SERVICE DATA
| MASS Air flow meter | Standard | Less than 0.48 g/sec | |
|---|---|---|---|
| Camshaft timing oil control valve assembly | Standard resistance | 6.9 to 7.9 ohms at 20°C (68°F) | |
| Camshaft position sensor | Standard resistance | 835 to 1400 ohms at cold 1060 to 1645 ohms at hot | |
| Crankshaft position sensor | Standard resistance | 985 to 1600 ohms at cold 1265 to 1890 ohms at hot | |
| Throttle with motor body assembly | Standard resistance | 1 (M-) - 2 (M+) | 0.3 to 100 ohms at 20°C (68°F) |
| EFI (20A) fuse | Standard resistance | T2 - T6 | Below 1 ohms |
| Knock sensor | Standard resistance | 120 to 280 kohms at 20°C (68°F) | |
| Integration relay | B1 - C1 | Below 1 ohms | |
| B5 - B8 | 10 kohms or higher | ||
| B1 - B4 | 10 kohms or higher | ||
| B1 - B4 | Below 1 ohms (Apply battery voltage between terminals B6 and B7) | ||
| B4 - C1 | Below 1 ohms (Apply battery voltage between terminals B6 and B7) | ||
| A1 - A4 | 10 kohms or higher | ||
| Below 1 ohms (When battery voltage applied to terminals B2 and B3) | |||
| ACCEL POS # 1 | Standard voltage | Accelerator pedal released | 0.5 to 1.1 V |
| Accelerator pedal depressed | 2.6 to 4.5 V | ||
| ACCEL POS # 2 | Standard voltage | Accelerator pedal released | 1.2 to 2.0 V |
| Accelerator pedal depressed | 3.4 to 5.0 V | ||
| Engine coolant temperature sensor | Standard resistance | 1 - 2 | 2.32 to 2.59 kohms at 20°C (68°F) |
| 0.310 to 0.326 kohms at 80°C (176°F) | |||
| No. 1 ignition relay | Standard resistance | 3 - 5 | 10 kohms or higher |
| Below 1 ohms (When battery voltage applied to terminals 1 and 2) | |||
| Air fuel ratio sensor | Standard resistance | 2 (+B) - 1 (HT) | 1.8 ohms to 3.4 ohms at 20°C (68°F) |
| 2 (HT) - 1 (AR) | 10 kohms or higher | ||
| Heated oxygen sensor | Standard resistance | 1 (HMB) - 2 (+B) | 11 ohms to 16 ohms at 20°C (68°F) |
| 1 (HMB) - 4 (E2) | 10 kohms or higher | ||
2AZ-FE ENGINE CONTROL SYSTEM - SERVICE DATA
| Engine | Ignition timing | Standard | When using Intelligent tester or Techstream | BTDC 0 to 15° at idle |
|---|---|---|---|---|
| When not using Intelligent tester and Techstream | BTDC 5 to 12° at idle (Connect terminals 13 (TC) and 4 (CG)) | |||
| BTDC 5 to 15° at idle (Remove terminals 13 (TC) and 4 (CG)) | ||||
| Engine idling speed | Standard | 600 to 700 rpm | ||
| Compression | Standard | 1300 kPa (13.3 kgf/cm 2 , 189 psi) | ||
| Minimum | 1000 kPa (10.0 kgf/cm 2 , 145 psi) | |||
| Difference between each cylinder | 100 kPa (1.0 kgf/cm 2 , 15 psi) | |||
| Camshaft | Valve clearance | Standard | Intake | 0.19 to 0.29 mm (0.0075 to 0.0114 in.) |
| Exhaust | 0.38 to 0.48 mm (0.0150 to 0.189 in.) | |||
| Thrust clearance | Standard | Intake | 0.040 to 0.095 mm (0.0016 to 0.0037 in.) | |
| Exhaust | 0.080 to 0.135 mm (0.0032 to 0.0053 in.) | |||
| Maximum | Intake | 0.110 mm (0.0043 in.) | ||
| Exhaust | 0.150 mm (0.0059 in.) | |||
| Oil clearance | Standard | Camshaft No. 1 journal bearing mark 1 | 0.007 to 0.038 mm (0.0003 to 0.0015 in.) | |
| Camshaft No. 1 journal bearing mark 2 | 0.008 to 0.038 mm (0.0003 to 0.0015 in.) | |||
| Camshaft No. 1 journal bearing mark 3 | 0.008 to 0.038 mm (0.0003 to 0.0015 in.) | |||
| Camshaft other journals | 0.025 to 0.062 mm (0.0010 to 0.0024 in.) | |||
| No. 2 camshaft No. 1 journal | 0.015 to 0.054 mm (0.0006 to 0.0021 in.) | |||
| No. 2 camshaft No. 1 journals | 0.025 to 0.062 mm (0.0010 to 0.0024 in.) | |||
| Maximum | Intake | 0.070 mm (0.0028 in.) | ||
| Exhaust | 0.100 mm (0.0039 in.) | |||
| Circle runout | Maximum | 0.03 mm (0.0012 in.) | ||
| Cam lobe height | Standard | Intake | 47.306 to 47.406 mm (1.8654 to 1.8664 in.) | |
| Exhaust | 45.983 to 46.083 mm (1.8104 to 1.8143 in.) | |||
| Minimum | Intake | 47.196 mm (1.8581 in.) | ||
| Exhaust | 45.873 mm (1.8060 in.) | |||
| Journal diameter | Standard | No. 1:35.971 to 35.985 mm (1.4162 to 1.4167 in.) Other: 22.9595 to 22.975 mm (0.9039 to 0.9045 in.) | ||
| Cylinder head | Flatness | Standard | Cylinder block side | 0.05 mm (0.0020 in.) |
| Intake manifold side | 0.08 mm (0.0031 in.) | |||
| Exhaust manifold side | 0.08 mm (0.0031 in.) | |||
| Lifter bore diameter | Standard | 31.009 to 31.025 mm (1.2208 to 1.2215 in.) | ||
| Inner compression spring | Length | Standard | 47.43 mm (1.867 in.) | |
| Deviation | Maximum | 1.6 mm (0.063 in.) | ||
| Intake valve | Overall length | Standard | 101.71 mm (4.0043 in.) | |
| Minimum | 101.21 mm (3.9846 in.) | |||
| Valve stem diameter | Standard | 5.470 to 5.485 mm (0.2154 to 0.2159 in.) | ||
| Margin thickness | Standard | 1.05 to 1.45 mm (0.0413 to 0.0571 in.) | ||
| Minimum | 0.50 mm (0.0197 in.) | |||
| Exhaust valve | Overall length | Standard | 101.15 mm (3.9823 in.) | |
| Minimum | 100.70 mm (3.9646 in.) | |||
| Valve stem diameter | Standard | 5.465 to 5.480 mm (0.2152 to 0.2157 in.) | ||
| Margin thickness | Standard | 1.20 to 1.60 mm (0.0472 to 0.0630 in.) | ||
| Minimum | 0.50 mm (0.0197 in.) | |||
| Intake valve guide bush | Inside diameter | Standard | 5.510 to 5.530 mm (0.2169 to 0.2177 in.) | |
| Oil clearance | Standard | 0.025 to 0.060 mm (0.0010 to 0.0024 in.) | ||
| Maximum | 0.080 mm (0.0031 in.) | |||
| Exhaust valve guide bush | Inside diameter | Standard | 5.510 to 5.530 mm (0.2169 to 0.2177 in.) | |
| Oil clearance | Standard | 0.030 to 0.065 mm (0.0012 to 0.0026 in.) | ||
| Maximum | 0.100 mm (0.0039 in.) | |||
| Valve lifter | Diameter | Standard | 30.966 to 30.976 mm (1.2191 to 1.2195 in.) | |
| Oil clearance | Standard | 0.033 to 0.059 mm (0.0013 to 0.0023 in.) | ||
| Maximum | 0.070 mm (0.0028 in.) | |||
| Connecting rod | Thrust clearance | Standard | 0.160 to 0.362 mm (0.0063 to 0.0143 in.) | |
| Maximum | 0.362 mm (0.0143 in.) | |||
| Oil clearance | Standard | 0.032 to 0.063 mm (0.0013 to 0.0025 in.) | ||
| Maximum | 0.063 mm (0.0025 in.) | |||
| Cylinder block | Warpage | Maximum | 0.05 mm (0.0020 in.) | |
| Cylinder bore diameter | Standard | 88.500 to 88.513 mm (3.4843 to 3.4847 in.) | ||
| Maximum | 88.633 mm (3.4894 in.) | |||
| Piston | Diameter | Standard | 88.469 to 88.479 mm (3.4830 to 3.4834 in.) | |
| Oil clearance | Standard | 0.021 to 0.044 mm (0.0008 to 0.0017 in.) | ||
| Maximum | 0.10 mm (0.0039 in.) | |||
| Ring groove clearance | Standard | No. 1 | 0.020 to 0.070 mm (0.0008 to 0.0028 in.) | |
| No. 2 | 0.020 to 0.060 mm (0.0008 to 0.0024 in.) | |||
| Oil | 0.020 to 0.070 mm (0.0008 to 0.0028 in.) | |||
| Piston ring | End gap | Standard | No. 1 | 0.24 to 0.31 mm (0.0094 to 0.0122 in.) |
| No. 2 | 0.33 to 0.43 mm (0.0130 to 0.0169 in.) | |||
| Oil | 0.10 to 0.30 mm (0.0040 to 0.0119 in.) | |||
| Maximum | No. 1 | 0.89 mm (0.0350 in.) | ||
| No. 2 | 1.37 mm (0.0539 in.) | |||
| Oil | 0.73 mm (0.0287 in.) | |||
| Piston pin | Oil clearance (Piston pin x Piston pin bore) | Standard | 0.001 to 0.007 mm (0.00004 to 0.00003 in.) | |
| Maximum | 0.010 mm (0.0004 in.)) | |||
| Oil clearance (Piston pin x Connecting rod small end bore) | Standard | 0.005 to 0.011 mm (0.0002 to 0.0004 in.) | ||
| Maximum | 0.011 mm (0.0004 in.) | |||
| Connecting rod bolt | Diameter | Standard | 7.2 to 7.3 mm (0.283 to 0.287 in.) | |
| Minimum | 7.0 mm (0.276 in.) | |||
| Connecting rod | Misalignment | Maximum | 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) | |
| Twist | Maximum | 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) | ||
| Crankshaft | Circle runout | Maximum | 0.03 mm (0.0012 in.) | |
| Main journal diameter | Standard | 54.988 to 55.000 mm (2.1649 to 2.1654 in.) | ||
| Main journal for taper and distortion | Maximum | 0.003 mm (0.0001 in.) | ||
| Crank pin diameter | Standard | 47.990 to 48.000 mm (1.8894 to 1.8898 in.) | ||
| Crank pin for taper and distortion | Maximum | 0.003 mm (0.0001 in.) | ||
| Thrust clearance | Standard | 0.04 to 0.24 mm (0.0016 to 0.0095 in.) | ||
| Maximum | 0.30 mm (0.0118 in.) | |||
| Oil clearance | Standard | 0.017 to 0.040 mm (0.0007 to 0.0016 in.) | ||
| Maximum | 0.060 mm (0.0024 in.) | |||
| Crankshaft bearing cap set bolt | Diameter | Standard | 7.3 to 7.5 mm (0.287 to 0.295 in.) | |
| Minimum | 7.2 mm (0.284 in.) | |||
| Front exhaust pipe compression spring | Length | Minimum | 41.5 mm (1.634 in.) | |
| Balanceshaft | Thrust clearance | Standard | 0.05 to 0.09 mm (0.0020 to 0.0035 in.) | |
| Maximum | 0.09 mm (0.0035 in.) | |||
| Oil clearance | Standard | 0.004 to 0.049 mm (0.0002 to 0.0019 in.) | ||
| Maximum | 0.049 mm (0.0019 in.) | |||
| Balanceshaft housing bolt | Length | Standard | 58.3 to 59.7 mm (2.295 to 2.350 in.) | |
| Maximum | 60.3 mm (2.374 in.) | |||
| Chain sub-assembly | Elongation | Maximum | 114.5 mm (4.508 in.) | |
| No. 2 chain sub-assembly | Elongation | Maximum | 102.2 mm (4.024 in.) | |
| Oil pump drive gear | Diameter (with chain) | Minimum | 48.2 mm (1.898 in.) | |
| Oil pump drive shaft gear | Diameter (with chain) | Minimum | 48.2 mm (1.898 in.) | |
| Camshaft timing gear assembly | Diameter (with chain) | Minimum | 97.3 mm (3.831 in.) | |
| Camshaft timing gear or sprocket | Diameter (with chain) | Minimum | 97.3 mm (3.831 in.) | |
| Crankshaft timing gear or sprocket | Diameter (with chain) | Minimum | 51.6 mm (2.031 in.) | |
| Chain tensioner slipper | Maximum | Wear | 1.0 mm (0.039 in.) | |
| No. 1 chain vibration damper | Maximum | Wear | 1.0 mm (0.039 in.) | |
| Chain tensioner plate | Maximum | Wear | 0.5 mm (0.020 in.) | |
2AZ-FE ENGINE MECHANICAL - SERVICE DATA
| Battery | Voltage | Standard | 11 to 14 V | |
|---|---|---|---|---|
| Fuel pump operation | Fuel pressure | Standard | 304 to 343 kPa (3.1 to 3.5 kgf/cm 2 , 44 to 50 psi) | |
| Fuel injector assembly | Resistance | Standard | 11.6 to 12.4 ohms at 20°C (68°F) | |
| Injection volume | Standard | 76 to 92 cm 3 (4.6 to 5.6 cu in.) per 15 seconds | ||
| Fuel pump | Resistance | Standard | 1 - 2 | 0.2 to 3.0 ohms at 20°C (68°F) |
| Fuel sender gauge assembly | Resistance | Standard | 1 - 2 | 13.5 to 16.5 ohms F (Upper end) |
| 1 - 2 | 405.5 to 414.5 ohms E (Lower end) | |||
2AZ-FE FUEL - SERVICE DATA
| VSV | Standard resistance | 1 - 2 | 23 to 26 ohms at 20°C (68°F) |
|---|---|---|---|
| 1 - Body | 10 kohms or higher | ||
| 2 - Body | 10 kohms or higher |
2AZ-FE EMISSION CONTROL - SERVICE DATA
| Compression spring | Minimum length Front side | 41.5 mm (1.634 in) |
|---|---|---|
| Minimum length Rear side | 38.5 mm (1.516 in.) |
2AZ-FE EXHAUST - SERVICE DATA
| Thermostat | Valve opening temperature | Standard | 80 to 84°C (176 to 183°F) | |
|---|---|---|---|---|
| Valve lift | Standard | 10 mm (0.39 in.) or more at 95°C (203°F) | ||
| Cooling fan motor | Current | Standard | 1(+) - 2(-) | 5.7 to 7.7 A at 20°C (68°F) |
| No. 2 cooling fan motor | Current | Standard | 1(+) - 2(-) | 5.7 to 7.7 A at 20°C (68°F) |
| No. 1 fan relay (FAN NO. 1) | Resistance | Standard | 3 - 5 | 10 ohms or higher (When battery voltage absent) |
| Below 1 ohms (When battery voltage is applied to terminal 1 and 2) | ||||
| No. 2 fan relay (FAN NO. 2) | Resistance | Standard | 3 - 4 | Below 1 ohms (When battery voltage absent) |
| 3 - 5 | 10 ohms or higher (When battery voltage absent) | |||
| 3 - 4 | 10 ohms or higher (When battery voltage is applied to terminal 1 and 2) | |||
| 3 - 5 | Below 1 ohms. (When battery voltage is applied to terminal 1 and 2) | |||
| No. 3 fan relay (FAN NO. 3) | Resistance | Standard | 3 - 5 | 10 ohms or higher (When battery voltage absent) |
| Below 1 ohms (When battery voltage is applied to terminal 1 and 2) | ||||
2AZ-FE COOLING - SERVICE DATA
| Oil pressure switch | Oil pressure | Standard | Idling | 29 kPa (0.3 kgf/cm 2 , 4.3 psi) or more |
|---|---|---|---|---|
| 3000 rpm | 170 to 300 kPa (1.7 to 3.1 kgf/cm 2 , 24 to 44 psi) | |||
| Oil pump rotor | Side clearance | Standard | 0.030 to 0.085 mm (0.0012 to 0.0033 in.) | |
| Maximum | 0.16 mm (0.0063 in.) | |||
| Tip clearance | Standard | 0.080 to 0160 mm (0.0031 to 0.0063 in.) | ||
| Maximum | 0.35 mm (0.0138 in.) | |||
| Body clearance | Standard | 0.100 to 0170 mm (0.0039 to 0.0067 in.) | ||
| Maximum | 0.325 mm (0.01128 in.) | |||
| No. 2 chain sub-assembly | Chain elongation | Maximum | 52.4 mm (2.063 in.) | |
| Crankshaft timing gear or sprocket | Sprocket diameter (with Chain) | Minimum | 48.2 mm (1.898 in.) | |
| Oil pump drive shaft sprocket | Sprocket diameter (with Chain) | Minimum | 48.2 mm (1.898 in.) | |
| Chain tensioner plate | Wear | Maximum | 0.5 mm (0.020 in.) | |
2AZ-FE LUBRICATION - SERVICE DATA
| For Used Spark plug | Electrode gap | Maximum | 1.3 mm (0.051 in.) |
|---|---|---|---|
| For New Spark plug | Electrode gap | Standard | 1.0 to 1.1 mm (0.039 to 0.043 in.) |
2AZ-FE IGNITION - SERVICE DATA
| Starter assembly | Specified current | 90 A or less at 11.5 V | |
|---|---|---|---|
| Magnet switch body | Standard resistance | Terminal 50 - Terminal C | Below 1 ohms |
| Standard resistance | Terminal 50 - Switch body | Below 2 ohms | |
| Starter armature assembly | Standard resistance | Segment - Segment | Below 1 ohms |
| Standard resistance | Commutator - Armature coil core | 10 kohms or higher | |
| Commutator depth | Specified depth | 3.1 mm (0.122 in.) | |
| Maximum depth | 3.8 mm (0.150 in.) | ||
| Starter commutator end frame assembly | Brush length | Specified length | 9.0 mm (0.354 in.) |
| Maximum length | 4.0 mm (0.157 in.) | ||
| Standard resistance | 10 kohms or higher | ||
| Starter relay | Standard resistance | 3 - 5 (When battery voltage absent) | 10 kohms or higher |
| 3 - 5 (When battery voltage applied to terminals 1 and 2) | Below 1 ohms | ||
| Ace relay | Standard resistance | 3 - 5 (When battery voltage absent) | 10 kohms or higher |
| 3 - 5 (When battery voltage applied to terminals 1 and 2) | Below 1 ohms | ||
| Ignition switch assembly | Standard resistance | LOCK: Between all terminals | 10 kohms or higher |
| ACC: 2 (AM1) - 3 (ACC) | Below 1 ohms | ||
| ON: 2 (AM1) - 3 (ACC) - 4 (IG1) | |||
| ON: 7 (AM2) - 6 (IG2) | |||
| START: 2 (AM1) - 4 (IG1) - 1 (ST1) | |||
| START: 7 (AM2) - 6 (IG2) - 8 (ST2) | |||
2AZ-FE STARTING - SERVICE DATA
| Battery voltage | Standard voltage | 12.5 to 12.9 V at 20°C (68°F) | |
|---|---|---|---|
| Fuse | Standard resistance | Below 1 ohms | |
| Charging circuit without load | Standard current | 10 A or less | |
| Standard voltage | 13.2 to 14.8 V | ||
| Generator brush holder assembly | Standard length | 9.5 to 11.5 mm (0.374 to 0.453 in.) | |
| Minimum length | 4.5 mm (0.177 in.) | ||
| Generator rotor assembly | Standard resistance | Between the slip rings | 2.3 to 2.7 ohms at 20°C (68°F) |
| Slip ring - Rotor core | 1 Mohms or higher | ||
| Standard diameter | 14.2 to 14.4 mm (0.559 to 0.567 in.) | ||
| Minimum diameter | 14 mm (0.551 in.) | ||
2AZ-FE CHARGING - SERVICE DATA
AUTOMATIC TRANSAXLE SYSTEM
| Line pressure (Wheel locked) AT stall (Throttle valve fully opened) | D position | 931 to 1,031 kPa (9.1 to 10.5 kgf*cm 2 , 129 to 149 psi) |
|---|---|---|
| R position | 1,768 to 1,968 kPa (18.0 to 20.0 kgf/cm 2 , 284 to 256 psi) | |
| Engine stall revolution | D positions | 2,420 to 2,720 rpm |
| Time lag | N --> D position | Less than 1.2 seconds |
| N --> R position | Less than 1.5 seconds | |
| Engine idle speed (A/C OFF) | N position | 650 to 750 rpm |
| Shift point | ||
| D position (Throttle valve fully opened) | 1 --> 2 | 57 to 65 km/h (35 to 40 mph) |
| 2 --> 3 | 107 to 116 km/h (66 to 72 mph) | |
| 3 --> 4 | 172 to 186 km/h (107 to 116 mph) | |
| 4 --> 3 | 164 to 178 km/h (102 to 111 mph) | |
| 3 --> 2 | 99 to 107 km/h (62 to 66 mph) | |
| 2 --> 1 | 48 to 55 km/h (30 to 34 mph) | |
| D position (Throttle valve fully closed) | 3 --> 4 | 41 to 47 km/h (25 to 29 mph) |
| 4 --> 3 | 24 to 30 km/h (15 to 19 mph) | |
| Lock-up point | ||
| D position (Throttle valve opening 4 %) | Lock-up ON 4 --> 4L | 60 to 66 km/h (37 to 41 mph) |
| Lock-up OFF 4L --> 4 | 56 to 63 km/h (35 to 39 mph) | |
| Flex lock-up point | ||
| D position (Throttle valve opening 4 %) | Flex lock-up ON 4 --> 4L | 44 to 50 km/h (27 to 31 mph) |
| Flex lock-up OFF 4L --> 4 | 41 to 47 km/h (25 to 29 mph) | |
| Flex lock-up ON 3 --> 3L | 32 to 38 km/h (20 to 24 mph) | |
| Flex lock-up OFF 3L --> 3 | 28 to 35 km/h (17 to 22 mph) | |
AUTOMATIC TRANSAXLE SYSTEM - SERVICE DATA
SPEED SENSOR
| Speed sensor NT resistance | ||
|---|---|---|
| 1 - 2 | 20°C (68°F) | 560 to 680 ohms |
| Speed sensor NC resistance | ||
| 1 - 2 | 20°C (68°F) | 560 to 680 ohms |
SPEED SENSOR - SERVICE DATA
PARK / NEUTRAL POSITION SWITCH
| Park/neutral position switch resistance | ||
|---|---|---|
| 2 (RB) - 6 (PL) and 4 (B) - 5 (L) | P | Below 1 ohms. |
| Except P | 10 kohms or higher | |
| 2 (RB) - 1 (RL) | R | Below 1 ohms |
| Except R | 10 kohms or higher | |
| 2 (RB) - 9 (NL) and 4 (B) - 5 (L) | N | Below 1 ohms |
| Except N | 10 kohms or higher | |
| 2 (RB) - 7 (DL) | D and S, "+" and "-" | Below 1 ohms |
| Except D and Except S, "+" and "-" | 10 kohms or higher | |
PARK / NEUTRAL POSITION SWITCH - SERVICE DATA
TRANSMISSION WIRE
| Transmission wire resistance | ||
|---|---|---|
| 1 (THO) - 6 (E2) | 10°C (50°F) | 5 to 8 kohms |
| 25°C (77°F) | 2.5 to 4.5 kohms | |
| 110°C (230°F) | 0.22 to 0.28 kohms | |
TRANSMISSION WIRE - SERVICE DATA
VALVE BODY ASSEMBLY
| Shift solenoid valve SL1 resistance | ||
|---|---|---|
| 1 - 2 | 20°C (68°F) | 5.0 to 5.6 ohms |
| Shift solenoid valve SL2 resistance | ||
| 1 - 2 | 20°C (68°F) | 5.0 to 5.6 ohms |
| Shift solenoid valve SLT resistance | ||
| 1 - 2 | 20°C (68°F) | 5.0 to 5.6 ohms |
| Shift solenoid valve DSL resistance | ||
| Solenoid Connector - Solenoid Body | 20°C (68°F) | 11 to 13 ohms |
| Shift solenoid valve S4 resistance | ||
| Solenoid Connector - Solenoid Body | 20°C (68°F) | 11 to 15 ohms |
VALVE BODY ASSEMBLY - SERVICE DATA
SHIFT LEVER
| Shift lock control ECU voltage | ||
|---|---|---|
| 6 (ACC) -1 (E) | Ignition switch ON | 11 to 14 V |
| Ignition switch ACC | 11 to 14 V | |
| Ignition switch OFF | Below 1 V | |
| 4 (STP) -1 (E) | Brake pedal depressed | 11 to 14 V |
| Brake pedal released | Below 1 V | |
| 5 (KLS+) - 1 (E) | 1. Ignition switch ACC and shift lever P position | 7.5 to 11 V |
| 2. Ignition switch ACC and shift lever except P position | Below 1 V | |
| 3. Ignition switch ACC and shift lever P position (After approx. 1 second) | 6 to 9 V | |
| 8 (IG) - 1 (E) | Ignition switch ON | 11 to 14 V |
| Ignition switch OFF | Below 1 V | |
| Shift lock control ECU resistance | ||
| 1 (E) - Body ground | When battery voltage absent | Below 1 ohms |
| Transmission control switch resistance | ||
| 7 (IG) - 13 (S) | S | Below 1 ohms |
| Except S | 10 kohms or higher | |
| 4 (SFTD) - 11 (E) | Continuously shift to "-" (Down-shift) | Below 1 ohms |
| S | 10 kohms or higher | |
| 5 (SFTU) - 11 (E) | Continuously shift to "+" (Up-shift) | Below 1 ohms |
| S | 10 kohms or higher | |
| Shift lock solenoid resistance | ||
| 3 (SLS-) - 4 (SLS+) | When battery voltage absent | 112 ohms |
| 1 (P) - 2 (E2) | Shift lever P position | 10 kohms or higher |
| Shift lever except P position | Below 1 ohms | |
SHIFT LEVER - SERVICE DATA
DIFFERENTIAL OIL SEAL
| Transaxle housing oil seal drive in depth | Standard | 0.5 to 0.5 mm (-0.0197 to 0.0197 in.) |
|---|---|---|
| Differential side bearing retainer oil seal drive in depth | Standard | 0.5 to 0.5 mm (-0.0197 to 0.0197 in.) |
DIFFERENTIAL OIL SEAL - SERVICE DATA
TORQUE CONVERTER AND DRIVE PLATE
| Drive plate runout | Maximum. | 0.20 mm (0.0079 in.) |
TORQUE CONVERTER AND DRIVE PLATE - SERVICE DATA
AUTOMATIC TRANSAXLE UNIT
| Input shaft end play | Standard | 0.262 to 1.249 mm (0.0103 to 0.0492 in.) |
|---|---|---|
| Underdrive brake return spring free length | Standard | 14.04 mm (0.5213 in.) |
| 1st and reverse brake return spring free length | Standard | 15.51 mm (0.6106 in.) |
| Forward clutch hub bush inside diameter | Standard | 23.025 to 23.045 mm (0.9065 to 0.9073 in.) |
| Maximum | 23.09 mm (0.9091 in.) | |
| Counter drive gear bearing turning torque (At 60 rpm) | Standard (New bearing) | 0.5 to 1.0 N*m (5.1 to 10.0 kgf*cm, 4.4 to 8.7 in.*lbf) |
| Standard (Used bearing) | 0.3 to 0.5 N*m (3.1 to 5.1 kgf*cm, 2.7 to 4.4 in.*lbf) | |
| 1st and reverse brake pack clearance | Standard | 1.02 to 1.21 mm (0.0402 to 0.0476 in.) |
| 1st and reverse brake flange thickness | Mark 1 | 1.8 mm (0.071 in.) |
| Mark 2 | 1.9 mm (0.075 in.) | |
| Mark 3 | 2.0 mm (0.079 in.) | |
| Mark 4 | 2.1 mm (0.083 in.) | |
| Mark 5 | 2.2 mm (0.087 in.) | |
| Mark 6 | 2.3 mm (0.091 in.) | |
| Mark 7 | 2.4 mm (0.094 in.) | |
| Mark 8 | 2.5 mm (0.098 in.) | |
| 2nd brake pack clearance | Standard | 0.62 to 0.91 mm (0.0244 to 0.0358 in.) |
| 2nd brake flange thickness | Mark 0 | 2.9 mm (0.114 in.) |
| Mark 1 | 3.0 mm (0.118 in.) | |
| Mark 2 | 3.1 mm (0.122 in.) | |
| Mark 3 | 3.2 mm (0.126 in.) | |
| Mark 4 | 3.3 mm (0.130 in.) | |
| Mark 5 | 3.4 mm (0.134 in.) | |
| Mark 6 | 3.5 mm (0.138 in.) | |
| Mark 7 | 3.6 mm (0.142 in.) | |
| Mark 8 | 3.7 mm (0.146 in.) | |
| Rear transaxle cover bearing press in depth | Standard | 12.05 to 12.75 mm (0.4744 to 0.5020 in.) |
| Underdrive brake pack clearance | Standard | 1.81 to 2.20 mm (0.0713 to 0.0866 in.) |
| Underdrive brake flange thickness | Mark Y | 2.8 mm (0.110 in.) |
| Mark A | 3.0 mm (0.118 in.) | |
| Mark B | 3.2 mm (0.126 in.) | |
| Mark C | 3.4 mm (0.134 in.) | |
| Mark D | 3.6 mm (0.142 in.) |
AUTOMATIC TRANSAXLE UNIT - SERVICE DATA
OIL PUMP
| Body clearance | Standard | 0.10 to 0.17 mm (0.0039 to 0.0067 in.) |
|---|---|---|
| Maximum | 0.17 mm (0.0067 in.) | |
| Tip clearance | Standard | 0.07 to 0.15 mm (0.0028 to 0.0059 in.) |
| Maximum | 0.15 mm (0.0059 in.) | |
| Side clearance | Standard | 0.02 to 0.05 mm (0.0008 to 0.0020 in.) |
| Maximum | 0.05 mm (0.0020 in.) | |
| Drive gear thickness (w/o Mark) | 10.690 to 10.699 mm (0.4209 to 0.4212 in.) | |
| 10.700 to 10.709 mm (0.4213 to 0.4216 in.) | ||
| 10.710 to 10.720 mm (0.4217 to 0.4220 in.) | ||
| 10.721 to 10.730 mm (0.4221 to 0.4224 in.) | ||
| 10.731 to 10.740 mm (0.4225 to 0.4228 in.) | ||
| Driven gear thickness (w/o Mark) | 10.690 to 10.699 mm (0.4209 to 0.4212 in.) | |
| 10.700 to 10.709 mm (0.4213 to 0.4216 in.) | ||
| 10.710 to 10.720 mm (0.4217 to 0.4220 in.) | ||
| 10.721 to 10.730 mm (0.4221 to 0.4224 in.) | ||
| 10.731 to 10.740 mm (0.4225 to 0.4228 in.) | ||
| Drive gear thickness (w/Mark) | Mark 1 | 10.690 to 10.699 mm (0.4209 to 0.4212 in.) |
| Mark 2 | 10.700 to 10.709 mm (0.4213 to 0.4216 in.) | |
| Mark 3 | 10.710 to 10.720 mm (0.4217 to 0.4220 in.) | |
| Mark 4 | 10.721 to 10.730 mm (0.4221 to 0.4224 in.) | |
| Mark 5 | 10.731 to 10.740 mm (0.4225 to 0.4228 in.) | |
| Driven gear thickness (w/Mark) | Mark 1 | 10.690 to 10.699 mm (0.4209 to 0.4212 in.) |
| Mark 2 | 10.700 to 10.709 mm (0.4213 to 0.4216 in.) | |
| Mark 3 | 10.710 to 10.720 mm (0.4217 to 0.4220 in.) | |
| Mark 4 | 10.721 to 10.730 mm (0.4221 to 0.4224 in.) | |
| Mark 5 | 10.731 to 10.740 mm (0.4225 to 0.4228 in.) | |
| Oil pump body bushing inside diameter | Standard | 38.113 to 38.138 mm (1.50050 to 1.50149 in.) |
| Maximum | 38.138 mm (1.50149 in.) | |
| Oil seal drive in depth | Standard | 0 +/- 0.5 mm (0 +/- 0.020 in.) |
| Stator shaft bushing inside diameter | Standard | 20.50 to 21.53 mm (0.8465 to 0.8475 in.) |
| Maximum | 21.57 mm (0.8492 in.) |
OIL PUMP - SERVICE DATA
SECOND BRAKE PISTON
| 2nd brake piston return spring free length | Standard | 16.61 mm (0.6539 in.) |
SECOND BRAKE PISTON - SERVICE DATA
FORWARD CLUTCH
| Forward clutch piston return spring free length | Standard | 28.23 mm (1.1102 in.) |
|---|---|---|
| Forward clutch pack clearance | Standard | 1.74 to 2.08 mm (0.0685 to 0.0819 in.) |
| Forward clutch flange thickness | Mark 0 | 2.85 mm (0.1122 in.) |
| Mark 1 | 3.00 mm (0.1181 in.) | |
| Mark 2 | 3.15 mm (0.1240 in.) | |
| Mark 3 | 3.30 mm (0.1299 in.) | |
| Mark 4 | 3.45 mm (0.1358 in.) | |
| Mark 5 | 3.60 mm (0.1417 in.) | |
| Mark 6 | 3.75 mm (0.1476 in.) |
FORWARD CLUTCH - SERVICE DATA
DIRECT CLUTCH
| Direct clutch piston return spring free length | Standard | 22.58 mm (0.8898 in.) |
|---|---|---|
| Direct clutch pack clearance | Standard | 0.605 to 0.825 mm (0.02382 to 0.03248 in.) |
| Direct clutch flange thickness | Mark 0 | 2.9 mm (0.114 in.) |
| Mark 1 | 3.0 mm (0.118 in.) | |
| Mark 2 | 3.1 mm (0.122 in.) | |
| Mark 3 | 3.2 mm (0.126 in.) | |
| Mark 4 | 3.3 mm (0.130 in.) | |
| Mark 5 | 3.4 mm (0.134 in.) | |
| Mark 6 | 3.5 mm (0.138 in.) | |
| Mark 7 | 4.0 mm (0.157 in.) |
DIRECT CLUTCH - SERVICE DATA
UNDERDRIVE PLANETARY GEAR
| Underdrive planetary gear turning torque (at 60 rpm) | Standard | 0.23 to 5.01 N*m (2 to 51 kgf*cm, 2.0 to 44.3 in.*lbf) |
UNDERDRIVE PLANETARY GEAR - SERVICE DATA
UNDERDRIVE CLUTCH
| Underdrive clutch piston return spring free length | Standard | 17.14 mm (0.6752 in.) |
|---|---|---|
| Underdrive clutch drum bushing inside diameter | Standard | 32.56 to 32.58 mm (1.2818 to 1.2826 in.) |
| Maximum | 32.63 mm (1.2846 in.) | |
| Underdrive clutch pack clearance | Standard | 1.51 to 1.90 mm (0.0594 to 0.0748 in.) |
| Underdrive clutch flange thickness | Mark Y | 2.8 mm (0.110 in.) |
| Mark A | 3.0 mm (0.118 in.) | |
| Mark B | 3.2 mm (0.126 in.) | |
| Mark C | 3.4 mm (0.134 in.) | |
| Mark D | 3.6 mm (0.142 in.) |
UNDERDRIVE CLUTCH - SERVICE DATA
DIFFERENTIAL
| Differential side gear backlash | Standard | 0.05 to 0.20 mm (0.0020 to 0.0070 in.) |
|---|---|---|
| Thrust washer thickness | Mark 1 | 1.0 mm (0.0394 in.) |
| Mark 2 | 1.1 mm (0.0433 in.) | |
| Mark 3 | 1.2 mm (0.0472 in.) | |
| Mark 4 | 1.3 mm (0.0512 in.) | |
| Differential case tapered roller bearing preload (turning torque at 60 rpm) | New bearing | 0.20 to 0.69 N*m (2.0 to 7.0 kgf*cm, 1.8 to 6.1 in.*lbf) |
| Used bearing | 0.10 to 0.35 N*m (1.0 to 3.6 kgf*cm, 0.9 to 3.1 in.*lbf) | |
| Adjust shim thickness | Mark 0 | 1.90 mm (0.074 in.) |
| Mark 1 | 1.95 mm (0.077 in.) | |
| Mark 2 | 2.00 mm (0.0787 in.) | |
| Mark 3 | 2.05 mm (0.0807 in.) | |
| Mark 4 | 2.10 mm (0.0827 in.) | |
| Mark 5 | 2.15 mm (0.0846 in.) | |
| Mark 6 | 2.20 mm (0.0866 in.) | |
| Mark 7 | 2.25 mm (0.0886 in.) | |
| Mark 8 | 2.30 mm (0.0906 in.) | |
| Mark 9 | 2.35 mm (0.0925 in.) | |
| Mark A | 2.40 mm (0.0945 in.) | |
| Mark B | 2.45 mm (0.0965 in.) | |
| Mark C | 2.50 mm (0.0984 in.) | |
| Mark D | 2.55 mm (0.1004 in.) | |
| Mark E | 2.60 mm (0.1024 in.) | |
| Mark F | 2.65 mm (0.1043 in.) | |
| Mark G | 2.70 mm (0.1063 in.) | |
| Mark H | 2.75 mm (0.1083 in.) | |
| Mark J | 2.80 mm (0.1102 in.) |
DIFFERENTIAL - SERVICE DATA
| Pedal height from dash panel | 151.8 to 161.8 mm (5.9764 to 6.3701 in.) | |
|---|---|---|
| Clutch pedal free play | 5.0 to 15.0 mm (0.197 to 0.591 in.) | |
| Clutch pedal push rod play at pedal top | 1.0 to 5.0 mm (0.039 to 0.197 in.) | |
| Clutch release point from pedal full stroke end position | 25 mm (0.98 in.) or more | |
| Clutch disc rivet head depth | Maximum | 0.3 mm (0.012 in.) |
| Clutch disc assembly runout | Minimum | 0.8 mm (0.031 in.) |
| Diaphragm spring finger wear | Maximum depth | 0.5 mm (0.020 in.) |
| Maximum width | 6.0 mm (0.236 in.) | |
| Flywheel sub-assembly runout | Maximum | 0.1 mm (0.004 in.) |
| Diaphragm spring tip non-alignment | Maximum depth | 0.5 mm (0.020 in.) |
CLUTCH - SERVICE DATA
| Transaxle case oil seal LH driven in depth | 3.0 to 4.0 mm (0.118 to 0.157 in.) | |
|---|---|---|
| Transaxle case cover oil seal RH drive in depth | 0.5 to 0.5 mm (- 0.020 to 0.020 in.) | |
| Manual transaxle unit | ||
| 5th gear thrust clearance | Standard clearance | 0.10 to 0.65 mm (0.0039 to 0.0256 in.) |
| 5th gear radial clearance | Standard clearance | 0.009 to 0.050 mm (0.0004 to 0.0020 in.) |
| Reverse idler gear sub-assembly inside diameter | Standard inside diameter | 20.056 to 20.074 mm (0.7896 to 0.7903 in.) |
| Maximum inside diameter | 20.074 mm (0.7903 in.) | |
| Reverse idler gear shaft outside diameter | Standard outside diameter | 19.984 to 20.000 mm (0.7868 to 0.7874 in.) |
| Minimum outside diameter | 19.984 mm (0.7868 in.) | |
| No. 3 transmission hub sleeve groove - thickness of the claw part on No. 3 gear shift fork | Standard clearance | 0.15 to 0.35 mm (0.0059 to 0.0138 in.) |
| 5th gear inside diameter | Standard inside diameter | 34.981 to 34.997 mm (1.3772 to 1.3778 in.) |
| Maximum inside diameter | 34.997 mm (1.3778 in.) | |
| Output shaft rear bearing clearance | 3.8 to 4.4 mm (0.150 to 0.173 in.) | |
| Output shaft bearing preload | New bearing | 0.8 to 1.6 N*m (8.16 to 16.32 kgf*cm, 7.1 to 14.2 in.*lbf) |
| Used bearing | 0.5 to 1.0 N*m (5.10 to 10.20 kgf*cm, 4.4 to 8.9 in.*lbf) | |
| Output shaft rear bearing shim thickness | 0 | 1.30 mm (0.0512 in.) |
| 1 | 1.35 mm (0.0531 in.) | |
| 2 | 1.40 mm (0.0551 in.) | |
| 3 | 1.45 mm (0.0571 in.) | |
| 4 | 1.50 mm (0.0591 in.) | |
| 5 | 1.55 mm (0.0610 in.) | |
| 6 | 1.60 mm (0.0630 in.) | |
| 7 | 1.65 mm (0.0650 in.) | |
| 8 | 1.70 mm (0.0669 in.) | |
| 9 | 1.75 mm (0.0689 in.) | |
| A | 1.80 mm (0.0709 in.) | |
| B | 1.85 mm (0.0728 in.) | |
| C | 1.90 mm (0.0748 in.) | |
| D | 1.95 mm (0.0768 in.) | |
| E | 2.00 mm (0.0787 in.) | |
| F | 2.05 mm (0.0807 in.) | |
| G | 2.10 mm (0.0827 in.) | |
| H | 2.15 mm (0.0846 in.) | |
| J | 2.20 mm (0.0866 in.) | |
| K | 2.25 mm (0.0886 in.) | |
| L | 2.30 mm (0.0906 in.) | |
| M | 2.35 mm (0.0925 in.) | |
| N | 2.40 mm (0.0945 in.) | |
| P | 2.45 mm (0.0965 in.) | |
| Q | 2.50 mm (0.0984 in.) | |
| Front differential case tapered roller bearing preload | New bearing | 0.8 to 1.6 N*m (8.16 to 16.32 kgf*cm, 7.1 to 14.2 in.*lbf) |
| Used bearing | 0.5 to 1.0 N*m (5.10 to 10.20 kgf*cm, 4.4 to 8.9 in.*lbf) | |
| Front differential case shim REAR thickness | 0 | 2.00 mm (0.0787 in.) |
| 1 | 2.05 mm (0.0807 in.) | |
| 2 | 2.10 mm (0.0827 in.) | |
| 3 | 2.15 mm (0.0846 in.) | |
| 4 | 2.20 mm (0.0866 in.) | |
| 5 | 2.25 mm (0.0886 in.) | |
| 6 | 2.30 mm (0.0906 in.) | |
| 7 | 2.35 mm (0.0925 in.) | |
| 8 | 2.40 mm (0.0945 in.) | |
| 9 | 2.45 mm (0.0965 in.) | |
| A | 2.50 mm (0.0984 in.) | |
| B | 2.55 mm (0.1004 in.) | |
| C | 2.60 mm (0.1024 in.) | |
| D | 2.65 mm (0.1043 in.) | |
| E | 2.70 mm (0.1063 in.) | |
| F | 2.75 mm (0.1083 in.) | |
| G | 2.80 mm (0.1102 in.) | |
| H | 2.85 mm (0.1122 in.) | |
| Front differential case oil seal clearance | 1 to 2 mm (0.039 to 0.079 in.) | |
| Input shaft front bearing clearance | 4.28 to 4.60 mm (0.1685 to 0.1811 in.) | |
| Reverse restrict pin clearance | 12.5 to 13.5 mm (0.492 to 0.531 in.) | |
| No. 3 transmission clutch hub snap ring clearance | 0.1 mm or less (0.004 in. or less) | |
| No. 3 transmission clutch hub snap ring thickness | A | 1.75 to 1.80 mm (0.0689 to 0.0709 in.) |
| B | 1.80 to 1.85 mm (0.0709 to 0.0728 in.) | |
| C | 1.85 to 1.90 mm (0.0728 to 0.0748 in.) | |
| D | 1.90 to 1.95 mm (0.0748 to 0.0768 in.) | |
| E | 1.95 to 2.00 mm (0.0768 to 0.0787 in.) | |
| F | 2.00 to 2.05 mm (0.0787 to 0.0807 in.) | |
| G | 2.05 to 2.10 mm (0.0807 to 0.0827 in.) | |
| H | 2.10 to 2.15 mm (0.0827 to 0.0846 in.) | |
| J | 2.15 to 2.20 mm (0.0846 to 0.0866 in.) | |
| Input shaft assembly | ||
| 4th gear thrust clearance | Standard clearance | 0.10 to 0.57 mm (0.0039 to 0.0224 in.) |
| 3rd gear thrust clearance | Standard clearance | 0.10 to 0.35 mm (0.0039 to 0.0138 in.) |
| 4th gear radical clearance | KOYO made | 0.009 to 0.053 mm (0.0004 to 0.0021 in.) |
| NSK made | 0.009 to 0.051 mm (0.0004 to 0.0020 in.) | |
| 3rd gear radical clearance | KOYO made | 0.009 to 0.053 mm (0.0004 to 0.0021 in.) |
| NSK made | 0.009 to 0.051 mm (0.0004 to 0.0020 in.) | |
| Input shaft run out | Maximum run out | 0.03 mm (0.0012 in.) |
| Input shaft standard outside diameter | A | 35.984 to 36.000 mm (1.4167 to 1.4173 in.) |
| B | 35.984 to 36.000 mm (1.4167 to 1.4173 in.) | |
| C | 27.957 to 27.972 mm (1.1007 to 1.1013 in.) | |
| Input shaft minimum outside diameter | A | 35.984 mm (1.4167 in.) |
| B | 35.984 mm (1.4167 in.) | |
| C | 27.957 mm (1.1007 in.) | |
| 4th gear inside diameter | Standard inside diameter | 42.009 to 42.025 mm (1.6539 to 1.6545 in.) |
| Maximum inside diameter | 42.025 mm (1.6545 in.) | |
| 3rd gear inside diameter | Standard inside diameter | 43.009 to 43.025 mm (1.6933 to 1.6939 in.) |
| Maximum inside diameter | 43.025 mm (1.6939 in.) | |
| Between the 4th gear spline end and synchronizer outer ring back clearance | 0.70 to 1.45 mm (0.0276 to 0.0571 in.) | |
| Between the 3rd gear spline end and synchronizer outer ring back clearance | 0.65 to 1.75 mm (0.0256 to 0.0689 in.) | |
| No. 2 transmission hub sleeve groove - thickness of the claw part on No. 2 gear shift fork | Standard clearance | 0.11 to 0.69 mm (0.0043 to 0.0272 in.) |
| No. 2 transmission clutch hub snap ring clearance | Standard clearance | 0.1 mm or less (0.004 in. or less) |
| Transmission clutch hub No. 2 snap ring thickness | H | 2.30 to 2.35 mm (0.0906 to 0.0925 in.) |
| J | 2.35 to 2.40 mm (0.0925 to 0.0945 in.) | |
| K | 2.40 to 2.45 mm (0.0945 to 0.0965 in.) | |
| L | 2.45 to 2.50 mm (0.0965 to 0.0984 in.) | |
| M | 2.50 to 2.55 mm (0.0984 to 0.1004 in.) | |
| N | 2.55 to 2.60 mm (0.1004 to 0.1024 in.) | |
| P | 2.60 to 2.65 mm (0.1024 to 0.1043 in.) | |
| Input shaft rear radical ball bearing snap ring clearance | Standard clearance | 0.1 mm or less (0.004 in. or less) |
| Input shaft rear radical ball bearing snap ring thickness | 1 | 2.35 to 2.40 mm (0.0925 to 0.0945 in.) |
| 2 | 2.40 to 2.45 mm (0.0945 to 0.0965 in.) | |
| 3 | 2.45 to 2.50 mm (0.0965 to 0.0984 in.) | |
| 4 | 2.50 to 2.55 mm (0.0984 to 0.1004 in.) | |
| 5 | 2.55 to 2.60 mm (0.1004 to 0.1024 in.) | |
| 6 | 2.60 to 2.65 mm (0.1024 to 0.1043 in.) | |
| 7 | 2.65 to 2.70 mm (0.1043 to 0.1063 in.) | |
| 8 | 2.70 to 2.75 mm (0.1063 to 0.1083 in.) | |
| Output shaft assembly | ||
| 1st gear thrust clearance | Standard clearance | 0.25 to 0.40 mm (0.0098 to 0.0157 in.) |
| 2nd gear thrust clearance | Standard clearance | 0.10 to 0.35 mm (0.0039 to 0.0138 in.) |
| 1st gear radical clearance | KOYO made | 0.009 to 0.053 mm (0.0004 to 0.0021 in.) |
| NSK made | 0.009 to 0.051 mm (0.0004 to 0.0020 in.) | |
| 2nd gear radical clearance | KOYO made | 0.009 to 0.053 mm (0.0004 to 0.0021 in.) |
| NSK made | 0.009 to 0.051 mm (0.0004 to 0.0020 in.) | |
| Output shaft run out | Maximum run out | 0.03 mm (0.0012 in.) |
| Output shaft standard outside diameter | A | 32.010 to 32.026 mm (1.2602 to 1.2609 in.) |
| B | 44.984 to 45.000 mm (1.7710 to 1.7717 in.) | |
| C | 28.010 to 28.023 mm (1.1028 to 1.1033 in.) | |
| Output shaft minimum outside diameter | A | 32.010 mm (1.2602 in.) |
| B | 44.984 mm (1.7710 in.) | |
| C | 28.010 mm (1.1028 in.) | |
| 2nd gear inside diameter | Standard inside diameter | 50.009 to 50.025 mm (1.9689 to 1.9695 in.) |
| Maximum inside diameter | 50.025 mm (1.9695 in.) | |
| 1st gear inside diameter | Standard inside diameter | 51.009 to 51.025 mm (2.0082 to 2.0089 in.) |
| Maximum inside diameter | 51.025 mm (2.0089 in.) | |
| Between the 2nd gear and No. 2 synchronizer ring back clearance | 0.70 to 1.45 mm (0.0276 to 0.0571 in.) | |
| Between the 1st gear and No. 1 synchronizer ring set back clearance | 0.70 to 1.45 mm (0.0276 to 0.0571 in.) | |
| Reverse gear groove - thickness of the claw part on No. 1 gear shift fork clearance | Standard clearance | 0.15 to 0.35 mm (0.0059 to 0.0138 in.) |
| Shift and select lever shaft assembly | ||
| Control shaft cover oil seal drive in depth | 28 to 29 mm (1.1024 to 1.1417 in.) | |
| Shift lever slotted pin clearance to the No. 1 shift lever inner | 0.4 to 0.6 mm (- 0.0158 to 0.0236 in.) | |
| Shift lever slotted pin clearance to the No. 2 shift lever inner | 0.7 to 1.7 mm (0.0276 to 0.0669 in.) | |
| Differential case assembly | ||
| Front differential side gear backlash | Standard backlash | 0.05 to 0.20 mm (0.0020 to 0.0079 in.) |
| Front differential pinion thrust washer thickness | Minimum thickness | 0.9 mm (0.035 in.) |
| Front differential pinion No. 1 shaft thickness | Minimum diameter | 17.975 mm (0.7077 in.) |
| Front differential side gear backlash | Standard backlash | 0.05 to 0.20 mm (0.0020 to 0.0079 in.) |
| Front differential side gear thrust washer thickness | 1 | 1.00 mm (0.0394 in.) |
| 2 | 1.10 mm (0.0433 in.) | |
| 3 | 1.20 mm (0.0472 in.) | |
| 4 | 1.30 mm (0.0512 in.) | |
E351 MANUAL TRANSAXLE - SERVICE DATA
FRONT DRIVE SHAFT ASSEMBLY
| Drive shaft dust cover position | Standard | 1 mm (0.039 in.) |
|---|---|---|
| Drive shaft dust cover RH distance | Standard | 91.0 to 92.0 mm (3.583 to 3.622 in.) |
| Outboard joint boot grease capacity | Standard | 190 to 200 g (6.7 to 7.1 oz.) |
| Drive shaft damper LH distance | Standard | 161.0 to 165.0 mm (6.339 to 6.496 in.) |
| Inboard joint boot grease capacity | Standard | 161.0 to 165.0 mm (6.339 to 6.496 in.) |
| Front drive shaft standard length | LH | 585.2 mm (23.039 in.) |
| RH | 884.0 mm (34.803 in.) |
FRONT DRIVE SHAFT ASSEMBLY - SERVICE DATA
Axle
| Front axle hub bearing looseness | Maximum: 0.05 mm (0.0020 in.) |
|---|---|
| Front axle hub runout | Maximum: 0.05 mm (0.0020 in.) |
| Rear axle hub bearing looseness | Maximum: 0.05 mm (0.0020 in.) |
| Rear axle hub runout | Maximum: 0.05 mm (0.0020 in.) |
AXLE - SERVICE DATA
| Front suspension | ||
|---|---|---|
| Vehicle height | Front C-A | 104 mm (4.09 in.) |
| Rear D-B | 19 mm (0.74 in.) | |
| Wheel turning angle | Inside wheel | 39°15' +/- 2°(39.25° +/-2°) |
| Outside wheel (Reference) | 33°00' (33.00°) | |
| Camber | 0°10' +/- 45' (-0.16° +/- 0.75°) | |
| Caster | 5°45' +/- 45' (5.75° +/- 0.75°) | |
| Steering Axis Inclination (Reference) | 12°10' (12.17°) | |
| Toe-in | B-A | 2.0 +/- 2 mm (0.08 +/- 0.08 in.) |
| Rack end length difference | 1.5 mm (0.059 in.) or less | |
| Front lower ball joint assembly | Front lower ball joint turning torque | 0.98 to 3.43 N*m (10 to 35 kgf*cm, 8.7 to 30 in.*lbf) |
| Front stabilizer link assembly | Front stabilizer link turning torque | 0.05 to 1.96 N*m (0.5 to 20.0 kgf*cm, 0.4 to 17.3 in.*lbf) |
| Rear suspension | ||
| Camber | 1°25' +/- 0°30' (-1.42° +/- 0.5°) | |
| Toe-in | B-A | 2.1 +/- 3 mm (0.08 +/- 0.11 in.) |
SUSPENSION - SERVICE DATA
TIRE AND WHEEL SYSTEM
| Tire pressure | ||
|---|---|---|
| P205/55R16 89H | Front | 240 kPa (2.4 kgf*cm 2 , 35psi) |
| Rear | 220 kPa (2.2 kgf*cm 2 , 32 psi) | |
| Tire runout | 1.4 mm (0.055 in.) or less | |
| Imbalance after adjustment | 8.0 g (0.0181b) or less | |
TIRE AND WHEEL SYSTEM - SERVICE DATA
TIRE PRESSURE WARNING RESET SWITCH
| Tire pressure warning switch resistance | ||
|---|---|---|
| 1 - 2 | ON | Below 1 ohms |
| OFF | 10 kohms or higher | |
TIRE PRESSURE WARNING RESET SWITCH - SERVICE DATA
| VSC off switch | 3 - 6 | Released | 10 kohms or higher |
|---|---|---|---|
| 3 - 6 | Pushed in | Below 25 ohms | |
| 4 - 5 | Battery's positive (+) lead connected to terminal 5 and negative (-) lead to terminal 4 | LED illuminates |
BRAKE CONTROL - SERVICE DATA
| Brake pedal height (from floor) | 145.8 to 155.8 mm (5.74 to 6.13 in.) | |
|---|---|---|
| Stop light switch clearance | 1.5 to 2.5 mm (0.059 to 0.098 in.) | |
| Brake pedal free play | 1.0 to 6.0 mm (0.039 to 0.236 in.) | |
| Brake pedal reserve distance (from floor) at 294 N (30 kgf, 66.1 lbf) | More than 87 mm (3.43 in.) | |
| Brake booster push rod to piston clearance | 0 mm (0 in.) | |
| Front disc brake pad lining thickness | Standard | 12.0 mm (0.472 in.) |
| Minimum | 1.0 mm (0.039 in.) | |
| Front disc thickness | Standard | 25.0 mm (0.984 in.) |
| Minimum | 22.0 mm (0.866 in.) | |
| Front disc runout | Maximum | 0.05 mm (0.0020 in.) |
| Rear disc brake pad lining thickness | Standard | 9.5 mm (0.374 in.) |
| Minimum | 1.0 mm (0.039 in.) | |
| Rear disc thickness | Standard | 10.0 mm (0.394 in.) |
| Minimum | 8.5 mm (0.335 in.) | |
| Rear disc runout | Maximum | 0.15 mm (0.0059 in.) |
BRAKE - SERVICE DATA
| Parking brake lever travel at 200 N (20 kgf, 45 lbf) | 6 to 9 clicks |
|---|---|
| Rear disc brake cylinder operation lever and stopper clearance | 0.5 mm (0.02 in.) or less |
PARKING BRAKE - SERVICE DATA
| Steering wheel free play | Maximum | 30 mm (1.18 in.) |
|---|---|---|
| Steering shaft preload | 0.6 to 1.2 N*m (6.1 to 12.2 kgf*cm, 5.3 to 10.6 in.*lbf) |
STEERING COLUMN - SERVICE DATA
| Tie rod assembly stud bolt torque | Turning | 0.98 to 3.92 N*m (10.0 to 40.0 kgf*cm, 8.67 to 34.7 in.*lbf) |
|---|---|---|
| Total preload | Turning | 0.5 to 1.1 N*m (5.1 to 11.2 kgf*cm, 4.4 to 9.7 in.*lbf) |
POWER STEERING - SERVICE DATA
| Refrigerant charge volume | 410 to 470 g (14.5 to 16.6 oz.) |
|---|---|
| Blower resistor | 1 - 4: 3.12 to 3.60 ohms 1 - 2: 1.45 to 1.67 ohms 1 - 3 : 0.52 to 0.60 ohms |
| Compressor assembly | 1 - 2:10 to 11 ohms |
| Heater blower motor relay | 3 - 4 : Below 1ohms (When battery voltage is absent) 3 - 4 : 10 kohms or higher (When battery voltage applied to terminals 1 and 2) 3 - 5 : 10 kohms or higher (When battery voltage is absent) 3 - 5 : Below 1ohms(When battery voltage applied to terminals 1 and 2) |
AIR CONDITIONING - SERVICE DATA
for Manual transaxle
| Idling speed Switch A/C OFF | 600 to 700 rpm |
|---|---|
| Idling speed Switch A/C ON (A/C Lo --> Hi) | 660 to 760 --> 750 to 850 rpm |
AIR CONDITIONING - SERVICE DATA
for Automatic transaxle
| Idling speed Switch A/C OFF | 600 to 700 rpm |
|---|---|
| Idling speed Switch A/C ON (A/C Lo --> Hi) | 690 to 790 --> 770 to 870 rpm |
AIR CONDITIONING - SERVICE DATA
| Tester connection | Condition | Specified condition |
|---|---|---|
| A1(D-) - D2(D-) | Center | Below 1 ohms |
| 2.5 rotation to the left | ||
| 2.5 rotation to the right | ||
| A2(D+) - D1(D+) | Center | Below 1 ohms |
| 2.5 rotation to the left | ||
| 2.5 rotation to the right | ||
| B1(D2-) - D3(2-) | Center | Below 1 ohms |
| 2.5 rotation to the left | ||
| 2.5 rotation to the right | ||
| B2(D2+) - D4(D2+) | Center | Below 1 ohms |
| 2.5 rotation to the left | ||
| 2.5 rotation to the right |
SUPPLEMENTAL RESTRAINT SYSTEM - SERVICE DATA
FRONT SEAT INNER BELT ASSEMBLY
| Item | Position | Tester Connection | Condition | Specified Condition |
|---|---|---|---|---|
| Standard resistance | LH side | 2 - 4 | Tongue plate fastened | 10 kohms or higher |
| Tongue plate released | Below 1 ohms | |||
| Standard resistance | RH side | 1 - 2 | Tongue plate fastened | 10 kohms or higher |
| Tongue plate released | Below 1 ohms |
FRONT SEAT INNER BELT ASSEMBLY - SERVICE DATA
| Headlight relay | 3 - 5 : 10 kohms or higher (When battery voltage absent) 3 - 5 : Below 1 ohms. (Apply battery voltage to terminals 1 and 2) |
|---|---|
| Headlight dimmer relay | 3 - 4 : Below 1 ohms (When battery voltage absent) 3 - 4 : 10 kohms or higher (Apply battery voltage to terminals 1 and 2) 3 - 5 :10 kohms or higher (When battery voltage absent) 3 - 5 : Below 1 ohms (Apply battery voltage to terminals 1 and 2) |
LIGHTING - SERVICE DATA
FRONT NO. 1 SPEAKER
| Item | Tester Connection | Specified Condition |
|---|---|---|
| Standard resistance | 1 - 2 | Approximately 4 ohms |
FRONT NO. 1 SPEAKER - SERVICE DATA
REAR PACKAGE TRAY SPEAKER
| Item | Tester Connection | Specified Condition |
|---|---|---|
| Standard resistance | 1 - 2 | Approximately 4 ohms |
REAR PACKAGE TRAY SPEAKER - SERVICE DATA
HORN SERVICE DATA
HORN RELAY
| Item | Tester Connection | Specified Condition |
|---|---|---|
| Standard resistance | A8-T6 | 10 kohms or higher |
| Below 1 ohms (Battery voltage applied to terminals A7 and T6) |
HORN - SERVICE DATA