 mm (0.610 in.) 10.0 mm (0.394 in.) 17.6 23.5 N (1.8 2.4 kgf, 3.9 5.3 lbf) 11.8 N (1.2 kgf, 2.6 lbf) 30.0 mm (1.181 in.) 29.0 mm (1.142 in.) 0.6 mm (0.024 in.) 0.2 mm (0.008 in.) 0.05 mm (0.0020 in.)

Maximum 0.9 mm (0.035 in.)

Author :

Date :

200

SS38
SERVICE SPECIFICATIONS STARTING (1MZFE)
SS07J01

TORQUE SPECIFICATION
Part tightened Starter mounting bolt End cover x Field frame Starter housing x Magnetic switch Field frame x Armature assembly Lead wire x Terminal C of starter Terminal nut x Terminal C of starter Terminal nut x Terminal 30 of starter Magnetic switch end cover x Magnetic switch housing Nm 37 1.5 5.9 5.9 5.9 17 17 2.5 kgfcm 380 15 60 60 60 170 170 26 ftlbf 27 13 in.lbf 52 in.lbf 52 in.lbf 52 in.lbf 12 12 23 in.lbf

Author :

Date :

201

SS39
SERVICE SPECIFICATIONS CHARGING (5SFE)

CHARGING(5SFE)
SS0AQ01

SERVICE DATA
Battery Specific gravity (Except maintenancefree battery) at 20C (68F) Voltage (Maintenancefree battery) at 20C (68F) Tension w/ A/C New belt Used belt w/o A/C New belt Used belt 1.25 1.29 12.5 12.9 V 165 25 lbf 110 10 lbf 125 25 lbf 95 20 lbf 12 V 80 A 2.7 3.1 14.2 14.4 mm (0.559 0.567 in.) 12.8 mm (0.504 in.) 10.5 mm (0.413 in.) 1.5 mm (0.059 in.) 13.5 15.1 V

Drive belt

Generator

Rated output Rotor coil resistance Slip ring diameter Brush exposed length

at 20C (68F) STD Minimum STD Minimum

Voltage regulator

Regulating voltage

Author :

Date :

202

SS40
SERVICE SPECIFICATIONS CHARGING (5SFE)
SS0AR01

TORQUE SPECIFICATION
Part tightened Bearing retainer x Drive end frame Rectifier end frame x Drive end frame Wire clip x Rectifier end frame Generator pulley x Rotor Rectifier holder x Coil lead on rectifier end frame Voltage regulator x Rectifier end flame Voltage regulator x Rectifier holder Brush holder x Rectifier holder Brush holder x Voltage regulator Rear end cover x Rectifier holder Plate terminal x Rectifier holder Nut Bolt Nm 3.0 4.5 5.4 110.5 2.9 2.0 2.0 2.0 2.0 4.4 4.4 3.9 4.1 52 18 kgfcm 31 46 55 1,125 30 20 20 20 20 45 45 39 42 530 185 ftlbf 27 in.lbf 40 in.lbf 48 in.lbf 81 26 in.lbf 18 in.lbf 18 in.lbf 18 in.lbf 18 in.lbf 39 in.lbf 39 in.lbf 35 in.lbf 36 in.lbf 38 13

Terminal insulator x Rectifier holder Generator x Generator bracket Generator x Adjusting bar

Author :

Date :

203

SS41
SERVICE SPECIFICATIONS CHARGING (1MZFE)

CHARGING (1MZFE)
SS07K01

SERVICE DATA
Battery Drive belt Voltage Tension New belt Used belt Rated output Rotor coil resistance Slip ring diameter Brush exposed length at 20C (68F) 12.5 12.9 V 175 5 lbf 115 20 lbf at 20C (68F) STD Limit STD Limit 12 V 80 A 2.1 2.5 14.2 14.4 mm (0.559 0.567 in.) 12.8 mm (0.504 in.) 10.5 mm (0.413 in.) 1.5 mm (0.059 in.) 13.5 15.1 V

Generator

Voltage regulator

Regulating voltage

Author :

Date :

204

SS42
SERVICE SPECIFICATIONS CHARGING (1MZFE)
SS07L01

TORQUE SPECIFICATION
Part tightened Bearing retainer x Drive end frame Rectifier end frame x Drive end frame Cord clip x Rectifier end frame Generator pulley x Rotor Rectifier holder x Coil lead on rectifier end frame Voltage regulator and brush holder x Rectifier end frame Plate terminal x Rectifier holder Nut Screw Nm 3.0 4.5 5.4 110.5 2.9 2.0 4.4 3.9 4.4 4.1 56 18 kgfcm 31 46 55 1,125 30 20 45 39 45 42 570 180 ftlbf 27 in.lbf 40 in.lbf 48 in.lbf 81 26 in.lbf 18 in.lbf 39 in.lbf 35 in.lbf 39 in.lbf 36 in.lbf 41 13

Rear end cover x Rectifier holder Terminal insulator x Rectifier holder Generator x Generator bracket Generator x Adjusting bar

Author :

Date :

205

SS43
SERVICE SPECIFICATIONS CLUTCH

CLUTCH
SS09Q01

SERVICE DATA
Pedal height from asphalt sheet Pedal height from asphalt sheet Push rod play at pedal top Pedal freeplay Clutch start switch ONOFF Stroke Clutch release point from pedal full stroke end position Disc rivet head depth Disc runout Flywheel runout Diaphragm spring finger wear Diaphragm spring finger wear Diaphragm spring tip nonalignment 1MZFE 161.8 171.8 mm (6.370 6.764 in.) 5SFE 156.8 166.8 mm (6.173 6.567 in.) 1.0 5.0 mm (0.039 0.197 in.) 5.0 15.0 mm (0.197 0.591 in.) 5.0 0.5 mm (0.197 0.020 in.) 25 mm (0.98 in.) or more Min. 0.3 mm (0.012 in.) Max. Max. Max. depth Max. width Max. 0.8 mm (0.031 in.) 0.1 mm (0.004 in.) 0.6 mm (0.024 in.) 5.0 mm (0.197 in.) 0.5 mm (0.020 in.)

Author :

Date :

206

SS44
SERVICE SPECIFICATIONS CLUTCH
SS09R01

TORQUE SPECIFICATION
Part tightened Master cylinder installation nut Clutch line Release cylinder installation bolt Bleeder plug Cruise control actuator bracket x Body Starter x Transaxle Clutch accumulator installation bolt Clutch accumulator installation nut Release fork support Release fork support Clutch cover x Flywheel 1MZFE 5SFE Nm 12 15 12 8.4 13 39 21 27 47 39 19 kgfcm 120 155 120 85 130 400 210 270 480 400 195 ftlbf 9 11 9 74 in.lbf 9 29 15 20 35 29 14

Author :

Date :

207

SS45
SERVICE SPECIFICATIONS MANUAL TRANSAXLE (E153)

MANUAL TRANSAXLE (E153)

SS09O01

SERVICE DATA
Input shaft 3rd & 4th gears journal diameter 5th gear journal diameter Runout Output shaft 1st & 2nd gears journal diameter Runout Oil pump clearance Rotor body Rotor tip Rotor side Min. 35.950 mm (1.4154 in.) Min. 27.950 mm (1.1004 in.) Max. 0.05 mm (0.0020 in.)

Min. 38.950 mm (1.5335 in.) Max. 0.06 mm (0.0024 in.)

STD Max. STD Max. STD Max.

0.10 0.16 mm (0.0039 0.0063 in.) 0.30 mm (0.0118 in.) 0.08 0.15 mm (0.0031 0.0059 in.) 0.30 mm (0.0118 in.) 0.03 0.08 mm (0.0012 0.0031 in.) 0.15 mm (0.0059 in.)

Gear thrust clearance 1st & 3rd 2nd 4th 5th

STD Max. STD Max. STD Max. STD Max.

0.10 0.35 mm (0.0039 0.0138 in.) 0.40 mm (0.0157 in.) 0.10 0.45 mm (0.0039 0.0177 in.) 0.50 mm (0.0197 in.) 0.10 0.55 mm (0.0039 0.0217 in.) 0.60 mm (0.0236 in.) 0.10 0.57 mm (0.0039 0.0224 in.) 0.65 mm (0.0256 in.)

Gear radial clearance 1st & 4th 2nd & 3rd 5th 1st, 2nd, 3rd, 4th & 5th Shift fork to hub sleeve clearance Synchronizer ring to gear clearance 1st, 4th & 5th 2nd & 3rd Drive in depth Control shaft cover oil seal Select inner lever slotted spring pin No.1 shift inner lever slotted spring pin No.2 shift inner lever slotted spring pin Input shaft snap ring thickness No.2 clutch hub

STD STD STD Max. Max.

0.009 0.051 mm (0.0004 0.0020 in.) 0.009 0.053 mm (0.0004 0.0021 in.) 0.009 0.050 mm (0.0004 0.0020 in.) 0.070 mm (0.0028 in.) 1.0 mm (0.039 in.)

Min. 0.8 mm (0.031 in.) Min. 0.7 mm (0.028 in.)

0 1.0 mm (0 0.039 in.) 0 0.5 mm (0 0.020 in.) 0 0.5 mm (0 0.020 in.) 0 0.5 mm (0 0.020 in.) Mark H J K L M N P 2.30 mm (0.0906 in.) 2.35 mm (0.0925 in.) 2.40 mm (0.0945 in.) 2.45 mm (0.0965 in.) 2.50 mm (0.0984 in.) 2.55 mm (0.1004 in.) 2.60 mm (0.1024 in.)

Author :

Date :

208

SS46
SERVICE SPECIFICATIONS Input shaft snap ring thickness No.3 clutch hub MANUAL TRANSAXLE (E153)

Ball bearing

Mark a b c d e f g h j 1 2 3 4 5 6 7 8 Mark A B C D E F G STD

1.75 mm (0.0689 in.) 1.80 mm (0.0709 in.) 1.85 mm (0.0729 in.) 1.90 mm (0.0748 in.) 1.95 mm (0.0768 in.) 2.00 mm (0.0787 in.) 2.05 mm (0.0807 in.) 2.10 mm (0.0827 in.) 2.15 mm (0.0847 in.) 2.35 mm (0.0925 in.) 2.40 mm (0.0945 in.) 2.45 mm (0.0965 in.) 2.50 mm (0.0984 in.) 2.55 mm (0.1004 in.) 2.60 mm (0.1024 in.) 2.65 mm (0.1043 in.) 2.70 mm (0.1063 in.)

Output shaft snap ring thickness No.1 clutch hub

2.80 mm (0.1102 in.) 2.85 mm (0.1122 in.) 2.90 mm (0.1142 in.) 2.95 mm (0.1161 in.) 3.00 mm (0.1181 in.) 3.05 mm (0.1201 in.) 3.10 mm (0.1220 in.) 0.050.20 mm (0.00200.0079 in.)

Differential pinion to side gear backlash Differential side gear thrust washer thickness

0.80 mm (0.0315 in.) 0.90 mm (0.0354 in.) 1.00 mm (0.0394 in.) 1.10 mm (0.0433 in.) 1.20 mm (0.0472 in.) 1.30 mm (0.0512 in.) 1.40 mm (0.0551 in.) Differential case side bearing preload (at starting) New bearing (Output shaft preload plus) Reused bearing (Output shaft preload plus) Differential side bearing adjusting shim thickness Mark 0 1 2 3 4 5 6 7 8 9 A B C D E F G H 0.2 0.3 Nm (1.8 3.5 kgfcm, 1.6 3.0 in.lbf) 0.1 0.2 Nm (1.1 2.2 kgfcm, 1.0 1.9 in.lbf)

2.00 mm (0.0787 in.) 2.05 mm (0.0807 in.) 2.10 mm (0.0827 in.) 2.15 mm (0.0846 in.) 2.20 mm (0.0866 in.) 2.25 mm (0.0886 in.) 2.30 mm (0.0906 in.) 2.35 mm (0.0925 in.) 2.40 mm (0.0945 in.) 2.45 mm (0.0965 in.) 2.50 mm (0.0984 in.) 2.55 mm (0.1004 in.) 2.60 mm (0.1024 in.) 2.65 mm (0.1043 in.) 2.70 mm (0.1063 in.) 2.75 mm (0.1083 in.) 2.80 mm (0.1102 in.) 2.85 mm (0.1122 in.)

Author :

Date :

209

SS47
SERVICE SPECIFICATIONS Output shaft bearing preload (at starting) New bearing Reused bearing Output shaft rear bearing adjusting shim thickness Mark 0 1 2 3 4 5 6 7 8 9 A B C D E F G H J K L M N P Q MANUAL TRANSAXLE (E153)

0.8 1.6 Nm (8 16 kgfcm, 6.9 13.9 in.lbf) 0.5 1.0 Nm (5 10 kgfcm, 4.3 8.7 in.lbf)

1.30 mm (0.0512 in.) 1.35 mm (0.0531 in.) 1.40 mm (0.0551 in.) 1.45 mm (0.0571 in.) 1.50 mm (0.0591 in.) 1.55 mm (0.0610 in.) 1.60 mm (0.0630 in.) 1.65 mm (0.0650 in.) 1.70 mm (0.0669 in.) 1.75 mm (0.0689 in.) 1.80 mm (0.0709 in.) 1.85 mm (0.0728 in.) 1.90 mm (0.0748 in.) 1.95 mm (0.0768 in.) 2.00 mm (0.0787 in.) 2.05 mm (0.0807 in.) 2.10 mm (0.0827 in.) 2.15 mm (0.0846 in.) 2.20 mm (0.0866 in.) 2.25 mm (0.0886 in.) 2.30 mm (0.0906 in.) 2.35 mm (0.0925 in.) 2.40 mm (0.0945 in.) 2.45 mm (0.0965 in.) 2.50 mm (0.0984 in.)

Author :

Date :

210

SS48
SERVICE SPECIFICATIONS MANUAL TRANSAXLE (E153)
SS09P01

TORQUE SPECIFICATION
Part tightened Transaxle x Engine (See page MX4) Cruise control actuator x Body (w/ Cruise control) Starter x Transaxle Clutch release cylinder x Transaxle Clutch acummulator x Transaxle Bolt Nut 17 mm head 14 mm head A 14 mm head B Nm 64 46 37 13 39 12 21 26 12 103 33 62 56 33 39 19 181 48 20 Silver bolt Green bolt 44 66 80 64 66 10 Bolt A Bolt B Nut C 181 32 36 7.8 4.9 12 20 49 20 29 49 123 24 42 25 13 29 29 17 17 kgfcm 650 470 380 130 400 120 210 270 120 1,050 330 630 570 330 400 195 1,850 490 200 450 670 820 650 670 100 1,850 330 370 80 50 120 200 500 200 300 500 1,250 240 430 250 130 300 300 175 175 ftlbf 47 34 27 9 29 9 15 20 9 76 24 46 41 24 29 14 134 35 14 33 48 59 47 48 7 134 24 27 69 in.lbf 43 in.lbf 9 14 36 14 22 36 90 17 31 18 9 22 22 13 13

Clutch line bracket x Transaxle Front wheel Exhaust pipe support stay Front exhaust pipe x Exhaust manifold Front exhaust pipe x Center exhaust pipe No.1 exhaust pipe support bracket x Front suspension member Stabilizer bar link x Stabilizer bar Stabilizer bar bracket x Front suspension member PS gear assembly x Front suspension member Front engine absorber x Transaxle RH exhaust manifold stay Front engine mounting insulator x Front suspension member

LH engine mounting insulator x Front suspension member LH engine mounting bracket x Transaxle Rear engine mounting insulator x Front suspension member Steering return pipe x Front suspension member Front suspension member with lower suspension arm (See page MX4) Flywheel housing under cover x Transaxle Shift cable grommet retainer x Body Shift lever assembly x Body No.2 selecting bellcrank with selecting bellcrank support Shift and select lever shaft lock bolt Shift and select lever shaft assembly x Transmission case Transmission case cover x Transmission case Breather plug Output shaft lock nut Shift fork and shift head set bolt Rear bearing retainer x Transmission case Straight screw plug Straight screw plug (Reverse restrict pin) Reverse idler gear shaft lock bolt Transmission case x Transaxle case Transmission oil pipe x Transaxle case Reverse shift arm bracket assembly x Transaxle case

Author :

Date :

211

SS49
SERVICE SPECIFICATIONS Transmission oil pump assembly x Transaxle case Transaxle case receiver x Transaxle case Clutch release fork support Control lever housing support bracket x Transaxle case Vehicle speed sensor Clutch release line bracket x Transaxle case Backup light switch Filler and drain plug No.1 and No.2 oil receiver pipe x Transmission case Transmission oil cooler subassembly x Elbow Elbow x Transaxle case Transmission oil pump case x Oil pump cover Transaxle case cover x Transaxle case Differential left case x Differential right case Ring gear set bolt MANUAL TRANSAXLE (E153) 17 7.4 47 17 17 17 40 49 17 34 27 10 54 63 124 175 75 480 175 175 175 410 500 175 350 275 105 550 640 1,260 13 65 in.lbf 35 13 13 13 30 36 13 25 20 8 40 46 91

Author :

Date :

212

SS50
SERVICE SPECIFICATIONS MANUAL TRANSAXLE (S51)

MANUAL TRANSAXLE (S51)

SS09M01

SERVICE DATA
Input shaft roller bearing journal diameter Input shaft 3rd gear journal diameter Input shaft 4th gear journal diameter Input shaft 5th gear journal diameter Input shaft runout Output shaft roller bearing journal diameter Output shaft 1st gear journal diameter Output shaft 2nd gear journal diameter Output shaft runout Gear thrust clearance 1st Min. 29.970 mm (1.799 in.) Min. 33.090 mm (1.3028 in.) Min. 32.470 mm (1.2783 in.) Min. 26.970 mm (1.0618 in.) Max. 0.05 mm (0.0020 in.)

Min. 31.970 mm (1.2587 in.) Min. 37.970 mm (1.4949 in.) Min. 31.990 mm (1.2594 in.) Max. STD Max. STD Max. STD Max. STD Max. STD Max. STD Max. STD Max. Max. 0.05 mm (0.0020 in.) 0.10 0.29 mm (0.0039 0.0114 in.) 0.35 mm (0.0138 in.) 0.20 0.44 mm (0.0079 0.0173 in.) 0.50 mm (0.0197 in.) 0.10 0.25 mm (0.0039 0.098 in.) 0.30 mm (0.0118 in.) 0.20 0.45 mm (0.0079 0.0177 in.) 0.50 mm (0.0197 in.) 0.20 0.40 mm (0.0079 0.0157 in.) 0.45 mm (0.0177 in.) 0.009 0.053 mm (0.0004 0.0021 in.) 0.070 mm (0.0028 in.) 0.009 0.050 mm (0.0004 0.0020 in.) 0.070 mm (0.0028 in.) 1.0 mm (0.039 in.)

Gear thrust clearance

2nd

Gear thrust clearance

3rd

Gear thrust clearance

4th

Gear thrust clearance

5th

Gear radial clearance

1st, 2nd, 3rd, and 4th

Gear radial clearance

5th

Shift fork to hub sleeve clearance Synchronizer ring to gear clearance 1st, 3rd and 4th Synchronizer ring to gear clearance 2nd Differential case side bearing preload (at starting)(For use with SST) Differential pinion to side gear backlash Drive in depth In ut shaft front oil seal Input Reverse restrict pin slotted spring pin in s ring in Shift and select lever shaft slotted spring pin Differential side gear thrust washer thickness

Min. 0.6 mm (0.024 in.) Min. 0.7 mm (0.028 in.) 0.8 1.6 Nm (8 16 kgfcm, 6.9 13.9 in.lbf) 0.05 0.20 mm (0.0020 0.0079 in.)

0 0.5 mm (0 0.020 in.) 13.5 0.5 mm (0.531 0.020 in.) 23.5 1.0 mm (0.925 0.039 in.) 0.95 0 95 mm (0 0374 in ) (0.0374 in.) 1 00 mm (0 0394 in ) 1.00 (0.0394 in.) 1.05 1 05 mm (0 0413 in ) (0.0413 in.) 1.10 1 10 mm (0 0433 i ) (0.0433 in.) ( 1.15 mm (0.0453 in.) ( ) 1.20 mm (0.0472 in.)

Author :

Date :

213

SS51
SERVICE SPECIFICATIONS MANUAL TRANSAXLE (S51)

Input shaft snap ring thickness No.2 clutch hub

No.3 clutch hub

Rear bearing

Mark 1 Mark 2 Mark 3 Mark M k4 Mark 5 Mark 6 Mark 13 Mark 14 Mark 15 Mark M k 16 Mark 17 Mark 18 Mark 19 Mark 20 Mark 21 Mark 22 Mark 23 Mark 24 Mark 25 Mark 26 Mark 27 Mark A Mark B Mark C Mark D Mark E

1.95 2.00 mm (0.0768 0.0787 in.) 2.00 2.05 mm (0.0787 0.0807 in.) ( ) 2.05 2.10 mm (0.0807 0.0827 in.) 2.10 2 15 2 10 2.15 mm (0.0827 0.0846 in.) (0 0827 0 0846 i ) 2.15 2.20 2 15 2 20 mm (0 0846 0.0866 in.) (0.0846 0 0866 in ) 2.20 2.25 mm (0.0866 0.0886 in.) 2.20 2.25 mm (0.0866 0.0886 in.) 2.25 2.30 mm (0.0886 0.0906 in.) ( ) 2.30 2.35 mm (0.0906 0.0925 in.) 2.35 2 40 2 35 2.40 mm (0.0925 0.0945 in.) (0 0925 0 0945 i ) 2.40 2.45 2 40 2 45 mm (0 0945 0 0965 in ) (0.0945 0.0965 in.) 2.45 2.50 mm (0.0965 0.0984 in.) 2.50 2.55 mm (0.0984 0.01004 in.) 2.55 2.60 mm (0.1004 0.01024 in.) ( ) 2.60 2.65 mm (0.1024 0.01043 in.) 2.65 2 70 2 65 2.70 mm (0.1043 0.01063 in.) (0 1043 0 01063 in ) 2.70 2.75 2 70 2 75 mm (0.1063 0 01083 in ) (0 1063 0.01083 in.) 2.75 2.80 mm (0.1083 0.01102 in.) 2.80 2.85 mm (0.1102 0.01122 in.) 2.85 2.90 mm (0.1122 0.01142 in.) 2.90 2.95 mm (0.1142 0.01161 in.) 2.15 2.20 2 15 2 20 mm (0 0846 0 0866 in ) (0.0846 0.0866 in.) 2.20 2.25 2 20 2 25 mm (0 0866 0 0886 in ) (0.0866 0.0886 in.) 2.25 2.30 mm (0.0886 0.0906 in.) 2.30 2.35 mm (0.0906 0.0925 in.) 2.35 2.40 mm (0.0925 0.0945 in.)

Differential side bearing adjusting shim thickness Mark 1 Mark 2 Mark 3 Mark 4 Mark 5 Mark 6 Mark 7 Mark 8 Mark 9 Mark 10 Mark 11 Mark 12 Mark 13 Mark 14 Mark 15 Mark 16 Mark 17 Mark 18 Mark M k 19 1.90 1 90 mm (0 0748 in ) (0.0748 in.) 1.95 1 95 mm (0 0768 in ) (0.0768 in.) 2 00 mm (0 0787 in ) 2.00 (0.0787 in.) 2 05 mm (0 0807 in ) 2.05 (0.0807 in.) 2.10 mm (0.0827 in.) 2.15 mm (0.0846 in.) 2.20 mm (0.0866 in.) 2.25 mm (0.0886 in.) 2.30 mm (0.0906 in.) 2.35 mm (0.0925 in.) 2.40 mm (0.0945 in.) 2.45 mm (0.0965 in.) 2.50 mm (0.0984 in.) ( ) 2.55 mm (0.1004 in.) ( ) 2.60 mm (0.1024 in.) ( ) 2.65 mm (0.1043 in.) 2.70 mm (0.1063 in.) 2.75 mm (0.1083 in.) 2.80 mm ( (0.1102 i ) in.)

Author :

Date :

214

SS52
SERVICE SPECIFICATIONS MANUAL TRANSAXLE (S51)
SS09N01

TORQUE SPECIFICATION
Part tightened Transaxle x Engine 17 mm head 14 mm head Nm 64 46 13 37 12 Bolt A Bolt B Front side Rear side 12 6.9 42 39 103 Bolt Nut 19 33 62 56 33 39 19 181 Silver bolt Green bolt 44 66 80 64 66 10 Bolt A Bolt B Nut C 181 32 36 37 39 9.3 4.9 12 29 29 18 42 18 7.4 123 29 37 6.4 83 37 kgfcm 650 470 130 378 120 120 70 425 400 1,050 195 330 630 570 330 400 195 1,850 450 670 820 650 670 100 1,850 330 370 380 400 95 50 120 300 300 185 430 185 75 1,250 300 375 65 850 380 ftlbf 47 34 9 28 9 9 61 in.lbf 31 29 76 14 24 46 41 24 29 14 134 33 48 59 47 48 7 134 24 27 27 29 82 in.lbf 43 in.lbf 9 22 22 13 31 13 65 in.lbf 90 22 27 56 in.lbf 61 27

Cruise control actuator x Body (w/ Cruise control) Starter x Transaxle Clutch release cylinder x Transaxle Clutch line bracket x Transaxle (See page MX4) Manifold stay Manifold stay Front wheel Exhaust pipe bracket i e

Front exhaust pipe x Exhaust manifold Front exhaust pipe x Center exhaust pipe No.1 exhaust pipe support bracket x Front suspension member Stabilizer bar link x Stabilizer bar Stabilizer bar bracket x Front suspension member PS gear assembly x Front suspension member Front engine mounting insulator x Front sus ension member suspension

LH engine mounting insulator x Front suspension member LH engine mounting bracket x Transaxle Rear engine mounting insulator x Front suspension member Steering return pipe x Front suspension member Front suspension member with lower suspension arm sus ension sus ension (See page MX4) LH stiffener plate RH stiffener plate Rear end plate Shift cable grommet retainer x Body Shift lever assembly x Body Transmission case x Transaxle case Transmission case x Case cover Transmission case protector Rear bearing retainer Output shaft front bearing lock plate Transaxle case receiver set bolt 5th driven gear lock nut Reverse idler shaft lock bolt Control shaft cover Control shift lever x Lever shaft Ring gear x Differential case Selecting bellcrank x Transmission case

Author :

Date :

215

SS53
SERVICE SPECIFICATIONS Engine mount bracket x Transaxle Reverse shift arm bracket No.3 shift fork x Shift fork shaft Lock ball assembly Filler and Drain plugs Backup light switch Differential side bearing retainer Release bearing retainer Straight screw plug Vehicle speed sensor driven gear Clutch release fork support MANUAL TRANSAXLE (S51) 52 18 18 29 49 44 18 7.4 13 5.4 39 530 185 185 300 500 450 185 75 130 55 400 38 13 13 22 36 33 13 65 in.lbf 9 48 in.lbf 29

Author :

Date :

216

SS54
SERVICE SPECIFICATIONS AUTOMATIC TRANSAXLE (A140E)

AUTOMATIC TRANSAXLE (A140E)

SS0AS01

SERVICE DATA
Line pressure (Wheel locked) Engine idling D position R position at stall (Throttle valve fully opened) D position R position Engine stall revolution Time lag D and R positions N D position N R position A/C OFF and N range 363 422 kPa (3.7 4.3 kgf/cm2, 53 61 psi) 618 794 kPa (6.3 8.1 kgf/cm2, 90 115 psi) 735 862 kPa (7.5 8.8 kgf/cm2, 107 125 psi) 1,373 1,608 kPa (14.0 16.4 kgf/cm2, 199 233 psi) 2,450 150 rpm Less than 1.2 seconds Less than 1.5 seconds 750 50 rpm Between boot end face and inner cable stopper 0 1 mm (0 0.04 in.) Max. Max. 0.20 mm (0.0079 in.) 0.30 mm (0.0118 in.) More than 13.0 mm (0.512 in.) 2.7 0.5 mm (0.106 0.020 in.) 0 0.5 mm (0 0.020 in.)

Engine idle speed Throttle cable adjustment (Throttle valve fully opened) Drive plate runout Torque converter runout Torque converter installation distance Differential oil seal drive in depth

LH side RH side

Shift point D position (Throttle valve fully opened)

(Throttle valve fully closed) 2 position (Throttle valve fully opened)

12 23 3 O/D O/D 3 32 21 O/D 3 3 O/D 12 32 21 21

58 63 km/h (36 39 mph) 109 117 km/h (68 73 mph) 145 151 km/h (90 94 mph) 138 146 km/h (86 91 mph) 100 108 km/h (62 67 mph) 51 56 km/h (32 35 mph) 38 43 km/h (24 27 mph) 18 22 km/h (11 14 mph) 58 63 km/h (36 39 mph) 106 114 km/h (66 71 mph) 51 56 km/h (32 35 mph) 47 51 km/h (29 32 mph)

L position (Throttle valve fully opened)

*1: The maximum vehicle speed for manual shift down when shifting down from D to 2. *2: The maximum vehicle speed for manual shift down when shifting down from 2 to L. Lockup point (Throttle valve fully opened) D position 3rd Gear (O/D main switch OFF) Lockup ON Lockup OFF O/D gear Lockup ON Lockup OFF 67 72 km/h (42 45 mph) 64 69 km/h (40 43 mph) 67 72 km/h (42 45 mph) 64 69 km/h (40 43 mph)

Author :

Date :

217

SS55
SERVICE SPECIFICATIONS AUTOMATIC TRANSAXLE (A140E)
SS0AT01

TORQUE SPECIFICATION
Part tightened Transaxle x Starter Transaxle x Rear end plate Transaxle x No.1 exhaust pipe support bracket Transaxle x Engine Torque converter clutch x Drive plate Body x Front lower brace Bolt Nut 19 mm head bolt 14 mm head bolt Nut Nm 42 25 19 66 27 181 36 181 32 36 80 66 44 66 80 64 10 19 39 127 181 62 33 56 33 294 49 16 Bolt Nut 5.4 6.9 13 15 49 4.9 10 10 32 Front side Rear side Front side Rear side 42 39 42 39 kgfcm 430 250 195 670 280 1,850 370 1,850 330 370 820 670 450 670 820 650 100 195 400 1,300 1,850 630 330 570 330 3,000 500 160 55 70 130 150 500 50 100 100 330 430 400 430 400 ftlbf 31 18 14 48 20 134 27 134 24 27 59 48 32 48 59 47 7 14 29 94 134 46 24 41 24 217 36 12 48 in.lbf 61 in.lbf 9 11 36 43 in.lbf 7 7 24 31 29 31 29

Body x Rear lower brace

Front suspension member x FR engine mounting TMC made TMMK made: Green color bolt TMMK made: Silver color bolt Front suspension member x RR engine mounting Front suspension member x LH engine mounting Transaxle x LH engine mounting Front suspension member x Steering return pipe mounting bracket Front suspension member x Stabilizer bar bracket Stabilizer bar x Stabilizer bar link Ball joint x Lower suspension arm Steering gear housing set bolt x Nut Exhaust manifold x Front exhaust pipe Front suspension member x Exhaust pipe No.1 support bracket Front exhaust pipe x Center exhaust pipe No.1 exhaust pipe support bracket x Exhaust pipe clamp Axle hub nut Steering knuckle x Tie rod end Vehicle speed sensor x Transaxle Park/neutral position switch x Transaxle

Park/neutral position switch x Control shaft lever Control shaft lever x Control cable Oil pan x Drain plug Oil pan x Transaxle Valve body x Manual valve body Valve body x Transaxle Drive shaft center bearing lock bolt Stiffener plate

Exhaust manifold stay

Author :

Date :

218

SS56
SERVICE SPECIFICATIONS AUTOMATIC TRANSAXLE (A541E)

AUTOMATIC TRANSAXLE (A541E)

SS0BL01

SERVICE DATA
Line pressure (wheel locked) Engine idling D position R position at stall (Throttle valve fully opened) D position R position 401 461 kPa (4.1 4.7 kgf/cm2, 58 66 psi) 804 882 kPa (8.2 9.0 kgf/cm2, 117 128 psi) 1,138 1,236 kPa (11.6 12.6 kgf/cm2, 165 179 psi) 1,716 1,854 kPa (17.5 18.9 kgf/cm2, 249 269 psi) 2,600 150 rpm N D position N R position N position Throttle cable adjustment (Throttle valve fully opened) Less than 1.2 seconds Less than 1.5 seconds 700 50 rpm Between boot and face and inner cable stopper 0 1 mm (0 0.04 in.) Max. Max. 0.3 mm (0.0118 in.) 0.20 mm (0.0079 in.) More than 13.7 mm (0.539 in.)

Engine stall revolution Time lag

Engine idle speed (A/C OFF)

Drive plate runout Torque converter clutch runout Torque converter clutch installation distance

Lockup point (Throttle valve opening 5%) 3rd gear (O/D main switch OFF) Lockup ON Lockup OFF O/D gear Lockup ON Lockup OFF Shift schedule D position (Throttle valve fully opened)

60 65 km/h (37 40 mph) 53 58 km/h (33 36 mph) 60 64 km/h (37 40 mph) 53 58 km/h (33 36 mph)

(Throttle valve fully closed) 2 position (Throttle valve fully opened)

12 23 3 O/D O/D 3 32 21 3 O/D O/D 3 12 32 21 32 21

60 66 km/h (37 41 mph) 112 121 km/h (70 75 mph) 174 183 km/h (108 114 mph) 167 176 km/h (104 109 mph) 104 112 km/h (65 70 mph) 50 55 km/h (31 34 mph) 35 40 km/h (22 25 mph) 20 25 km/h (12 16 mph) 60 66 km/h (37 41 mph) 122 130 km/h (76 81 mph) 50 55 km/h (31 34 mph) 106 115 km/h (66 71 mph) 54 59 km/h (34 37 mph)

L position (Throttle valve fully opened)

Author :

Date :

219

SS57
SERVICE SPECIFICATIONS AUTOMATIC TRANSAXLE (A541E)
SS0BM01

TORQUE SPECIFICATION
Part tightened Front engine front mounting insulator x Front frame assembly TMC: TMMK: Green color bolt Silver color bolt Nm 80 66 44 80 64 48 17 mm bolt 12 mm bolt 66 48 41 11 11 7.8 49 5.4 6.9 11 11 11 11 10 181 19 4.9 11 11 Except California California Except California California 19 mm 14 mm Nut 20 34 20 34 181 32 36 56 62 33 33 39 15 15 83 15 5.4 6.6 kgfcm 820 670 450 820 650 490 670 490 420 110 110 80 500 55 70 110 110 110 110 100 1,850 195 50 110 110 200 350 200 350 1,850 330 370 570 630 330 330 400 150 150 850 150 55 67 ftlbf 59 48 32 59 47 35 48 35 30 8 8 69 in.lbf 36 48 in.lbf 61 in.lbf 8 8 8 8 7 134 14 43 in.lbf 8 8 14 25 14 25 134 24 27 41 46 24 24 29 11 11 61 11 48 in.lbf 58 in.lbf

Rear engine mounting insulator x Front frame assembly LH transaxle mounting insulator x Transaxle Engine mounting absorber x Front frame assembly Transaxle x Engine Transaxle x Engine Torque converter clutch x Drive plate Valve body x Transaxle case Oil strainer x Valve body Oil pan x Transaxle case Oil pan drain plug Park/Neutral position switch x Transaxle case (bolt) Park/Neutral position switch (nut) B3 apply pipe retainer Connector clamp Manual valve body x Transaxle case Detent spring x Manual valve body Oil pipe bracket Steering gear housing x Front suspension member Stabilizer bar bracket Vehicle speed sensor x Transaxle case Direct clutch speed sensor x Transaxle case Transfer lubrication apply pipe retainer Exhaust manifold bracket x Transaxle case

Exhaust manifold plate

Front frame x Body Front frame x Body Front frame x Body Exhaust front pipe x Exhaust center pipe Exhaust manifold x Exhaust front pipe Exhaust front pipe support stay x Exhaust front pipe support bracket Exhaust pipe support x Front frame Starter x Torque converter clutch housing Transaxle control shaft lever x Park/neutral position switch Throttle cable adjusting nut Drive plate x Crankshaft Shift control cable x Transaxle control shaft lever Throttle cable retaining plate set bolt Shift solenoid valve No.1, No.2, SL, SLN x Valve body

Author :

Date :

220

SS58
SERVICE SPECIFICATIONS Front wheel nut Exhaust front pipe support bracket x Body PS reseroir pipe x Front frame Engine hood x Hood hinge AUTOMATIC TRANSAXLE (A541E) 103 21 10 26 1,050 210 100 265 76 15 7 19

Author :

Date :

221

SS59
SERVICE SPECIFICATIONS SUSPENSION AND AXLE

SUSPENSION AND AXLE

SS04W01

SERVICE DATA
Front, Rear*1 Cold tire inflation pressure (Normal driving) P195/70R14 90S Front, Rear*2 Front, Rear*1 P205/65R15 92H Front, Rear*2 Front, Rear*3 Cold tire inflation pressure (Trailer towing) P195/70R14 90S Front, Rear*4 Front, P205/65R15 92H Rear*3 210 kPa (2.1 kgf/cm2, 30 psi) 210 kPa (2.1 kgf/cm2, 30 psi) 220 kPa (2.2 kgf/cm2, 32 psi) 200 kPa (2.0 kgf/cm2, 29 psi) 210 kPa (2.1 kgf/cm2, 30 psi) 240 kPa (2.4 kgf/cm2, 35 psi) 220 kPa (2.2 kgf/cm2, 32 psi) 240 kPa (2.4 kgf/cm2, 35 psi) 212 mm (8.35 in.) 264 mm (10.39 in.) 215 mm (8.46 in.) 266 mm (10.49 in.)

Front, Rear4 Front5

Vehicle height V hi l h i ht

195/70R14

Rear*6 Front*5

205/65R15 Camber 5S FE 1MZ FE Left right error Caster 5S FE 1MZ FE Left right error Steering axis inclination 5S FE 1MZ FE Left right error Toein (Total)

Rear*6 0 36 036 45 (0.6 0.75) 45 (0.6 0.75 ) 0 37 037 45 (0.62 0.75) 45 (0.62 0.75 ) 45 (0.75) or less 210 45 (2.17 0.75) 211 45 (2.18 0.75) 45 (0.75) or less 1301 45 (13.02 0.75) 1304 45 (13.07 0.75) 45 (0.75) or less

Front wheel alignment

0 12 (0 0.2) 0 2 mm (0 0.08 in.) Rack end length difference 1.5 mm (0.059 in.) or less Inside wheel 3712 2 (37.2 2) 3221 (32.45) 3547 2 (35.78 2) 3125 (31.42) 195/70R14

Wheel Wh l angle l

Outside wheel Inside wheel

205/65R15 Camber 5S FE 1MZ FE Left right error Toein (Total)

Outside wheel 042 45 (0.7 0.75) 045 45 (0.75 0.75) 45 (0.75) or less

Rear wheel alignment li t

024 12 (0.4 0.2) 4 2 mm (0.16 0.08 in.) No.2 lower suspension arm length difference 1 mm (0.04 in.) or less

*1: For all loads including rated loads *2: For reduced loads (1 to 4 passengers) *3: For driving under 160 km/h (100 mph) *4: For driving at 160 km/h (100 mph) or over *5: Front measuring point Measure from the ground to the center of the front side lower suspension arm mounting bolt. *6: Rear measuring point Measure from the ground to the center of the strut rod mounting bolt.

Author :

Date :

222

SS60
SERVICE SPECIFICATIONS Axle bearing backlash Front l F t axle Axle hub deviation Drive shaft standard length 5S FE Front drive shaft 1MZ FE (M/T) 1MZ FE (A/T) SUSPENSION AND AXLE 0.05 mm (0.0020 in.) 0.05 mm (0.0020 in.) 609.2 2.0 mm (23.984 0.079 in.) 867.3 2.0 mm (34.146 0.079 in.) 601.5 2.0 mm (23.681 0.079 in.) 871.6 2.0 mm (34.315 0.079 in.) 586.0 2.0 mm (23.071 0.079 in.) 881.6 2.0 mm (34.709 0.079 in.) 1.0 3.4 Nm (10 35 kgfcm, 8.7 30 in.lbf) 0.05 1.0 Nm (0.5 10 kgfcm, 0.4 8.7 in.lbf) 0.05 mm (0.0020 in.) 0.07 mm (0.0028 in.) 512.3 mm (20.169 in.) 0.05 1.0 Nm (0.5 10 kgfcm, 0.4 8.7 in.lbf)

LH RH LH RH LH RH

Lower ball joint turning torque Front F t suspension i Stabilizer bar link turning torque Axle bearing backlash Rear axle R l Axle hub deviation No.2 lower suspension arm length Rear suspension R i Stabilizer bar link turning torque

Author :

Date :

223

SS61
SERVICE SPECIFICATIONS SUSPENSION AND AXLE
SS04X01

TORQUE SPECIFICATION
Part tightened FRONT: Hub nut Tie rod end lock nut Steering knuckle x Shock absorber Steering knuckle x Brake caliper Steering knuckle x Tie rod end Axle hub x Drive shaft Lower ball joint x Lower suspension arm Lower ball joint x Steering knuckle Steering knuckle x Disc brake dust cover Drive shaft center bearing lock bolt Suspension support x Body Suspension support x Piston rod ABS speed sensor set bolt Flexible hose and ABS speed sensor wire harness x Shock absorber Lower suspension arm set bolt Stabilizer bar bracket x Suspension member Stabilizer bar link set bolt REAR: Hub nut No.2 lower suspension arm lock nut Brake caliper x Rear axle carrier Axle hub bearing set bolt Shock absorber x Rear axle carrier New nut Reused nut (apply engine oil the threads) 103 56 47 80 255 196 29 8.0 5.5 18 39 49 56 5.4 181 181 113 113 51 38 19 39 1,050 570 475 820 2,600 2,000 300 82 56 185 400 500 570 55 1,850 1,850 1,150 1,150 520 390 195 400 76 41 34 59 188 145 22 71 in.lbf 49 in.lbf 13 29 36 41 48 in.lbf 134 134 83 83 38 28 14 29 103 74 211 107 49 294 127 123 8.3 32 80 49 8.0 29 206 19 39 1,050 750 2,150 1,090 500 3,000 1,300 1,250 85 330 820 500 82 300 2,100 195 400 76 54 156 79 36 217 94 90 74 in.lbf 24 59 36 71 in.lbf 22 152 14 29 Nm kgfcm ftlbf

Flexible hose x Shock absorber ABS speed sensor set bolt ABS speed sensor wire harness x Shock absorber Rear side seatback set bolt Suspension support x Body Suspension support x Piston rod Exhaust center pipe set nut Parking brake cable set bolt Lower suspension arm x Suspension member Lower suspension arm x Rear axle carrier Strut rod x Body Strut rod x Rear axle carrier Suspension member x Body Suspension member lower stopper subassembly x Body Stabilizer bar bracket x Suspension member Stabiliser bar link set nut

Author :

Date :

224

SS62
SERVICE SPECIFICATIONS BRAKE

BRAKE
SS09X01

SERVICE DATA
Brake pedal height (from asphalt sheet) Brake pedal freeplay Brake pedal reserve distance at 490 N (50 kgf, 110.2 lbf) Brake booster push rod to piston clearance (w/SST) Front brake pad thickness (5SFE engine) Front brake pad thickness (1MZFE engine) Front brake pad thickness Front brake disc thickness Front brake disc thickness Front brake disc runout Rear brake drum inside diameter Rear brake drum inside diameter Rear brake shoe lining thickness Rear brake shoe lining thickness Rear brake drum to shoe clearance Rear brake pad thickness Rear brake pad thickness Rear brake disc thickness Rear brake disc thickness Rear brake disc runout Rear brake disc inside diameter Rear brake disc inside diameter Parking brake lining thickness for rear disc brake Parking brake lining thickness for rear disc brake Parking brake lever travel at 196 N (20 kgf, 44 lbf) Parking brake clearance between rear shoe and lever STD STD STD 152.0 162.0 mm (5.984 6.378 in.) 1 6 mm (0.04 0.24 in.) More than 70 mm (2.76 in.) 0 mm (0 in.) 12.0 mm (0.472 in.) 11.0 mm (0.433 in.)

Minimum 1.0 mm (0.039 in.) STD 28.0 mm (1.102 in.)

Minimum 26.0 mm (1.024 in.) Maximum 0.05 mm (0.0020 in.) STD 228.6 mm (9.000 in.)

Maximum 230.6 mm (9.079 in.) STD 5.0 mm (0.197 in.)

Minimum 1.0 mm (0.039 in.) 0.6 mm (0.024 in.) 10.0 mm (0.394 in.)

Minimum 1.0 mm (0.039 in.) STD 10.0 mm (0.394 in.)

Minimum 9.0 mm (0.354 in.) Maximum 0.15 mm (0.0059 in.) STD 170 mm (6.69 in.)

Maximum 171 mm (6.73 in.) STD 2.0 mm (0.079 in.)

Minimum 1.0 mm (0.039 in.) 5 8 clicks Less than 0.35 mm (0.0138 in.) 0.3 mm (0.012 in.) 0.6 mm (0.024 in.) 0.9 mm (0.035 in.)

Parking brake adjusting shim thickness for rear disc brake

Author :

Date :

225

SS63
SERVICE SPECIFICATIONS BRAKE
SS09Y03

TORQUE SPECIFICATION
Part tightened Master cylinder x Piston stopper bolt Master cylinder x Reservoir Master cylinder x Brake booster Brake line union nut 10 mm nut 12 mm nut Brake booster clevis lock nut Brake booster x Pedal bracket Brake pedal x Pedal bracket Pedal bracket x Instrument panel reinforcement Front brake caliper installation bolt Bleeder plug Front brake torque plate x Steering knuckle Front brake caliper x Flexible hose Flexible hose x Shock absorber bracket Rear drum brake wheel cylinder x Backing plate Parking brake cable bracket x Backing plate Rear brake caliper installation bolt Rear disc brake cariper main pin installation bolt Rear brake caliper x Flexible hose Rear brake torque plate x Rear axle carrier Proportioning valve installation bolt ABS actuator x Actuator bracket ABS actuator x Actuator bracket ABS actuator x ECU ABS & TRAC actuator x Actuator bracket ABS (& TRAC) actuator bracket x Body Front speed sensor installation bolt Front speed sensor harness clamp bolt Rear speed sensor installation bolt Rear speed sensor harness clamp bolt DENSO type BOSCH type BOSCH type Nm 10 1.7 13 15 20 25 13 39 13 34 8.3 107 29 29 10 7.8 20 26 29 47 8.8 5.4 9.0 2.6 5.4 19 7.8 5.4 7.8 5.4 kgfcm 100 18 130 155 200 260 130 400 130 350 85 1,090 300 300 100 80 200 270 300 475 90 55 92 27 55 195 80 55 80 55 ftlbf 7 16 in.lbf 9 11 14 19 9 29 9 25 74 in.lbf 79 21 21 7 69 in.lbf 14 20 21 34 78 in.lbf 48 in.lbf 80 in.lbf 23 in.lbf 48 in.lbf 14 69 in.lbf 48 in.lbf 69 in.lbf 48 in.lbf

Author :

Date :

226

SS64
SERVICE SPECIFICATIONS STEERING

STEERING
SS06L03

SERVICE DATA
ONVEHICLE INSPECTION Steering wheel freeplay 5SFE Engine : Drive belt tension Drive belt tension 1MZFE Engine : Drive belt tension Drive belt tension Fluid level rise Fluid pressure at idle speed with valve closed Steering effort at idle speed PS VANE PUMP 5SFE and 1MZFE Engines: Vane pump rotating torque Oil clearance between pump shaft and bushing Oil clearance between pump shaft and bushing Vane plate height Vane plate thickness Vane plate length Clearance between the rotor groove and plate Vane plate length Maximum 0.3 Nm (2.8 kgfcm, 2.4 in.lbf) STD 0.03 0.05 mm (0.0012 0.0020 in.) New belt Used belt 150 185 lbf 95 135 lbf New belt Used belt 95 145 lbf 60 100 lbf Maximum 30 mm (1.18 in.)

Maximum 5 mm (0.20 in.) Minimum 7,845 kPa (80 kgf/cm2, 1,138 psi) Maximum 5.9 Nm (60 kgfcm, 52 in.lbf)

Maximum 0.07 mm (0.0028 in.) Minimum 8.6 mm (0.339 in.) Minimum 1.397 mm (0.0550 in.) Minimum 14.991 mm (0.5902 in.) Maximum 0.035 mm (0.0014 in.)

Pump rotor and cam ring mark NONE 1 2 3 4 14.999 15.001 mm (0.59051 0.59059 in.) 14.997 14.999 mm (0.59043 0.59051 in.) 14.995 14.997 mm (0.59035 0.59043 in.) 14.993 14.995 mm (0.59027 0.59035 in.) 14.991 14.993 mm (0.59020 0.59027 in.)

Spring free length PS GEAR Steering rack runout Total preload (Control valve rotating torque)

Minimum 32.3 mm (1.272 in.)

Maximum 0.30 mm (0.0118 in.) 0.8 1.4 Nm (8 14 kgfcm, 6.9 12.2 in.lbf)

Author :

Date :

227

SS65
SERVICE SPECIFICATIONS STEERING
SS06M01

TORQUE SPECIFICATION
Part tightened STEERING COLUMN Steering wheel pad set screw (Torx screw) Steering wheel set nut Intermediate shaft assembly x Control valve shaft Steering column assembly x Intermediate shaft assembly Steering column assembly set nut Turn signal bracket x Column tube Lower column tube attachment x Column tube PS VANE PUMP 5SFE and 1MZFE Engines: Pressure feed tube x Control valve housing Pressure feed tube x Pressure feed tube Clamp plate set nut Clamp plate set nut PS vane pump set bolt PS vane pump set bolt Oil pressure switch x Union bolt Union bolt x Pressure feed tube Vane pump pulley set nut Front bracket x Rear bracket Suction port union set bolt Pressure port union Rear housing set bolt PS GEAR Pressure feed tube clamp plate set nut Pressure feed and return tubes x Control valve housing Stabilizer bar set bolt PS gear assembly set bolt and nut Turn pressure tube union nut Tie rod end lock nut Rack x Rack end Rack guide spring cap lock nut Rack housing cap Seltlocking nut Control valve housing set bolt 10 32 (25) 19 181 10 (13) 74 60 (83) 50 (69) 59 25 18 100 326 (250) 195 1,850 102 (130) 750 615 (850) 513 (700) 600 250 185 7 24 (18) 14 134 7 (9) 54 45 (62) 37 (51) 43 18 13 5SFE Engine 1MZFE Engine 5SFE Engine 1MZFE Engine A bolt B bolt 32 (25) 20 (25) 10 7.8 29 (43) 43 21 52 43 43 13 83 24 326 (250) 203 (250) 100 80 293 (440) 440 210 525 440 440 130 850 240 24 (18) 15 (18) 7 69 in.lbf 21 (32) 32 15 38 32 32 9 62 17 7.1 35 35 35 25 7 19 72 360 360 360 260 70 195 63 in.lbf 26 26 26 19 61 in.lbf 14 Nm kgfcm ftlbf

( ): For use without SST

Author :

Date :

228

SS66
SERVICE SPECIFICATIONS SUPPLEMENTAL RESTRAINT SYSTEM

SUPPLEMENTAL RESTRAINT SYSTEM

SS06117

TORQUE SPECIFICATION
Part tightened Steering wheel Steering wheel pad Front passenger airbag assembly x Instrument panel reinforcement Front seat installation bolt Seatback frame set bolt (See page RS49) Airbag sensor assembly Front airbag sensor Side airbag sensor assembly Front seat outer belt retractor Upper bolt Lower bolt Bolt A Bolt B Nm 35 7.1 20 37 18 15 20 20 20 7.5 42 kgfcm 360 72 205 375 185 150 205 205 205 76 430 ftlbf 26 63 in.lbf 15 27 13 11 15 15 15 66 in.lbf 31

Author :

Date :

229

SS67
SERVICE SPECIFICATIONS BODY ELECTRICAL

BODY ELECTRICAL
SS0B005

SERVICE DATA
TURN SIGNAL FLASHER Flashes/ Minute SPEEDOMETER (ONVEHICLE) USA: Standard indication (mph) 20 40 60 80 100 120 CANADA: Standard indication (km/h) 20 40 60 80 100 120 140 160 TACHOMETER (ONVEHICLE)/ DC 13.5 V 25 C at (77 F) Standard indication 700 1,000 2,000 3,000 4,000 5,000 6,000 7,000 FUEL RECEIVER GAUGE AB AC BC FUEL SENDER GAUGE Float position mm (in.) F: Approx. 91.1 (3.587) 1/2: Approx. 34.2 (1.346) E: Approx. 30.8 (1.213) ENGINE COOLANT TEMPERATURE RECEIVER GAUGE (Resistance) AB AC Approx. 175.7 Approx. 54.0 Resistance () Approx. 3.0 Approx. 31.7 Approx. 110.0 Approx. 126.2 Approx. 280.5 Approx. 154.3 Allowable range 630 770 900 1,100 1,850 2,150 2,800 3,200 3,800 4,200 4,800 5,200 5,750 6,250 6,700 7,300 Allowable range (km/h) 17 24 38 46 57.5 67 77 88 96 109 115 130 134 151.5 153 173 Allowable range (mph) 18 24 38 44 56 66 78 88 98 110 118 132 60 120

Author :

Date :

230

SS68
SERVICE SPECIFICATIONS BC ENGINE COOLANT TEMPERATURE SENDER GAUGE (Resistance) Temperature C (F) 50 (122.0) 120 (248.0) Resistance () 274 26.4 BODY ELECTRICAL Approx. 229.7

Author :

Date :

231

SS69
SERVICE SPECIFICATIONS BODY

BODY
SS0BY01

TORQUE SPECIFICATION
Part tightened FRONT BUMPER Front bumper cover x Body Front bumper reinforcement x Body REAR BUMPER Rear bumper cover x Body Rear bumper reinforcement x Body HOOD Hood hinge x Hood Hood lock x Body FRONT AND REAR DOOR Front door hinge x Body Rear door hinge x Body Door hinge x Door panel Door lock striker x Body Outside rear view mirror x Front door panel Door inside handle x Door panel Door glass x Window regulator Window regulator x Door panel Door lock x Door panel Door outside handle x Door panel Door check x Body Door check x Door panel LUGGAGE COMPARTMENT DOOR AND HINGE Luggage door hinge x Luggage door Luggage door lock striker x Body Luggage door lock x Luggage door FRONT WIPER AND WASHER Wiper motor assembly x Body Wiper arm x Wiper pivot SLIDING ROOF Sliding roof assembly x Body INSTRUMENT PANEL Front passenger airbag assembly x Reinforcement Steering wheel lock nut SEAT Front Seat (Power Seat for TMC Made) Hinge cover x Seatback frame Seatback frame x Power seat adjuster Seatback frame x Side airbag assembly Front Seat (Manual Seat for TMC Made) Front seat adjuster x Body Nm 5.5 34 5.0 34 26 8.0 31 26 26 26 5.5 3.5 8.0 5.5 5.0 7.0 30 8.0 8.0 5.5 5.5 24 5.5 5.5 20 35 18 15 6.0 37 kgfcm 55 350 50 350 260 80 310 260 260 260 55 35 80 55 50 70 300 80 80 55 55 245 55 55 200 360 185 150 61 375 ftlbf 49 in.lbf 25 43 in.lbf 25 19 71 in.lbf 22 19 19 19 49 31 in.lbf 71 in.lbf 49 in.lbf 43 in.lbf 61 in.lbf 22 71 in.lbf 71 in.lbf 49 in.lbf 49 in.lbf 18 49 in.lbf 49 in.lbf 14 26 13 11 53 in.lbf 27

Author :

Date :

232

SS70
SERVICE SPECIFICATIONS Front seat inner upper track x Seat cushion Side Airbag assembly x Seatback frame Seatback assembly x Seat cushion frame Front Seat (Power Seat for TMMK Made) Side airbag assembly x Seat cushion frame Front Seat (Manual Seat for TMC Made) Side airbag assembly x Seat cushion frame Rear Seat (TMC Made) Seatback hinge x Body Rear seatback lock control x Rear seatback frame Rear Seat (TMMK Made) Seatback pad (RH bolt) x Body Seatback pad (center bolt) x Body Child restraint seat x Body Seatback hinge x Body Rear seatback lock control x Rear seatback frame SEAT BELT Front Seat belt Shoulder anchor x Adjustable anchor Adjustable anchor x Body Inner belt x Seat Retractor x Body Floor anchor x Body Rear Seat Belt Lap outer belt anchor x Body ELR x Body Inner belt x Body Center belt x Body BODY 18 18 6.0 6.0 6.0 18 17.5 7.8 42 13 18 17.5 42 42 42 7.8 42 42 42 42 42 185 185 61 61 61 185 178 79 428 130 185 178 420 420 420 79 420 420 420 420 420 13 13 53 in.lbf 53 in.lbf 53 in.lbf 13 12.5 69 in.lbf 31 9 13 12.5 31 31 31 69 in.lbf 31 31 31 31 31

Author :

Date :

233

SS71
SERVICE SPECIFICATIONS AIR CONDITIONING

AIR CONDITIONING
SS05V02

SERVICE DATA
Refrigerant charge volume Drive belt tension New belt Used belt Idleup speed Magnetic clutch not engaged Magnetic clutch engaged Magnetic clutch clearance 700 50 rpm 700 50 rpm 0.5 0.15 mm (0.020 0.0059 in.) 165 26 lbf 110 11 lbf 800 50 g (28.22 1.76 oz.)

Author :

Date :

234

SS72
SERVICE SPECIFICATIONS AIR CONDITIONING
SS05W06

TORQUE SPECIFICATION
Part tightened Compressor x Discharge hose Compressor x Suction hose Condenser x Disaharge hose Condenser x Liquid tube Receiver x Liquid tube Expansion valve x Evaporator Compressor x Engine Compressor x Compressor bracket (1MZFE Only) Drive belt adjusting bar bracket x Compressor Drive belt adjusting bar bracket x Adjusting bar Pivot bolt 5S FE 5SFE 1MZFE Nm 10 10 10 14 5.4 5.4 25 25 25 18 52 56 18 10 13.2 32 10 kgfcm 100 100 100 140 55 55 250 250 250 185 520 570 185 100 135 330 100 ftlbf 7 7 7 10 48 in.lbf 48in.lbf 18 18 18 13 38 41 13 7 9 24 7

Adjusting lock bolt Pressure switch x Liquied tube Pressure plate x Compressor Suction line (Piping joint) Suction line (Block joint)

Author :

Date :

235

SS1
SERVICE SPECIFICATIONS STANDARD BOLT

STANDARD BOLT
SS0ZS01

HOW TO DETERMINE BOLT STRENGTH

Bolt Type Hexagon Head Bolt Normal Recess Bolt Deep Recess Bolt Stud Bolt Weld Bolt Class

4
No Mark No Mark No Mark

6
w/ Washer w/ Washer

10T

11T

B06431

Author :

Date :

SS2
SERVICE SPECIFICATIONS STANDARD BOLT
SS0ZT01

SPECIFIED TORQUE FOR STANDARD BOLTS

10T

11T

SS3
SERVICE SPECIFICATIONS STANDARD BOLT
SS0ZU01

HOW TO DETERMINE NUT STRENGTH

Nut Type Present Standard Hexagon Nut Old Standard Hexagon Nut Cold Forging Nut Cutting Processed Nut Class

4N
No Mark

5N (4T)
No Mark (w/ Washer) No Mark (w/ Washer) No Mark

6N
6N

7N (5T) *

8N
8N

10N (7T)
10N

No Mark

11N
11N

12N
12N

*: Nut with 1 or more marks on one side surface of the nut.

B06432

SS4
SERVICE SPECIFICATIONS ENGINE MECHANICAL

ENGINE MECHANICAL
SS0AD04

SERVICE DATA
Compression pressure at 250 rpm STD 1,736 kPa (17.7 kgf/cm2, 252 psi) or more Minimum 1,393 kPa (14.2 kgf/cm2, 202 psi) Difference of pressure between each cylinder 98 kPa (1.0 kgf/cm2, 14 psi) or less at cold Intake Exhaust Shim No.00 Shim No.04 Shim No.08 Shim No.02 Shim No.16 Shim No.20 Shim No.24 Shim No.28 Shim No.32 Shim No.36 Shim No.40 Shim No.44 Shim No.48 Shim No.52 Shim No.56 Shim No.60 Shim No.64 Shim No.68 Shim No.72 Shim No.76 Shim No.80 0.19 0.29 mm (0.007 0.011 in.) 0.28 0.38 mm (0.011 0.015 in.) 2.000 mm (0.0787 in.) 2.040 mm (0.0803 in.) 2.080 mm (0.0819 in.) 2.120 mm (0.0835 in.) 2.160 mm (0.0850 in.) 2.200 mm (0.0866 in.) 2.240 mm (0.0882 in.) 2.280 mm (0.0898 in.) 2.320 mm (0.0913 in.) 2.360 mm (0.0929 in.) 2.400 mm (0.0945 in.) 2.440 mm (0.0961 in.) 2.480 mm (0.0976 in.) 2.520 mm (0.0992 in.) 2.560 mm (0.1008 in.) 2.600 mm (0.1024 in.) 2.640 mm (0.1039 in.) 2.680 mm (0.1055 in.) 2.720 mm (0.1071 in.) 2.760 mm (0.1087 in.) 2.800 mm (0.1102 in.)

Valve clearance Adjusting shim (for repair part)

Valve spring

Deviation Free length Installed tension at 35 mm (1.378 in.) Cam lobe height

Maximum 2.0 mm (0.079 in.) 45.9 47.9 mm (1.8071 1.8858 in.) 169 184 N (17.2 18.8 kgf, 37.9 41.4 lbf) STD Intake Exhaust Minimum Intake Exhaust STD Mark 1 Mark 2 Mark 3 O/S 0.50 STD Maximum No.1 No.2 STD No.1 No.2 Oil (side rail) Maximum No.1 No.2 Oil (side rail) 42.21 42.31 mm (1.6618 1.6657 in.) 40.62 40.72 mm (1.5992 1.6031 in.) 42.10 mm (1.6575 in.) 40.51 mm (1.5949 in.) 86.815 86.825 mm (3.4179 3.4183 in.) 86.825 86.835 mm (3.4183 3.4186 in.) 86.835 86.845 mm (3.4201 3.4205 in.) 87.350 87.380 mm (3.4375 3.4387 in.) 0.175 0.195 mm (0.0068 0.0076 in.) 0.215 mm (0.0085 in.) 0.020 0.070 mm (0.0008 0.0003 in.) 0.020 0.055 mm (0.0008 0.0022 in.) 0.220 0.440 mm (0.0087 0.0173 in.) 0.600 0.820 mm (0.0177 0.0322 in.) 0.100 0.470 mm (0.0039 0.0185 in.) 1.04 mm (0.0409 in.) 1.42 mm (0.0559 in.) 1.07 mm (0.0421in.)

Camshaft

Piston and piston ring

Piston diameter

Piston oil clearance Piston ring groove clearance Piston ring end gap

Author :

Date :

SS5
SERVICE SPECIFICATIONS SFI

SFI
SS0AG04

SERVICE DATA
Fuel pressure Fuel pressure between fuel tank and pressure regulatorat 20C (68F) between pressure regulator and injector Resistance Resistance at 20C (68F) at 20C (68F) 24,800 kPa (250 kgf/cm2, 3,600 psi) 834 932 kPa (8.5 9.5 kgf/cm2, 121 135 psi) 2.65 3.0 1.8 2.2 1.4 1.8

Injector Fuel shutoff valve for delivery pipe Fuel shutoff valve for fuel pressure regulator Fuel shutoff valve for fuel tank Fuel temperature sensor for delivery pipe Fuel temperature sensor for fuel tank

Resistance

at 20C (68F)

Resistance

at 20C (68F)

Approx 19 13.9 16.3 k 2.32 2.59 k 0.31 0.326 k 80 100 k 4.80 5.20 k 2.51 2.81 k 0.30 0.37 k 4.5 5.5 V 3.1 3.6 V 4.5 5.5 V Approx. 2.8 V Approx. 2.4 V Approx. 1.8 V Approx. 1.3 V 1,400 rpm

Resistance

at 20C (4F) at 20C (68F) at 80C (176F) at 30C (22F) at 25C (77F) at 40C (104F) at 100C (212F) at 20C (68F) at 20C (68F) at 20C (68F) at 20C (68F) at 4/4 at 3/4 at 2/4 at 1/4 A/C OFF

Resistance

Fuel pressure sensor for delivery pipe Fuel pressure sensor for fuel pipe

Power source voltage Power output voltage Power source voltage Power output voltage Needle position of fuel level gauge

Fuel cut rpm

Fuel return rpm

Author :

Date :

SS6
SERVICE SPECIFICATIONS SFI
SS0AH04

TORQUE SPECIFICATION
Part tightened Fuel line for union for fuel inlet coupler for others Nm 42 28 10.8 21.5 31 24.5 20 for 10 mm head bolt for 12 mm head bolt 9.9 19.6 42 13 52 100 for fuel pipe filter pipe for others 31 18 8.2 8.2 60.2 39.2 18.1 35 15 20.4 24.6 68.6 9.9 kgfcm 428 286 110 219 316 250 200 100 200 428 130 530 1,020 316 184 84 84 614 400 185 357 153 208 251 700 100 ftlbf 31 21 8 16 23 18 15 88 in.lbf 14 31 10 38 74 23 13 73 in.lbf 73 in.lbf 44 29 13 26 11 15 18 51 88 in.lbf

Fuel filter x Drain plug Fuel filter x Fuel filter bracket Fuel filter x Union Oil separator x Fuel pressure regulator Fuel pressure regulator x Bracket Fuel pressure regulator bracket x Body

Fuel relief pipe x Fuel pressure regulator Delivery pipe x cylinder head Fuel tank band x Fuel tank frame Rear side plate x Front side plate Union x Fuel shutoff valve

Fuel tank bracket x Fuel tank valve case Fuel tank valve cover x Fuel tank valve case Fuel tank frame x Body Performance rod x Body Performance rod x Fuel tank band Fuel shutoff valve core x Delivery pipe Fuel shutoff valve coil x Core Fuel temperature sensor x Delivery pipe Fuel pressure sensor x Delivery pipe Fuel pressure sensor x Fuel main pipe Fuel inlet hose x Fuel pressure regulator

SS7
SERVICE SPECIFICATIONS IGNITION

IGNITION
SS0AM04

SERVICE DATA
Spark plug Recommended spark plug DENSO made Correct electrode gap for new spark plug Maximum electrode gap for used spark plug SK20R11G 1.1 mm (0.043 in.) 1.2 mm (0.047 in.)

Author :

Date :

SS8
SERVICE SPECIFICATIONS IGNITION
SS0AN04

TORQUE SPECIFICATION
Part tightened Spark plug x Cylinder head Nm 18 kgfcm 180 ftlbf 13

SS9
SERVICE SPECIFICATIONS SUSPENSION AND AXLE

SUSPENSION AND AXLE

SS04W03

SERVICE DATA
Vehicle height Tire size: 205/65R15 Camber Rightleft Ri h l f error Caster Rightleft error Front wheel alignment Steering axis inclination Rightleft error Toein (Total) 0 12 (0 0.2 0 2 mm 0 0.08 in.) Rack end length difference 1.5 mm (0.059 in.) or less Wheel angle Inside wheel Outside wheel 045 45 (0.75 0.75) 45 (0.75) or less 3550 2 (35.84 2) 3128 (31.47) Front*5 Rear*6 036 45 (0 6 0.75) 036 (0.6 0 75) 45 (0 75) or l (0.75) less 210 45 (2.17 0.75) 45 (0.75) or less 1301 45 (13.02 0.75) 45 (0.75) or less 218 mm (8.58 in.) 270 mm (10.63 in.)

Camber Rightleft error Rear wheel alignment Toein (total)

024 12 (0.4 0.2) 4 2 mm (0.16 0.08 in.) No. 2 lower suspension arm length difference 1 mm (0.04 in.) or less

*1: Front measuring point Measure the distance from the ground to the center of the front side lower suspension arm mounting bolt. *2: Rear measuring point Measure the distance from the ground to the center of the front side strut rod mounting bolt.
Axle bearing backlash Front l F t axle Axle hub deviation Drive shaft standard length Front drive shaft Lower ball joint turning torque Front F t suspension i Stabilizer bar link turning torque Axle bearing backlash Rear axle R l Axle hub deviation No. 2 lower suspension arm length Rear suspension R i Stabilizer bar link turning torque LH RH 609.2 2.0 mm (23.984 0.079 in.) 842.9 2.0 mm (33.185 0.079 in.) 1.0 3.4 Nm (10 35 kgfcm, 8.7 30 in.lbf) 0.05 1.0 Nm (0.5 10 kgfcm, 0.4 8.7 in.lbf) 0.05 mm (0.0020 in.) 0.07 mm (0.0028 in.) 512.3 mm (20.169 in.) 0.05 1.0 Nm (0.5 10 kgfcm, 0.4 8.7 in.lbf) Maximum 0.05 mm (0.0020 in.) Maximum 0.05 mm (0.0020 in.)

Author :

Date :

SS10
SERVICE SPECIFICATIONS SUSPENSION AND AXLE
SS04X03

TORQUE SPECIFICATION
Part tightened FRONT AXLE Hub nut Steering knuckle x Shock absorber Steering knuckle x Brake caliper Steering knuckle x Tie rod end Axle hub x Drive shaft Lower ball joint x Lower suspension arm Lower ball joint x Steering knuckle ABS speed sensor set bolt Tie lod end lock nut FRONT DRIVE SHAFT Drive shaft center bearing lock bolt FRONT SUSPENSION Suspension support x Body Suspension support x Piston rod Flexible hose and ABS speed sensor wire harness x Shock absorber Lower suspension arm set bolt Stabilizer bar link set bolt REAR AXLE Hub nut Axle hub set bolt Shock absorber x Rear axle carrier New nut Reused nut (Apply engine oil to the threads.) No. 1, No. 2 lower suspension arm x Rear axle carrier Strut rod x Rear axle carrier Flexible hose x Shock absorber ABS speed sensor set bolt REAR SUSPENSION ABS speed sensor wire harness x Shock absorber Rear seat outer belt lower side set bolt Suspension support x Body Suspension support x Piston rod Parking brake cable set bolt No. 2 lower suspension arm lock nut No. 1, No. 2 lower suspension arm x Suspension member Strut rod x Body Stabilizer bar bracket x Suspension member Stabilizer bar link set nut 5.4 42 39 49 5.4 56 181 113 19 39 55 430 400 500 55 570 1,850 1,150 195 400 48 in.lbf 31 29 36 48 in.lbf 41 134 83 14 29 103 80 255 196 181 113 29 8.0 1,050 820 2,600 2,000 1,850 1,150 300 82 76 59 188 145 134 83 22 71 in.lbf 80 49 29 206 39 820 500 300 2,100 400 59 36 22 152 29 32 330 24 103 211 107 49 294 127 123 8.0 74 1,050 2,150 1,090 500 3,000 1,300 1,250 82 750 76 156 79 36 217 94 90 71 in.lbf 54 Nm kgfcm ftlbf

SS11
SERVICE SPECIFICATIONS BODY ELECTRICAL

BODY ELECTRICAL
SS0B006

SERVICE DATA
FUEL RECEIVER GAUGE AB AC BC ENGINE COOLANT TEMPERATURE RECEIVER GAUGE (Resistance) AB AC BC ENGINE COOLANT TEMPERATURE SENDER GAUGE (Resistance) Temperature C (F) 50 (122.0) 120 (248.0) Resistance () 160 240 17.1 21.2 Approx. 175.7 Approx. 54.0 Approx. 229.7 Approx. 270.1 Approx. 141.3 Approx. 128.8

Author :

Date :

SS12
SERVICE SPECIFICATIONS BODY
SS13F01

TORQUE SPECIFICATION
Part tightened REAR BUMPER Rear bumper cover x Body Rear bumper reinforcement x Body Rear bumper side retainer x Body LUGGAGE COMPARTMENT DOOR AND HINGE Door lock striker x Body Door lock x Door panel Luggage compartment door hinge x Door panel REAR SEAT Rear seatback x Body SEAT BELT Front seat belt Retractor x Body Upper: Lower: Inner belt x Seat Shoulder anchor x Body Floor anchor x Body Rear seat belt Retractor x Body Floor anchor x Body RH center belt x Body LH center belt x Body Nm 4.9 34 4.9 5.4 5.4 7.8 18 7.8 41 41 41 41 41 41 41 41 kgfcm 51 350 51 55 55 80 185 80 420 420 420 420 420 420 420 420 ftlbf 43 in.lbf 25 43 in.lbf 49 in.lbf 49 in.lbf 69 in.lbf 13 69 in.lbf 30 30 30 30 30 30 30 30

Author :

Date :

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