Service Specifications: Other — Service Specifications — Cruise Control Systems

SERVICE DATA

1ZZ-FE (FF)

Intake air flow meter sub-assy
Resistance 4 (THA) - 5 (E2)	Standard	13.6 to 18.4 kohms at - 20°C (-4°F)
		2.21 to 2.69 kohms at 20°C (68°F)
		0.493 to 0.667 kohms at 60°C (140°F)
Camshaft timing oil control valve assy
Resistance 1 (+B) - 2 (GND)		6.9 to 7.9 ohms at 20°C (68°F)
Throttle body assy
Resistance	1 (M-) - 2(M+)	0.3 to 100 ohms 2 at 20°C (68°F)
	3 (E2) - 5 (VC)	2.0 to 4.0 kohms at 20°C (68°F)
Accelerator pedal assy
Resistance	3(EP1)-6(VCP1)	1.5 to 6.0 kohms
	1 (EP2)-4(VCP2)	1.5 to 6.0 kohms
E.F.I. Engine coolant temperature sensor
Resistance	1 (E2)-2(THW)	2.32 to 2.59 kohms at 20°C (68°F)
	1 (E2)-2(THW)	0.31O to 0.326 kohms at 80°C (176°F)
Knock control sensor
Resistance		120 to 280 kohms at 20°C (68°F)
E.F.I. Circuit opening relay assy
Resistance (3 - 5)	Standard	10kohms or higher
		Below 1 ohms (Apply battery voltage to terminal 1 and 2)
E.F.I. ECU relay
Resistance (3 - 5)	Standard	10 kohms or higher
		Below 1 ohms (Apply battery voltage to terminal 1 and 2)

Engine Control System Service Specifications - 1ZZ-FE (FF)

1ZZ-FE (4WD)

Throttle idle air control valve assy
Movement	Ignition switch ON	Half open --> fully close --> fully open --> half open
Intake airflow meter sub-assy
Resistance 4 (THA) - 5 (E2)	Standard	13.6 to 18.4 kohms 2 at - 20°C (-4°F)
		2.21 to 2.69 kohms at 20°C (68°F)
		0.493 to 0.667 kohms at 60°C (140°F)
Camshaft timing oil control valve assy
Resistance 1 (+B) - 2 (GND)		6.9 to 7.9 ohms at 20°C (68°F)
E.F.I. Throttle position sensor
Resistance (VC - E2)		2.5 to 6.0 kohms
E.F.I. Engine coolant temperature sensor
Resistance	1 (E2)-2(THW)	2.32 to 2.59 kohms at 20°C (68°F)
	1 (E2)-2(THW)	0.310 to 0.326 kohms at 80°C (176°F)
Knock control sensor
Resistance		120 to 230 kohms at 20°C (68°F)
E.F.I. Circuit opening relay assy
Resistance (3 - 5)	Standard	10 ohms or higher
		Below 1 ohms (Apply battery voltage to terminal 1 and 2)
E.F.I. ECU relay
Resistance (3 - 5)	Standard	10 kohms or higher
		Below 1 ohms (Apply battery voltage to terminal 1 and 2)

Engine Control System Service Specifications - 1ZZ-FE (4WD)

2ZZ-GE

Throttle idle air control valve assy
Movement	Ignition switch ON	Half open --> fully close --> fully open --> half open
Intake air flow meter sub-assy
Resistance 4 (THA) - 5 (E2)	Standard	13.6 to 18.4 kohms at - 20°C (-4°F)
		2.21 to 2.69 kohms at 20°C (68°F)
		0.493 to 0.667 kohms at 60°C (140°F)
E.F.I. Throttle position sensor
Resistance (VC - E2)		2.5 to 6.0 kohms
E.F.I. Engine coolant temperature sensor
Resistance	1 (E2) - 2 (THW)	2.32 to 2.59 ohms at 20°C (68°F)
	1 (E2) - 2 (THW)	0.310 to 0.326 kohms at 80°C (176°F)
Knock control sensor
Resistance		120 to 280 kohms at 20°C (68°F)
E.F.I. Circuit opening relay assy
Resistance (3 - 5)	Standard	10kohms or higher
		Below 1 ohms (Apply battery voltage to terminal 1 and 2)
E.F.I. ECU relay
Resistance (3 - 5)	Standard	10 kohms or higher
		Below 1 ohms (Apply battery voltage to terminal 1 and 2)

Engine Control System Service Specifications - 2ZZ-GE

Fuel pressure
	Standard	304 to 343 kPa (3.1 to 3.5 kgf/cm 2 ,44 to 50 psi)
Fuel injector assy
Resistance (1-2)	1ZZ-FE (2WD),2ZZ-GE Engine Type	11.6 to 12.4ohms at 20°C (68°F)
Resistance (1 - 2)	1ZZ-FE (4WD) Engine Type	13.4 to 14.2 ohms at 20°C (68°F)
Injection volume	1ZZ-FE Engine Type	60 to 73 cm 3 (3.6 to 4.5 cu in.) per 15 seconds
	2ZZ-GE Engine Type	77 to 94 cm 3 (4.7 to 5.7 cu in.) per 15 seconds
Difference between each fuel injector	1ZZ-FE Engine Type	13 cm 3 (0.9 cu in.) or less
	2ZZ-GE Engine Type	17 cm 3 (1.0 cu in.) or less
Leakage	Standard	1 drop or less per 12 minutes
Fuel pump
Resistance (1(+)-2 (-))	Standard	0.2 to 3.0 ohms at 20°C (68°F)
Compression spring (Exhaust pipe assy front x Exhaust manifold)		1 ZZ-FE (2WD),2ZZ-GE Engine Type
Free length	Minimum	41.5 mm (1.6339 in.)
Compression spring (Exhaust pipe assy tail x Exhaust pipe assy front)		1 ZZ-FE (2WD),2ZZ-QE Engine Type
Free length	Minimum	38.5 mm (1.5158 in.)
Compression spring (Exhaust pipe assy center x Exhaust pipe assy front)		1ZZ-FE (4WD) Engine Type
Free length	Minimum	38.5 mm (1.5158 in.)

Service Specifications - Fuel

1ZZ-FE(2WD)

Vacuum switching valve
Resistance	1 - 2	26 to 30 ohms at 20°C (68°F)
	1 - Body	10 Mohms or higher
	2 - Body	10Mohms or higher
Air fuel ratio sensor
Resistance	Bank 1 sensor 1
	1 (HT) - 2 (+B)	1.8 to 3.4 ohms at 20°C (68°F)
	1(HT)-4(E1)	10kohms or higher
Heated oxygen sensor
Resistance	Bank 1 sensor 2
	1 (+B)-2{HT)	11 to 16 ohms at 20°C (68°F)
	2(HT)-3(E)	10 kohms or higher

Service Specifications - Emission Control - 1ZZ-FE(2WD)

1ZZ-FE(4WD)

Vacuum switching valve for chrcoal canister
Resistance	1 - 2	37 to 44ohms at 20°C (68°F)
	1 - Body	5 Mohms or higher
	2 - Body	5 Mohms or higher
Vacuum switching valve No.1
Resistance	1 - 2	26 to 30 ohms at 20°C (68°F)
	1 - Body	1 Mohms or higher
	2 - Body	1 Mohms or higher
Vacuum switching valve No.1
Resistance	1 - 2	26 to 30 ohms at 20°C (68°F)
	1 - Body	1 Mohms or higher
	2 - Body	1 Mohms or higher
Heated oxygen sensor (Bank1 Sensor1)
Resistance	Bank 1 sensor2
	1(+B) - 2(HT)	5 to 10ohms at 20°C (68°F)
	2(HT) - 3(E)	10 kohms or higher
Heated oxygen sensor (Bank1 Sensor2)
Resistance	Bank 1 sensor 2
	1(+B) - 2(HT)	11 to 16ohms at 20°C (68°F)
	2(HT) - 3(E)	10kohms or higher

Service Specifications - Emission Control - 1ZZ-FE(4WD)

2ZZ-GE

Vacuum switching valve
Resistance	1 - 2	26 to 30ohms at 20°C (68°F)
	1 - Body	10 Mohms or higher
	2 - Body	10Mohms or higher
Heated oxygen sensor
Resistance	Bank 1 sensor 1
	1(+B) - 2(HT)	5 to 10ohms at 20°C (68°F)
	2(HT) - 3(E)	10kohms or higher
Heated oxygen sensor
Resistance	Bank1 sensor 2
	1(+B) - 2(HT)	11 to 16 ohms at 20°C (68°F)
	2(HT) - 3(E)	10 kohms or higher
Pressure sensor
Voltage	C34(AIP) - A28(E2)	1.0 to 2.2 V
Air pump relay
Standerd	3 - 4	10kohms or higher
	3 - 4 (Apply battery voltage to terminal 1 and 2)	Below 1 ohms
Vacuum switching valve (Air pump)
Resistance	1-2	33 to 39ohms at 20°C (68°F)
	1 - Body	10 kohms or higher
	2-Body	10 kohms or higher

Service Specifications - Emission Control - 2ZZ-GE

1ZZ-FE

Ignition timing	W/ Terminal TC and CG of DLC3 connected	8 to 12°BTDC
	W/Terminal TC and CG of DLC3 disconnected	10 to 18°BTDC
Idle speed		650 to 750 rpm
Compression pressure		1,300 kPa (13.3 kgf.cm 2 ,189 psi)
Minimum pressure		1,000 kPa (10.2 kgf.cm 2 , 145 psi)
Difference between each cylinder		100 kPa (1.0 kgf.cm 2 ,15 psi)
Valve clearance at cold	Intake	0.15 to 0.25 mm (0.0059 to 0.0098 in.)
	Exhaust	0.25 to 0.35 mm (0.0098 to 0.0138 in.)
Chain elongation	Maximum	115.3 mm (4.539 in.)
Camshaft timing gear diameter (w/ chain)	Minimum	96.8 mm (3.811 in.)
Crankshaft timing gear diameter (w/ chain)	Minimum	51.0 mm (2.008 in.)
Chain tensioner slipper wear	Maximum	1.0 mm (0.039 in.)
Chain vibration damper wear	Maximum	1.0 mm (0.039 in.)
Cylinder head set bolt length	Standard	146.8 to 148.2 mm (5.780 to 5.835 in.)
	Maximum	148.5 mm (5.846 in.)
Camshaft
Circle runout	Maximum	0.03 mm (0.0012 in.)
Cam lobe height	Standard Intake	44.333 to 44.433 mm (1.7454 to 1.7493 in.)
	Exhaust	43.761 to 43.861 mm (1.7229 to 1.7268 in.)
	Minimum Intake	44.18 mm (1.7394 in.)
	Exhaust	43.61 mm (1.7169 in.)
Journal diameter	No. 1	34.449 to 34.465 mm (1.3563 to 1.3569 in.)
	Others	22.949 to 22.965 mm (0.9035 to 0.9041 in.)
Cylinder head warpage	Cylinder block side	0.05 mm (0.0020 in.)
	Intake manifold side	0.10 mm (0.0039 in.)
	Exhaust manifold side	0.10 mm (0.0039 in.)
Camshaft thrust clearance	Standard	0.040 to 0.095 mm (0.0016 to 0.0037 in.)
	Maximum	0.110 mm (0.0043 in.)
Camshaft oil clearance	Standard	0.035 to 0.072 mm (0.0014 to 0.0028 in.)
	Maximum	0.10 mm (0.0039 in)
Valve lifter diameter		30.966 to 30.976 mm (1.2191 to 1.2195 in.)
Valve lifter bore diameter		31.000 to 31.025 mm (1.2205 to 1.2215 in.)
Valve lifter oil clearance	Standard	0.024 to 0.059 mm (0.0009 to 0.0023 in.)
	Maximum	0.079 mm (0.0031 in.)
Inner compression spring
Free length		43.40 mm (1.7087 in.)
Deviation	Maximum	1.6 mm (0.063 in.)
Angle (reference)	Maximum	2°
Installed tension	At 33.6 mm (1.323 in.)	158.6 to 75.4 N (16.2 to 17.9 kgf, 35.7 to 39.5 lbf)
Maximum working tension	At 24.1 mm (0.949 in.)	335.3 to 370.7 N (34.2 to 37.8 kgf, 75.4 to 83.3 lbf)
Valve
Overall length	Standard Intake	88.65 mm (3.4902 in.)
	Exhaust	88.69 mm (3.4917 in.)
	Minimum Intake	88.35 mm (3.4784 in.)
	Exhaust	88.39 mm (3.4799 in.)
Valve stem diameter	Intake	5.470 to 5.485 mm (0.2154 to 0.2159 in.)
	Exhaust	5.465 to 5.480 mm (0.2152 to 0.2158 in.)
Margin thickness	Standard	1.0 mm (0.039 in.)
	Minimum	0.7 mm (0.028 in.)
Valve guide bush inside diameter		5.510 to 5,.530 mm (0.2169 to 0.2177 in.)
Valve guide bush oil clearance	Standard Intake	0.025 to 0.060 mm (0.0010 to 0.0024 in.)
	Exhaust	0.030 to Q.065 mm (0.0012 to 0.0026 in.)
	Maximum Intake	0.08 mm (0.0032 in.)
	Exhaust	0.10 mm (0.0039 in.)
Valve guide bush bore diameter	STD	10.285 to 10.306 mm (0.4049 to 0.4058 in.)
	O/S0.05	10.335 to 10.356 mm (0.4069 to 0.4077 in.)
Valve guide bush protrusion height		8.7 to 9.1 mm (0.343 to 0.358 in.)
Straight pin protrusion height (cylinder head)		5 mm (0.197 in.)
Union protrusion height	A	29 mm (1.142 in.)
(See page 14-121)	B	66.5 mm (2.618 in.)
	C	24 mm (0.945 in.)
Connecting rod thrust clearance	Standard	0.160 to 0.342 mm (0.0063 to 0.0135 in.)
	Maximum	0.342 mm (0.0135 in.)
Connecting rod oil clearance	Standard	0.028 to 0.060 mm (0.0011 to 0.0024 in.)
	Maximum	0.080 mm (0.0032 in.)
Connecting rod large end bore diameter	1	47.000 to 47.008 mm (1.8504 to 1.8507 in.)
	2	47.009 to 47.016 mm (1.8507 to 1.8510 in.)
	3	47.017 to 47.024 mm (1.8511 to 1.8513 in.)
Connecting rod bearing thickness	1	1.486 to 1.490 mm (0.0585 to 0.0587 in.)
	2	1.491 to 1.494 mm (0.0587 to 0.0588 in.)
	3	1.495 to 1.498 mm (0.0589 to 0.0590 in.)
Crankshaft pin outer diameter		43.992 to 44.000 mm (1.7320 to 1.7323 in.)
Crankshaft thrust clearance	Standard	0.04 to 0.24 mm (0.0016 to 0.0094 in.)
	Maximum	0.30 mm (0.0118 in.)
Cylinder block warpage	Maximum	0.05 mm (0.0020 in.)
Cylinder bore diameter	Standard	79.000 to 79.013 mm (3.1102 to 3.1107 in.)
	Maximum	79.133 mm (3.1155 in.)
Piston diameter	At 28.0 mm (1.102 in.) from piston head	78.917 to 78.927 mm (3.1070 to 3.1074 in.)
Piston oil clearance	Standard 2WD	0.073 to 0.096 mm (0.0029 to 0.0038 in.)
	4WD	0.065 to 0.088 mm (0.0026 to 0.0035 in.)
	Maximum 2WD	0.10 mm (0.0039 in.)
	4WD	0.09 mm (0.0035 in.)
Piston pin bore diameter	A	20.006 to 20.009 mm (0.7876 to 0.7878 in.)
	B	20.010 to 20.012 mm (0.7878 to 0.7879 in.)
	C	20.013 to 20.015 mm (0.7879 to 0.7880 in.)
Piston pin outer diameter	A	20.004 to 20.007 mm (0.7876 to 0.7877 in.)
	B	20.008 to 20.010 mm (0.7877 to 0.7878 in.)
	C	20.011 to 20.013 mm (0.7878 to 0.7879 in.)
Connecting rod small end bore diameter	A	20.012 to 20.015 mm (0.7879 to 0.7880 in.)
	B	20.016 to 20.018 mm (0.7880 to 0.7881 in.)
	C	20.019 to 20.021 mm (0.7881 to 0.7882 in.)
Piston pin oil clearance
Piston pin x Piston	Standard	0.002 to 0.011 mm (0.0001 to 0.0004 in.)
	Maximum	0.011 mm (0.0004 in.)
Piston pin x Connecting rod	Standard	0.001 to 0.017 mm (-0.00004 to 0.0007 in.)
	Maximum	0.017 mm (0.0007 in.)
Ring groove clearance	No. 1	0.02 to 0.07 mm (0.0008 to 0.0028 in.)
	No. 2	0.03 to 0.07 mm (0.0012 to 0.0028 in.)
	Oil	0.03 to 0.11 mm (0.0012 to 0.0043 in.)
Piston ring end gap	Standard No. 1	0.25 to 0.35 mm (0.0098 to 0.0138 in.)
	No. 2	0.35 to 0.50 mm (0.0138 to 0.0197 in.)
	Oil	0.15 to 0.40 mm (0.0059 to 0.157 in.)
	Maximum No. 1	1.05 mm (0.0413 in.)
	No. 2	1.20 mm (0.0472 in.)
Connecting rod
Out-of-alignment	Maximum	0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
Twist	Maximum	0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
Connecting rod bolt diameter	Standard	6.6 to 6.7 mm (0.260 to 0.264 in.)
	Maximum	6.4 mm (0.252 in.)
Crankshaft
Circle runout	Maximum	0.03 mm (0.0012 in.)
Main journal diameter		47.988\| to 48.000 mm (1.8893 to 1.8898 in.)
Taper and out-of-round	Maximum	0.02 mm (0.0008 in.)
Crank pin diameter		43.992 to 44.000 mm (1.7320 to 1.7323 in.)
Taper and out-of-round	Maximum	0.02 mm (0.0008 in.)
Crankshaft bearing cap set bolt diameter	Standard	7.3 to 7.5 mm (0.287 to 0.295 in.)
	Minimum	7.3 mm (0.287 in.)
Crankshaft oil clearance	Standard	0.015 to 0.032 mm (0.0006 to 0.0013 in.)
	Minimum	0.05 mm (0.0020 in.)
Cylinder block journal bore diameter	0	52.000 to 52.002 mm (2.0472 to 2.0473 in.)
	1	52.003 to 52.004 mm (2.0474 to 2.0474 in.)
	2	52.005 to 52.006 mm (2.0474 to 2.0475 in.)
	3	52.007 to 52.009 mm (2.0475 to 2.0476 in.)
	4	52.010 to 52.011 mm (2.0476 to 2.0477 in.)
	5	52.012 to 52.013 mm (2.0477 to 2.0478 in.)
	6	52.014 to 52.015 mm (2.0478 to 2.0478 in.)
Crankshaft journal diameter	0	47.999 to 48.000 mm (1.8897 to 1.8898 in.)
	1	47.997 to 47.998 mm (1.8896 to 1.8897 in.)
	2	47.995 to 47.996 mm (1.8896 to 1.8896 in.)
	3	47.993 to 47.994 mm (1.8895 to 1.8895 in.)
	4	47.991 to 47.992 mm (1.8894 to 1.8894 in.)
	5	47.988 to 47.990 mm (1.8893 to 1.8894 in.)
Standard bearing center wall thickness	1	1.994 to 1.997 mm (0.0785 to 0.0786 in.)
	2	1.998 to 2.000 mm (0.0787 to 0.0787 in.)
	3	2.001 to 2.003 mm (0.0788 to 0.0789 in.)
	4	2.004 to 2.006 mm (0.0789 to 0.0790 in.)
Straight pin (cylinder block) (See page 14-134)	A	5 mm (0.197 in.)
	B	7.5 mm (0.295 in.)
	C	12 mm (0.472 in.)
	D	8 mm (0.315 in.)
Ring pin (cylinder block) (See page 14-134)	A	6 mm (o;.236 in.)
	B	7 mm (0,276 in.)
	C	10 mm (0.394 in.)

Service Specifications - Engine Mechanical (1ZZ-FE)

2ZZ-GE

Ignition timing	W/ Terminal TC and CG of DLC3 connected	8 to 12° BTDC
	W/Terminal TC and CG of DLC3 disconnected	4 to 12° BTDC
Idle speed		750 to 850 rpm
Compression pressure		1,400 kPa (14.3 kgf/cm 2 ,203 psi)
Minimum pressure		1,000 kPa (10.3 kgf/cm 2 ,145 psi)
Difference between each cylinder		110 kPa;(1.1 kgf/cm 2 ,16 psi)
Valve clearance at cold	Intake	0.08 to 0.18 mm (0.0031 to 0.0071 in.)
	Exhaust	0.22 to 0.32 mm (0.0087 to 0.0126 in.)
Chainelongation	Maximum	115.3 mm (4.539 in.)
Camshaft timing gear diameter (w/ chain)	Minimum	96.8 mm; (3.811 in.)
Crankshaft timing gear diameter (w/ chain)	Minimum	51.0 mm (2.008 in.)
Chain tensioner slipper wear	Maximum	1.0 mm (0.039 in.)
Chain vibration damper wear	Maximum	1.0 mm (0.039 in.)
Cylinder head set bolt length	Standard	146.8 to 148.2 mm (5.780 to 5.835 in.)
	Maximum	148.5 mm (5.846 in.)
Valve rocker shaft diameter		15.965 to 15.985 mm (0.6285 to 0.6293 in.)
Camshaft
Circle runout	Maximum	0.03 mm (0.0012 in.)
Cam lobe height	Standard No. 1	40.716 to 40.816 mm (1.6030 to 1.6069 in.)
	No. 2	38.769 to 38.869 mm (1.5236 to 1.5303 in.)
	Minimum No. 1	40.45 mm (1.5925 in.)
	No. 2	38.61 mm (1.5201 in.)
Journal diameter	No. 1	34.449 to 34.465 mm (1.3563 to 1.3569 in.)
	Other	27.949 to 27.965 mm (1.1004 to 1.1010 in.)
No. 2 Camshaft
Circle runout	Maximum	0.03 mm (0.0012 in.)
Cam lobe height	Standard No. 1	40.019 to 40.119 mm (1.5755 to 1.5795 in.)
	No. 2	38.863 to 38.963 mm (1.5300 to 1.5340 in.)
	Minimum No. 1	39.86 mm (1.5693 in.)
	No. 2	38.71 mm (1.5240 in.)
Journal diameter	No. 1	34.449 to 34.465 mm (1.3563 to 1.3569 in.)
	Other	27.949 to 27.965 mm (1.1004 to 1.1010 in.)
Cylinder head warpage	Cylinder block side	0.20 mm (0.0080 in.)
	Intake manifold side	0.20 mm (0.0080 in.)
	Exhaust manifold side	0.30 mm (0.0120 in.)
Valve guide bush inside diameter		5.500 to 5.518 mm (0.2165 to O.2172 in.)
Valve stem diameter	Intake	5.460 to 5.475 mm (0.2145 to 0.2156 in.)
	Exhaust	5.455 to 5.470 mm (0.2144 to 0.2154 in.)
Valve guide bush oil clearance	Standard Intake	0.025 to 0.058 mm (0.0010 to 0.0023 in.)
	Exhaust	0.030 to 0.063 mm (0.0012 to 0.0025 in.)
	Maximum	0.10 mm (0.0039 in.)
Valve guide bush bore diameter	STD	10.448 to 10.506 mm (0.4129 to 0.4136 in.)
	O/S 0.05	10.538 to 10.556 mm (0.4149 to 0.4156 in.)
Inner compression spring
Free length	Intake	46.4 mm (1.827 in.)
	Exhaust	46.5 mm (1.831 in.)
Deviation	Maximum	1.6 mm (0.063 in.)
Angle (reference)	Maximum	2°
Intake valve
Overall length	Standard	111.3 mm (4.382 in.)
	Minimum	110.9 mm (4.366 in.)
Margin thickness	Standard	1.0 mm (0.039 in.)
	Minimum	0.7 mm (0.028 in.)
Exhaust valve
Overall length	Standard	111.7 mm (4.392 in.)
	Minimum	111.3 mm(4.382 in.)
Margin thickness	Standard	1.0 mm (0.039 in.)
	Minimum	0.7 mm (0.028 in.)
Camshaft thrust clearance	Standard	0.04 to 0.14 mm (0.0016 to 0.0055 in.)
	Maximum	0.15 mm (0.0059 in.)
Camshaft oil clearance	Standard	0.025 to 0.062 mm (0.0001 to 0.0024 in.)
	Maximum	0.062 mm (0.0024 in.)
Ring pin protrusion height		6.4 mm (0.252 in.)
Union protrusion height (See page 14-264)	A	29 mm (1.14 in.)
	B	69.8 mm (2.748 in.)
	C	24 mm (0.95 in.)
Valve guide bush protrusion height		15.3 to 15.7 mm (0.602 to 0.618 in.)
Connecting rod thrust clearance	Standard	0.160 to 0.342 mm (0.0063 to 0.0135 in.)
	Maximum	0.342 mm (0.0135 in.)
Connecting rod oil clearance	Standard	0.028 to 0.052 mm (0.0011 to 0.0020 in.)
	Maximum	0.080 mm (0.0031 in.)
Connecting rod large end bore diameter	1	48.000 to 48.008 mm (1.8898 to 1.8901 in.)
	2	48.009 to 48.016 mm (1.8901 to 1.8904 in.)
	3	48.017 to 48.024 mm (1.8904 to 1.8907 in.)
Connecting rod bearing thickness	1	1.482 to 1.486 mm (0.0583 to 0.0585 in.)
	2	1.487 to 1.490 mm (0.0585 to 0.0587 in.)
	3	1.491 to 1.494 mm (0.0587 to 0.0588 in.)
Crankshaft pin outer diameter		44.992 to 45.000 mm (1.7713 to 1.7717 in.)
Crankshaft thrust clearance	Standard	0.04 to 0.24 mm (0.0016 to 0.0094 in.)
	Maximum	0.24 mm (0.0094 in.)
Cylinder block warpage	Maximum	0.05 mm (0.0020 in.)
Cylinder bore diameter	Standard	82.000 to 82.013 mm (3.2283 to 3.2289 in.)
Piston diameter	At 12 mm (0.472 in.) from piston skirt	81.975 to 81.933 mm (3.2274 to 3.2281 in.)
Piston oil clearance	Standard	0.007 to 0.038 mm (0.0003 to 0.0015 in.)
	Maximum	0.10 mm (0.0039 in.)
Connecting rod small end bore diameter		20.011 to 20.023 mm (0.7878 to 0.7883 in.)
Piston pin bore diameter		20.013 to 20.025 mm (0.7879 to 0.7884 in.)
Piston pin outer diameter		20.004 to 20.016 mm (0.7876 to 0.7880 in.)
Piston pin oil clearance
Piston x Piston pin		0.005 tip 0.013 mm (0.0002 to 0.0005 in.)
Piston pin x Connecting rod		0.005 to 0.009 mm (0.0002 to 0.0004 in.)
Piston ring groove clearance	No. 1	0.02 to 0.07 mm (0.0009 to 0.0028 in.)
	No. 2	0.03 to 0.07 mm (0.0012 to 0.0028 in.)
Piston ring end gap	Standard No. 1	0.25 to 0.35 mm (0.0098 to 0.0138 in.)
	No. 2	0.40 to 0.80 mm (0.0276 to 0.0315 in.)
	Oil	0.10. to 0.40 mm (0.0039 to 0.0157 in.)
	Maximum No. 1	1.05 mm (0.0413 in.)
	No. 2	1.20 mm (0.0472 in.)
	Oil	1.05 mm (0.0413 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.)
Connecting rod bolt diameter	Standard	8.7 to 8(8 mm (0.3425 to 0.3465 in.)
	Minimum	6.7 mm (0.263 in.)
Crankshaft
Circle runout	Maximum	0.03 mm (0.0012 in.)
Main journal diameter		47.988 to 48.000 mm (1.8893 to 1.8898 in.)
Taper and out-of-round	Maximum	0.02 mm (0.0008 in.)
Crank pin diameter		44.992 to 45.000 mm (1.7713 to 1.7717 in.)
Taper and out-of-round	Maximum	0.02 mm (0.0008 in.)
Crankshaft bearing cap set bolt diameter	Standard	7.3 to 7.5 mm (0.287 to 0.295 in.)
	Minimum	7.3 mm (0.287 in.)
Crankshaft oil clearance	Standard	0.016 to 0.032 mm (0.0006 to 0.0013 in.)
	Maximum	0.08 mm (0.0031 in.)
Cylinder block main journal bore diameter	0	52.000 to 52.002 mm (2.0472 to 2.0473 in.)
	1	52.003 to 52.004 mm (2.0473 to 2.0474 in.)
	2	52.005 to 52.006 mm (2.0474 to 2.0475 in.)
	3	52.007 to 52.009 mm (2.0475 to 2.0476 in.)
	4	52.010 to 52.011 mm (2.0476 to 2.0477 in.)
	5	52.012 to 52.013 mm (2.0477 to 2.0478 in.)
	6	52.014 to 52.016 mm (2.0478 to 2.0479 in.)
Crankshaft main journal diameter	0	47.999 to 48.000 mm (1.8897 to 1.8898 in.)
	1	47.997 to 47.998 mm (1.8896 to 1.8897 in.)
	2	47.995 to 47.996 mm (1.8896 to 1.8896 in.)
	3	47.993 to 47.994 mm (1.8895 to 1.8895 in.)
	4	47.991 to 47.992 mm (1.8894 to 1.8894 in.)
	5	47.988 to 47.990 mm (1.8892 to 1.8893 in.)
Standard bearing center wall thickness	1	1.989 to 1.992 mm (0.0783 to 0.0784 in.)
	2	1.993 to 1.995 mm (0.0785 to 0.0785 in.)
	3	1.996 to 1.998 mm (0.0786 to 0.0787 in.)
	4	1.999 to 2.001 mm (0.0787 to 0.0788 in.)
	5	2.002 to 2.004 mm (0.0788 to 0.0789 in.)
Ring pin (cylinder block)	A	7 mm (0.276 in.)
	B	6 mm (0.236 in.)
	C	10 mm (0.394 in.)
Straight pin (cylinder block)	A	5 mm (0.197 in.)
	B	7.5 mm (0.295 in.)
	C	9 mm (0.354 in.)
	D	8 mm (0.315 in.)

Service Specifications - Engine Mechanical (2ZZ-GE)

SERVICE DATE

1ZZ-FE(2WD)/2ZZ-GE

Compression spring (Exhaust pipe assy front x Exhaust manifold)
Free length	Minimum	41.5 mm (1.634 in.)
Compression spring (Exhaust pipe assy tail x Exhaust pipe assy front)
Free length	Minimum	38.5 mm (1.516 in.)

Service Specifications - Exhaust - 1ZZ-FE(2WD)/2ZZ-GE

1ZZ-FE(4WD)

Scheme 3

Compression spring (Exhaust pipe assy center x Exhaust pipe assy front)
Free length	Minimum	38.5 mm (1.516 in.)

Service Specifications - Exhaust - 1ZZ-FE(4WD)

Thermostat
Valve opening temperature		80 to 84°C (176 to 183°F)
Valve lift	At 95°C (203°F)	10 mm {0.39 in.) or more
Radiator cap sub-assy
Standard opening pressure		74 to 103 kPa (0.75 to 1.05 kgf/cm 2 , 10.7 to 14.9 psi)
Minimum opening pressure		59 kPa (0.6 kgf/cm 2 , 8.6 psi)
Cooling fan
Standard amperage	At 20°C (68°F)
Standard amperage	1ZZ-FE	7.9 to 10.9 A
Cooling fan relay
Resistance	3 - 5	10 kohms or higher
Resistance	3-5 (Apply battery voltage to terminals 1 and 2)	Below 1 ohms
Cooling fan relay No. 2
Resistance	3 - 4	Below 1 ohms
	3 - 4 (Apply battery voltage to terminals 1 and 2)	10 kohms or higher
	3 - 5	10kohms or higher
	3 - 5 (Apply battery voltage to terminals 1 and 2)	Below 1 ohms
Cooling fan
Resistance	At 20°C (68°F)	1.17 to 1.43 ohms

Service Specifications - Cooling

1ZZ-FE

Oil pressure	At idle speed	29 kPa (0.3 kgf.cm 2 ,4.3 psi) or more
Oil pressure	At 3,000 rpm	294 to 539 kPa (3.0 to 5.5 kgf cm 2 ,43 to 78 psi)
Oil pump assy
Tip clearance	Standard	0.040 to 0.160 mm (0.0016 to 0.0063 in.)
Tip clearance	Maximum	0.160 mm (0.0063 in.)
Side clearance	Standard	0.025 to 0.071 mm (0.0010 to 0.0028 in.)
Side clearance	Maximum	0.071 mm (0.0028 in.)
Body clearance	Standard	0.260 to 0.325 mm (0.0102 to 0.0128 in.)
Body clearance	Maximum	0.325 mm (0.0128 in.)

Service Specifications - Lubrication (1ZZ-FE)

2ZZ-GE

Oil pressure	At idle speed	39.2 kPa (0.4 kgf cm 2 ,5.7 psi) or more
Oil pressure	At 3,000 rpm	294 to 539 kPa (3.0 to 5.5 kgf.cm 2 ,43 to 78 psi)
Oil pump assy
Tip clearance	Standard	0.060 to 0.180 mm (0.0024 to 0.0071 in.)
Tip clearance	Maximum	0.35 mm (0.0138 in.)
Body clearance	Standard	0.125 to 0.180 mm (0.0049 to 0.0071 in.)
Body clearance	Maximum	0.325 mm (0.0128 in.)
Side clearance	Standard	0.030 to 0.080 mm (0.0012 to 0.0032 in,)
Side clearance	Maximum	0.16 mm (0.0063 in.)

Service Specifications - Lubrication (2ZZ-GE)

1ZZ-FE

Spark plug
Recommended spark plug	DENSO made	SK16R11
Recommended spark plug	NGK made	IFR5A11
Electrode gap	Standard	1.0 to 1.3 mm (0.039 to 0.051 in.)
Camshaft position sensor
Resistance	At cold	835 to 1,400ohms
Resistance	At hot	1,060 to 1,645 ohms
Crankshaft position sensor
Resistance	At cold	1,630 to 2,740 ohms
Resistance	At hot	2,065 to 3,225 ohms
Ignition relay No. 1	Standard	10 kohms or higher
Resistance (3 - 5)		Below 1 ohms (Apply battery voltage to terminals 1 and 2)

Service Specifications - Ignition (1ZZ-FE)

2ZZ-GE

Sparkplug
Recommended spark plug	DENSO made	SK20R11
Recommended spark plug	NGK made	IFR6A11
Electrode gap		1.0 to 1.3 mm (0.039 to 0.051 in.)
Camshaft position sensor
Resistance	At cold	835 to 1,400 ohms
Resistance	At hot	1,060 to 1,645 ohms
Crankshaft position sensor
Resistance	At cold	1,630 to 2,740 ohms
Resistance	At hot	2,065 to 3,225 ohms
Ignition relay	Standard	10kohms or higher
Resistance (3-5)		Below 1 ohms (Apply battery voltage to terminals 1 and 2)

Service Specifications - Ignition (2ZZ-GE)

1ZZ-FE/2ZZ-GE

Starter assy
Specified current		90 A or less at 11.5 V
Starter relay assy
Resistance (3 - 5)	Standard	10kohms or higher
		Below 1 ohms (Apply battery voltage to terminals 1 and 2)
Magnetic switch resistance	Terminal 50 - C	1 ohms or lower
Magnetic switch resistance	Terminal 50 - Switch body	2 ohms or lower
Starter armature
Resistance	Segments	1 ohms or lower
Resistance	Commutator-Armature coil	10kohms or higher
Commutator depth	Standard	3.1 mm (0.122 in.)
Commutator depth	Maximum	3.8 mm (0.150 in.)
Starter commutator end frame assy
Brush length	Standard	9.0 mm (0.354 in.)
Brush length	Minimum	4.0 mm (0.158 in.)
Resistance
Positive (+) brush - Positive (-) brush	Standard	10 kohms or higher
Snap ring
Length	Maximum	5.0 mm (0.197 in.)
Ignition or starter switch assy
Resistance	LOCK	10 kohms or higher
	ACC	Below 1 ohms
	ON	Below 1 ohms
	START	Below 1 ohms
Battery
Voltage	Standard	12.5 to 12.9 V at 20°C (68°F)
Charging circuit without load
Amperage	Standard	10 A or less
Voltage	Standard	12.9 to 14.9 V
Charging circuit with load
Amperage	Standard	30 A or more
Generator brush holder assy
Brush length	Standard	9.5 to 11.5 mm (0.374 to 0.453 in.)
Brush length	Minimum	4.5 mm (0.177 in.)
Generator regulator assy
Resistance	B and F	When the positive and negative poles of terminals F and B are switched over, there is a resistance of below 1 ohms in one direction but 10 kohms or higher in the other direction
Resistance	E and F	When the positive and negative poles of terminals F and E are switched over, there is a resistance of below 1 ohms in one direction but 10 kohms or higher in the other direction
Generator holder w/ rectifier
Resistance	Positive (+) and each rectifier terminal	When the positive and negative poles of the positive (+) terminal and each rectifier terminal are switched over, there is a resistance of below 1 ohms in one direction but 10 kohms or higher in the other direction
Resistance	Negative (-) and each rectifier terminal	When the positive and negative poles of the negative (-) terminal and each rectifier terminal are switched over, there is a resistance of below 1 ohms in one direction but 10 kohms or higher in the other direction
Generator rotor assy
Resistance	At 20°C (68°F)	2.1 to 2.5 ohms
Slip ring diameter	Standard	14.2 to 14.4 mm (0.559 to 0.567 in.)
Slip ring diameter	Minimum	14.0 mm (0.551 in.)
Generator rectifier end frame
Resistance	Coil wires	Below 1 ohms
Resistance	Coil wire and body	1Mohms or higher

Service Specifications - Starting And Charging (1ZZ-FE/2ZZ-GE)

Front wheel alignmwt	Vehicle height
	2WD (USA, Canada)	Front: A (1) - B (2)	89 mm (3.50 in.)
	2WD (USA, Canada)	Rear: D (5) - C (3)	41 mm (1.61 in.)
	2WD (Mexico)	Front: A (1) - B (2)	74 mm (2.91 in.)
	2WD (Mexico)	Rear: D (5) - C (3)	30 mm (1.18 in.)
	4WD	Front: A (1) - B (2)	83 mm (3.27 in.)
	4WD	Rear: D (5) - C (4)	38 mm (1.50 in.)
	Toe-in (total)		0° ± 12' (0° ± 0.2°), 0 ± 2 mm, (0 ± 0.08 in.)
	Toe-in (total)	Rack end length difference	1.5 mm (0.059 in.) or less
	Wheel angle
	2WD (USA, Canada)	Inside wheel	36°40' ± 2° (36°67' ± 2°)
	2WD (USA, Canada)	Reference: Outside wheel	31°53'(31.88°)
	2WD (Mexico)	Inside wheel	36°55' ± 2° (36.92° ± 2°)
	2WD (Mexico)	Reference: Outside wheel	32°11' (32.18°)
	4WD	Inside wheel	37°03' ± 2° (37°05' ± 2°)
	4WD	Reference: Outside wheel	32°02' (32.03°)
	Camber
		2WD (USA, Canada)	0°34' ± 45' (-0.57° ± 0.75°)
		2WD (Mexico)	0°24' ± 45'(-0.40° ± 0.75°)
		4WD	0°29' ± 45' (-0.48° ± 0.75°)
		Right-left error	45'(0.75°) or less
	Caster
		2WD (USA, Canada)	2°47' ± 45' (2.78° ± 0.75°)
		2WD (Mexico)	2°40' ± 45'(2.67° ± 0.75°)
		4WD	2°46' ±45'(2.77° ± 0.75°)
		Right-left error	45'(0.75°) or less
	Steering axis inclination
		2WD (USA, Canada)	12°28' ± 45'(12.47° ± 0.75°)
		2WD (Mexico)	12°05' ± 45'(12.08° ± 0.75°)
		4WD	12°13' ± 45'(12.22° ± 0.75°)
		Right-left error	45'(0.75°) or less
Front suspension	Lower ball joint turning torque		0.98 - 4.9 N-m (10 - 50 kgf.cm, 8.7 - 43 in..lbf)
Front suspension	Stabilizer bar link ball joint turning torque		0.05 - 1.96 N.m (0.5 - 20 kgf.cm, 0.4 -1.7 in..lbf)
(1) Ground clearance of front wheel center (2) Ground clearance of lower suspension arm front bolt center (3) Ground clearance of rear axle beam set bolt center (4) Ground clearance of rear suspention lower arm rear bolt center (5) Ground clearance of rear wheel center

(1)	Ground clearance of front wheel center

(2)	Ground clearance of lower suspension arm front bolt center

(3)	Ground clearance of rear axle beam set bolt center

(4)	Ground clearance of rear suspention lower arm rear bolt center

(5)	Ground clearance of rear wheel center

Service Specifications - Front Suspension

Rear wheel alignment (2WD USA, Canada)	Toe-in (total)		0°16' ± 16' (0.26° ± 0.26°), 2.8 ± 2.7 mm (0.11 ± 0.11 in.)
	Camber		1°27'+30'(-1.45° ± 0.5°)
	Camber	Right-left error	30'(0.5°) or less
Rear wheel alignment (2WD Mexico)	Toe-in (total)		0°13' ± 16' (0.22° ± 0.26°), 2.2 ± 2.7 mm (0.09 ± 0.11 in.)
	Camber		1°26' ± 30'(-1.43° ± 0.5°)
	Camber	Right-left error	30'(0.5°) or less
Rear wheel alignment (4WD)	Toe-in (total)		0°12' ± 12° (0.20° ± 0.20°) 2.0 ± 2.0 mm (0.08 ± 0.08 in.)
	Camber		0°44' ±45'(-0.73° ± 0.75°)
	Camber	Right-left error	45'(0.75°) or less
Rear suspension	Stabilizer bar link ball joint turning torque		0.05 - 1.0 N.m (0.5 - 10 kgf.cm, 0.4 - 8.7 in..lbf)

Service Specifications - Rear Suspension

2WD (USA, Canada)
P205/55R1689H	Front, Rear	220 kPa (2.2 kgf/cm 2 , 32 psi)
P215/50ZR17
2WD (Mexico)
205/65R1594V	Front, Rear	230 kPa (2.3 kgf/cm 2 , 32 psi)
4WD
P205/55R1689H	Front	240 kPa (2.4 kgf/cm 2 , 35 psi)
P205/55R1689H	Rear	220 kPa (2.2 kgf/cm 2 ,32 psi)

Service Specifications - Tire And Wheel

Tire runout	3.0 mm (0.118 in.) or less
Imbalance after adjustment	8.0 g (0.018 lb) or less

TIRE RUNOUT DETAILS

Rear differential	Oil diaphragm seal drive in depth		0.7 to 1.3 mm (0.03 to 0.05 in.)
	Side gear shaft oil seal drive in depth		4.2 to 4.8 mm (0.165 to 0.189 in.)
	Transmission coupling vertically	Maximum	0.05 mm (0.002 in.)
	Transmission coupling horizontally	Minimum	0.05 mm (0.002 in.)
	Drive pinion to ring gear backlash		0.10 to 0.15 mm (0.0039 to 0.0059 in.)
	Side gear backlash		0.05 to 0.20 mm (0.002 to 0.0079 in.)
	Drive pinion preload (at starting)	New bearing	0.7 to 1.3 Nm (7 to 13 kgf.cm, 6 to 11 in..lbf)
	Drive pinion preload (at starting)	Reused bearing	0.4 to 0.7 Nm (4 to 7 kgf.cm, 3 to 6 in..lbf)
	Total preload (Drive pinion preload plus)		0.3 to 0.5 Nm (3 to 5 kgf.cm, 2.6 to 4.3 in..lbf)
	Side gear thrust No.1 washer thickness	Mm (in.)	1.48 to 1.52 (0.0583 to 0.0598)
			1.53 to 1.57 (0.0602 to 0.0618)
			1.58 to 1.62 (0.0622 to 0.0638)
			1.63 to 1.67 (0.0642 to 0.0657)
			1.68 to 1.72 (0.0661 to 0.0677)
			1.73 to 1.77 (0.0681 to 0.0697)
	Side gear shaft washer plate thickness	Mm (in.)	25	1.59 to 1.61 (0.0626 to 0.0634)
			26	1.62 to 1.64 (0.0638 to 0.0646)
			27	1.65 to 1.67 (0.0650 to 0.0657)
			28	1.68 to 1.70 (0.0661 to 0.0669)
			29	1.71 to 1.73 (0.0673 to 0.0681)
			30	1.74 to 1.76 (0.0685 to 0.0693)
			31	1.77 to 1.79 (0.0697 to 0.0705)
			32	1.80 to 1.82 (0.0709 to 0.0717)
			33	1.83 to 1.85 (0.0720 to 0.0728)
			34	1.86 to 1.88 (0.0732 to 0.0740)
			35	1.89 to 1.91 (0.0744 to 0.0752)
			36	1.92 to 1.94 (0.0756 to 0.0764)
			37	1.95 to 1.97 (0.0768 to 0.0776)
			38	1.98 to 2.00 (0.0780 to 0.0787)
			39	2.01 to 2.03 (0.0791 to 0.0799)
			40	2.04 to 2.06 (0.0803 to 0.0811)
			41	2.07 to 2.09 (0.0815 to 0.0823)
			42	2.10 to 2.12 (0.0827 to 0.0835)
			43	2.13 to 2.15 (0.0839 to 0.0846)
			44	2.16 to 2.18 (0.0850 to 0.0858)
			45	2.19 to 2.21 (0.0862 to 0.0870)
			46	2.22 to 2.24 (0.0874 to 0.0882)
			47	2.25 to 2.27 (0.0886 to 0.0894)
			48	2.28 to 2.30 (0.0898 to 0.0906)
			49	2.31 to 2.33 (0.0909 to 0.0917)
			50	2.34 to 2.36 (0.0921 to 0.0929)
			51	2.37 to 2.39 (0.0933 to 0.0941)
			52	2.40 to 2.42 (0.0945 to 0.0953)
			53	2.43 to 2.45 (0.0957 to 0.0965)
			54	2.46 to 2.48 (0.0969 to 0.0976)
			55	2.49 to 2.51 (0.0980 to 0.0988)
			56	2.52 to 2.54 (0.0992 to 0.1000)
			57	2.55 to 2.57 (0.1004 to 0.1012)
			58	2.58 to 2.60 (0.1016 to 0.1024)
			59	2.61 to 2.63 (0.1028 to 0.1035)
			60	2.64 to 2.66 (0.1039 to 0.1047)
Rear differential	Drive pinion plate washer thickness	Mm (in.)	41	1.695 to 1.705 (0.0667 to 0.0671)
			42	1.705 to 1.715 (0.0671 to 0.0675)
			43	1.715 to 1.725 (0.0675 to 0.0679)
			44	1.725 to 1.735 (0.0679 to 0.0683)
			45	1.735 to 1.745 (0.0683 to 0.0687)
			46	1.745 to 1.755 (0.0687 to 0.0691)
			47	1.755 to 1.765 (0.0691 to 0.0695)
			48	1.765 to 1.775 (0.0695 to 0.0699)
			49	1.775 to 1.785 (0.0699 to 0.0703)
			50	1.785 to 1.795 (0.0703 to 0.0707)
			51	1.795 to 1.805 (0.0707 to 0.0711)
			52	1.805 to 1.815 (0.0711 to 0.0715)
			53	1.815 to 1.825 (0.0715 to 0.0719)
			54	1.825 to 1.835 (0.0719 to 0.0722)
			55	1.835 to 1.845 (0.0722 to 0.0726)
			56	1.845 to 1.855 (0.0726 to 0.0730)
			57	1.855 to 1.865 (0.0730 to 0.0734)
			58	1.865 to 1.875 (0.0734 to 0.0738)
			59	1.875 to 1.885 (0.0738 to 0.0742)
			60	1.885 to 1.895 (0.0742 to 0.0746)
			61	1.895 to 1.905 (0.0746 to 0.0750)
			62	1.905 to 1.915 (0.0750 to 0.0754)
			63	1.915 to 1.925 (0.0754 to 0.0758)
			64	1.925 to 1.935 (0.0758 to 0.0762)
			65	1.935 to 1.945 (0.0762 to 0.0766)
			70	1.945 to 1.955 (0.0766 to 0.0770)
			71	1.955 to 1.965 (0.0770 to 0.0774)
			72	1.965 to 1.975 (0.0774 to 0.0778)
			73	1.975 to 1.985 (0.0778 to 0.0781)
			74	1.985 to 1.995 (0.0781 to 0.0785)
			75	1.995 to 2.005 (0.0785 to 0.0789)
			76	2.005 to 2.015 (0.0789 to 0.0793)
			77	2.015 to 2.025 (0.0793 to 0.0797)
			78	2.025 to 2.035 (0.0797 to 0.0801)
			79	2.035 to 2.045 (0.0801 to 0.0805)
			80	2.045 to 2.055 (0.0805 to 0.0809)
			81	2.055 to 2.065 (0.0809 to 0.0813)
			82	2.065 to 2.075 (0.0813 to 0.0817)
			83	2.075 to 2.085 (0.0817 to 0.0821)
			84	2.085 to 2.095 (0.0821 to 0.0825)
			85	2.095 to 2.105 (0.0825 to 0.0829)
			86	2.105 to 2.115 (0.0829 to 0.0833)
			87	2.115 to 2.125 (0.0833 to 0.0837)
			88	2.125 to 2.135 (0.0837 to 0.0841)
			89	2.135 to 2.145 (0.0841 to 0.0844)
			90	2.145 to 2.155 (0.0844 to 0.0848)
			91	2.155 to 2.165 (0.0848 to 0.0852)
			92	2.165 to 2.175 (0.0852 to 0.0856)
			93	2.175 to 2.185 (0.0856 to 0.0860)
			94	2.185 to 2.195 (0.0860 to 0.0864)
			95	2.195 to 2.205 (0.0864 to 0.0868)

Service Specifications - Differential

Propeller shaft sub-assy runout	Max.	0.4 mm (0.016 in.)
Intermediate shaft sub-assy runout	Max.	0.4 mm (0.016 in.)
Intermediate shaft sub-assy flange runout (horizontal direction)	Max.	0.1 mm (0.004 in.)
Intermediate shaft sub-assy flange runout (vertical direction)	Max.	0.1 mm (0.004 in.)
Front axle hub bearing	Backlash	Maximum: 0.05 mm (0.0020 in.)
Front axle hub sub-assy	Deviation	Maximum: 0.05 mm (0.0020 in.)
Rear axle hub & bearing assy	Backlash	Maximum: 0.05 mm (0.0020 in.)
Rear axle hub & bearing assy	Deviation	Maximum: 0.07 mm (0.0028 in.)

Service Specifications - Drive Shaft / Propeller Shaft / Axle

Drive pinion preload (at starting)
Drive pinion and ring gear		0.30 to 0.53 N-m (3.0 to 5.4 kgf.cm, 2.6 to 4.7 in..lbf)
Total		0.49 to 0.86 N.m (5.0 to 8.8 kgf.cm, 4.3 to 7.6 in..lbf)
Ring gear backlash		0.10 to 0.18 mm (0.0039 to 0.0071 in.)
Ring gear runout		0.06 mm (0.0024 in.)
Transfer ring gear mounting case runout		0.14 mm (0.0055 in.)
Driven pinion preload (at starting)
New bearing		0.53 to 0.97 N.m (5.4 to 9.9 kgf.cm, 4.7 to 8.6 in..lbf)
Used bearing		0.30 to 0.53 N.m (3.0 to 5.4 kgf.cm, 2.6 to 4.7 in..lbf)
Thrust washer thickness (Backlash adjust)	Mark
	50	2.05 mm (0.0807 in.)
	51	2.08 mm (0.0819 in.)
	52	2.11 mm (0.0831 in.)
	53	2.14 mm (0.0843 in.)
	54	2.17 mm (0.0854 in.)
	55	2.20 mm (0.0866 in.)
	56	2.23 mm (0.0878 in.)
	57	2.26 mm (0.0890 in.)
	58	2.29 mm (0.0902 in.)
	59	2.32 mm (0.0913 in.)
	60	2.35 mm (0.0925 in.)
	61	2.38 mm (0.0937 in.)
	62	2.41 mm (0.0949 in.)
	63	2.44 mm (0.0961 in.)
	64	2.47 mm (0.0973 in.)
	65	2.50 mm (0.0984 in.)
	66	2.53 mm (0.0996 in.)
	67	2.56 mm (0.1008 in.)
	68	2.59 mm (0.1020 in.)
	69	2.62 mm (0.1031 in.)
	70	2.65 mm (0.1043 in.)
	71	2.68 mm (0.1055 in.)
	72	2.71 mm (0.1067 in.)
	73	2.74 mm (0.1079 in.)
	74	2.77 mm (0.1091 in.)
	75	2.80 mm (0.1102 in.)
	76	2.83 mm (0.1114 in.)
	77	2.86 mm (0.1126 in.)
	78	2.89 mm (0.1138 in.)
	79	2.92 mm (0.1150 in.)
	80	2.95 mm (0.1161 in.)
	81	2.98 mm (0.1173 in.)
	82	3.01 mm (0.1185 in.)
	83	3.04 mm (0.1197 in.)
	84	3.07 mm (0.1209 in.)
Thrust washer thickness (Tooth adjust)	Mark
	AA	2.10 mm (0.0827 in.)
	AC	2.12 mm (0.0835 in.)
	BB	2.14 mm (0.0843 in.)
	CA	2.16 mm (0.0850 in.)
	CC	2.18 mm (0.0858 in.)
	DB	2.20 mm (0.0866 in.)
	EA	2.22 mm (0.0874 in.)
	EC	2.24 mm (0.0882 in.)
	FB	2.26 mm (0.0890 in.)
	GA	2.28 mm (0.0898 in.)
	GC	2.30 mm (0.0906 in.)
	HB	2.32 mm (0.0913 in.)
	JA	2.34 mm (0.0921 in.)
	JC	2.26 mm (0.0929 in.)
	KB	2.38 mm (0.0937 in.)
	LA	2.40 mm (0.0945 in.)
	LC	2.42 mm (0.0953 in.)
	MB	2.44 mm (0.0961 in.)
	NA	2.46 mm (0.0969 in.)
	NC	2.48 mm (0.0976 in.)
	PB	2.50 mm (0.0984 in.)
	QA	2.52 mm (0.0992 in.)
	QC	2.54 mm (0.1000 in.)
Total preload
New bearing		Driven pinion preload +
		0.30 to 0.45 Nm (3.0 to 4.6 kgf.cm, 2.6 to 4.0 in..lbf)
Used bearing		Driven pinion preload +
		0.19 to 0.34 Nm (1.9 to 3.4 kgf.cm, 1.7 to 3.0 in..lbf)
Thrust washer thickness (Preload adjust)	Mark
	AO	2.47 mm (0.0972 in.)
	A1	2.50 mm (0.0984 in.)
	A2	2.53 mm (0.0996 in.)
	A3	2.56 mm (0.1008 in.)
	A4	2.59 mm (0.1020 in.)
	A5	2.62 mm (0.1031 in.)
	A6	2.65 mm (0.1043 in.)
	A7	2.68 mm (0.1055 in.)
	A8	2.71 mm (0.1067 in.)
	A9	2.74 mm (0.1079 in.)
	BO	2.77 mm (0.1091 in.)
	B1	2.80 mm (0.1102 in.)
	B2	2.83 mm (0.1114 in.)
	B3	2.86 mm (0.1126 in.)
	B4	2.89 mm (0.1138 in.)
	B5	2.92 mm (0.1150 in.)
	B6	2.95 mm (0.1161 in.)
	B7	2.98 mm (0.1173 in.)
	B8	3.01 mm (0.1185 in.)
	B9	3.04 mm (0.1197 in.)
	CO	3.07 mm (0.1209 in.)
	C1	3.10 mm (0.1220 in.)
	C2	3.13 mm (0.1232 in.)
	C3	3.16 mm (0.1244 in.)
	C4	3.19 mm (0.1256 in.)
	C5	3.22 mm (0.1268 in.)
	C6	3.25 mm (0.1280 in.)
	C7	3.28 mm (0.1291 in.)
	C8	3.31 mm (0.1303 in.)
	C9	3.34 mm (0.1315 in.)
	DO	3.37 mm (0.1327 in.)
	D1	3.40 mm (0.1339 in.)
	D2	3.43 mm (0.1350 in.)
	D3	3.46 mm (0.1362 in.)
	D4	3.49 mm (0.1374 in.)
	D5	3.52 mm (0.1386 in.)
	D6	3.55 mm (0.1398 in.)
	D7	3.58 mm (0.1409 in.)
	D8	3.61 mm (0.1421 in.)
	D9	3.64 mm (0.1433 in.)
	E0	3.67 mm (0.1445 in.)
	E1	3.70 mm (0.1457 in.)
	E2	3.73 mm (0.1469 in.)
	E3	3.76 mm (0.1480 in.)
	E4	3.79 mm (0.1492 in.)
	E5	3.82 mm (0.1504 in.)

Service Specifications - Transfer

Brake pedal height (from asphalt sheet)	M/T	134.9 to 144.9 mm (5.311 to 5.703 in.)
Brake pedal height (from asphalt sheet)	A/T	136.0 to 146.0 mm (5.353 to 5.747 in.)
Brake Pedal freeplay		1.0 to 6.0 mm (0.04 to 0.24 in.)
Stop lamp switch clearance		0.5 to 2.4 mm (0.020 to 0.094 in.)
Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf)
	W/o ABS	More than 78 mm (3.07 in.)
	W/ABS	More than 76 mm (2.99 in.)
	W/VSC	More than 76 mm (2.99 in.)
Brake booster push rod clearance		0.21 to 0 mm (-0.0083 to 0 in.)
Front brake pad thickness	Standard	11.0 mm (0.433 in.)
Front brake pad thickness	Minimum	1.0 mm (0.039 in.)
Front brake disc thickness	Standard	25.0 mm (0.984 in.)
Front brake disc thickness	Minimum	23.0 mm (0.906 in.)
Front brake disc runout	Maximum	0.05 mm (0.0020 in.)
Rear brake drum inside diameter	Standard	228.6 mm (9.000 in.)
Rear brake drum inside diameter	Maximum	229.6 mm (9.039 in.)
Rear drum brake shoe lining thickness	Standard	5.5 mm (0.217 in.)
Rear drum brake shoe lining thickness	Minimum	1.0 mm (0.039 in.)
Rear brake pad thickness	Standard	10.0 mm (0.394 in.)
Rear brake pad thickness	Minimum	1.0 mm (0.039 in.)
Rear disc brake thickness	Standard	9.0 mm (0.354 in.)
Rear disc brake thickness	Minimum	7.5 mm (0.295 in.)
Rear brake disc runout	Maximum	0.15 mm (0.0059 in.)

Service Specifications - Brake

Parking brake lever travel at 196 N (20 kgf, 44.1 lbf)		5 - 8 clicks
Rear brake disc inside diameter	Standard	173 mm (6.81 in.)
Rear brake disc inside diameter	Maximum	174 mm (6.85 in.)
Parking brake shoe lining thickness	Standard	3.5 mm (0.138 in.)
Parking brake shoe lining thickness	Maximum	1.0 mm (0.039 in.)

Service Specifications - Parking Brake

A246E
Line pressure (Wheel locked)
		Engine idling
		D position	382 to 422 kPa (3.9 to 4.3 kgf/cm 2 , 55 to 61 psi)
		R position	647 to 760 kPa (6.6 to 7.8 kgf/cm 2 , 94 to 111 psi)
		At stall (Throttle valve fully opened)
		D position	713 to 844 kPa (7.27 to 8.61 kgf/cm 2 ,103 to 122 psi)
		R position	1,520 to 1,755 kPa (15.5 to 17.9 kgf/cm 2 , 220 to 254 psi)
Engine stall revolution		D and R positions	2,400 to 2700 rpm
Time lag		N --> D position	Less than 1.2 seconds
Time lag		N --> R position	Less than 1.5 seconds
Engine idle speed
(A/C OFF)		N position	600 to 700 rpm
Drive plate runout		Max.	0.20 mm (0.0079 in.)
Differential oil seal drive in depth		LH side	4.8 to 5.8 mm (0.189 to 0.229 in.)
Differential oil seal drive in depth		RH side	1.5 to 2.5 mm (0.059 to 0.098 in.)
Shift schedule
	D position
	(Throttle valve fully opened)	1 --> 2	55 to 64 km/h (34 to 40 mph)
2 --> 3			103 to 114 km/h (64 to 71 mph)
3 --> O/D			161 to 178 km/h (100 to 110 mph)
O/D --> 3			154 to 170 km/h (96 to 106 mph)
3 --> 2			96 to 105 km/h (60 to 65 mph)
2 --> 1			42 to 48 km/h (26 to 30 mph)
	(Throttle valve fully closed)	3 --> O/D	32 to 39 km/h (20 to 24 mph)
O/Dh --> 3			15 to 21 km/h (9 to 13 mph)
2 position
	(Throttle valve fully opened)	1 --> 2	55 to 64 km/h (34 to 40 mph)
3 --> 2			97 to 107 km/h (60 to 66 mph)
2 --> 1			42 to 48 km/h (26 to 30 mph)
L position
	(Throttle valve fully opened)	2 --> 1	46 to 53 km/h (29 to 33 mph)
Locktoup point	Throttle valve opening 5 %
	3rd gear (O/D main switch OFF)	Locktoup ON	70 to 79 km/h (43 to 49 mph)
Locktoup OFF			63 to 71 km/h (39 to 44 mph)
	O/D gear	Locktoup ON	57 to 65 km/h (35 to 40 mph)
Locktoup OFF			51 to 58 km/h (32 to 36 mph)
U341F
Line pressure (Wheel locked)
		Engine idling
		D position	372 to 412 kPa (3.8 to 4.2 kgf/cm 2 , 54 to 60 psi)
		R position	553 to 623 kPa (5.6 to 6.4 kgf/cm 2 , 80 to 100 psi)
		At stall (Throttle valve fully opened)
		D position	1,126 to 1,226 kPa (11.5 to 12.5 kgf/cm 2 ,164 to 178 psi)
		R position	1,764 to 1,964 kPa (18.0 to 20.0 kgf/cm 2 ,256 to 284 psi)
Engine stall revolution	D and R positions		2,400 to 2700 rpm
Time lag	N --> D position		Less than 1.2 seconds
Time lag	N --> R position	Less than 1.5 seconds
Engine idle speed
(A/C OFF)	N position		600 to 700 rpm
Drive plate runout	Max.		0.20 mm (0.0079 in.)
Differential oil seal drive in depth		LH side	2.2 to 3.2 mm (0.087 to 0.126 in.)
		RH side (Front transaxle case oil seal)	3.5 to 4.5 mm (0.137 to 0.177 in.)
		RH side (Front differential case oil seal)	0.5 to 0.5 mm (-0.020 to 0.020 in.)
Shift schedule
	D position
	(Throttle valve fully opened)	1 --> 2	52 to 59 km/h (32 to 37 mph)
2 --> 3			100 to 110 km/h (62 to 68 mph)
3 --> O/D			161 to 173 km/h (100 to 108 mph)
O/D --> 3			154 to 165 km/h (96 to 103 mph)
3 --> 2			94 to 104 km/h (58 to 65 mph)
2 --> 1			43 to 48 km/h (27 to 30 mph)
	(Throttle valve fully closed)	3 --> O/D	42 to 47 km/h (26 to 29 mph)
O/D --> 3			31 to 36 km/h (19 to 22 mph)
2 position
	(Throttle valve fully opened)	1 --> 2	52 to 59 km/h (32 to 37 mph)
3 --> 2			96 to 105 km/h (60 to 65 mph)
2 --> 1			43 to 48 km/h (27 to 30 mph)
L position
	(Throttle valve fully opened)	2 --> 1	48 to 53 km/h (30 to 33 mph)
Locktoup point	Throttle valve opening 5 %
	3rd gear(O/D main switch OFF)	Locktoup ON	70 to 77 km/h (43 to 48 mph)
Locktoup OFF			63 to 68 km/h (39 to 42 mph)
	O/D gear	Locktoup ON	57 to 63 km/h (35 to 39 mph)
Locktoup OFF			51 to 56, km/h (32 to 35 mph)

Service Specifications - Automatic Transmission / Transaxle

MANUAL TRANSAXLE ASSY (C59)
5th gear thrust clearance	STD	0.10 to 0.57 mm (0.0039 to 0.0224 in.)
5th gear thrust clearance	MAX	0.57 mm (0.0224 in.)
5th gear radial clearance	KOYO made STD	0.015 to 0.058 mm (0.0006 to 0.0023 in.)
	MAX	0.058 mm (0.0023 in.)
	NSK made STD	0.015 to 0.056 mm (0.0006 to 0.0022 in.)
	MAX	0.056 mm (0.0022 in.)
Synchronizer ring No.3 back and 5th gear spline end clearance	MIN	0.75 mm (0.0295 in.)
Transmission hub sleeve No.3 and gear shift fork No.3 clearance	STD	0.3 to 0.5 mm (0.012 to 0.0197 in.)
5th gear inner diameter	STD	29.915 to 29.931 mm (1.1778 to 1.1784 in.)
5th gear inner diameter	MAX	29.931 mm (1.1784 in.)
Reverse idler gear sub-assy inner diameter	STD	18.040 to 18.058 mm (0.7102 to 0.7109 in.)
Reverse idler gear sub-assy inner diameter	MAX	18.058 mm (0.7109 in.)
Reverse idler gear shaft outer diameter	STD	17.966 to 17.984 mm (0.7073 to 0.7080 in.)
Reverse idler gear shaft outer diameter	MIN	17.966 mm (0.7073 in.)
Front transaxle case oil seal drive in depth		15.6 to 16.0 mm (0.6142 to 0.6299 in.)
Input shaft front bearing drive in depth		0 to 0.3 mm (0 to 0.012 in,)
Front differential case tapered roller bearing preload	New bearing	0.78 to 1.57 N.m (8 to 16 kgf.cm, 6.9 to 13.9 in..lbf)
Front differential case shim thickness	AA	2.10 mm (0.0827 in.)
	BB	2.15 mm (0.0846 in.)
	CC	2.20 mm (0.0866 in.)
	DD	2.25 mm (0.0886 in.)
	EE	2.30 mm (0.0906 in.)
	FF	2.35 mm (0.0925 in.)
	GQ	2.40 mm (0.0945 in.)
	HH	2.45 mm (0.0965 in.)
	JJ	2.50 mm (0.0984 in.)
	KK	2.55 mm (0.1004 in.)
	LL	2.60 mm (0.1024 in.)
	MM	2.65 mm (0.1043 in.)
	NN	2.70 mm (0.1063 in.)
	PP	2.75 mm (0.1083 in.)
	QQ	2.80 mm (0.1102 in.)
	RR	2.85 mm (0.1122 in.)
	SS	2.90 mm (0.1142 in.)
	TT	2.95 mm (0.1161 in.)
	UU	3.00 mm(0.1181 in.)
Transmission case oil seal drive in depth		9.6 to 10.2 mm (0.378 to 0.402 in.)
Transaxle case oil seal drive in depth		1.6 to 2.2 mm (0.063 to 0.087 in.)
Reverse restrict pin slotted pin drive in depth		15.5 to 16.5 mm (0.6102 to 0.6496 in.)
Transmission clutch hub No.3 snap ring thickness	A	2.25 mm (0.0886 in.)
	B	2.31 mm (0.0909 in.)
	C	2.37 mm (0.0933 in.)
	D	2.43 mm (0.0957 in.)
	E	2.49 mm (0.0980 in.)
	F	2.55 mm (0.1004 in.)
	G	2.61 mm (0.1028 in.)
MANUAL TRANSAXLE ASSY (C60)
6th gear thrust clearance	STD	0.10 to 0.60 mm (0.0039 to 0.0236 in.)
6th gear thrust clearance	MAX	0.60 mm (0.0236 in.)
5th gear thrust clearance	STD	0.10 to 0.62 mm (0.0039 to 0.0244 in.)
5th gear thrust clearance	MAX	0.62 mm (0.0244 in.)
6th gear radial clearance	STD	0.009 to 0.050 mm (0.0004 to 0.0020 in.)
6th gear radial clearance	MAX	0.050 mm (0.0020 in.)
5th gear radial clearance	STD	0.015 to 0.056 mm (0.0006 to 0.0022 in.)
5th gear radial clearance	MAX	0.056 mm (0.0022 in.)
Transmission hub sleeve No.3 and gear shift fork No.3 clearance	STD	0.31 to 0.89 mm (0.0122 to 0.035 in.)
Synchronizer ring No.3 (for 6th gear MT) back and 6th gear spline end clearance
	STD	0.75 to 1.65 mm (0.0295 to 0.065 in.)
	MIN	1.6 mm (0.063 in.)
6th gear inner diameter	STD	28.015 t0 28.031 mm (1.1030 to 1.1036 in.)
6th gear inner diameter	MAX	28.031 mm (1.1036 in.)
Synchronizer ring No.3 back and 5th gear spline end clearance	STD	0.75 to 1.65 mm (0.0295 to 0.065 in.)
	MIN	1.65 mm (0.065 in)
5th gear inner diameter	STD	29.915 to 29.931 mm (1.1778 to 1.1784 in.)
5th gear inner diameter	MAX	29.931 mm (1.1784 in.)
Reverse idler gear sub-assy inner diameter	STD	18.040 to 18.058 mm (0.7102 to 0.7109 in.)
Reverse idler gear sub-assy inner diameter	MAX	18.058 mm (0.7109 in.)
Reverse idler gear shaft outer diameter	STD	17.966 to 17.984 mm (0.7073 to 0.7080 in.)
Reverse idler gear shaft outer diameter	MIN	17.966 mm (0.7073 in.)
Transaxle case oil seal drive in depth		1.6 to 2.2 mm (0.063 to 0.087 in.)
Front differential case tapered roller bearing preload	New bearing	0.78 to 1.57 N m (8 to 16 kgf.cm, 7 to 14 in..lbf)
Front differential case tapered roller bearing preload	Used bearing	0.49 to 0.98 N m (5 to 10 kgf.cm, 4 to 9 in..lbf)
Front differential case shim thickness	AA	2.10 mm (0.0827 in.)
	BB	2.15 mm (0.0846 in.)
	CC	2.20 mm (0.0866 in.)
	DD	2.25 mm (0.0886 in.)
	EE	2.30 mm (0.0906 in.)
	FF	2.35 mm (0.0925 in.)
	GG	2.40 mm (0.0945 in.)
	HH	2.45 mm (0.0965 in.)
	JJ	2.50 mm (0.0984 in.)
	KK	2.55 mm (0.1004 in.)
	LL	2.60 mm (0.1024 in.)
	MM	2.65 mm (0.1043 in.)
	NN	2.70 mm (0.1063 in.)
	PP	2.75 mm (0.1083 in.)
	QQ	2.80 mm (0.1102 in.)
	RR	2.85 mm (0.1122 in.)
	SS	2.90 mm (0.1142 in.)
	TT	2.95 mm (0.1161 in.)
	UU	3.00 mm (0.1181 in.)
Front transaxle case oil seal drive in depth		15.6 to 16.0 mm (0.6142 to 0.6299 in.)
Input shaft front bearing drive in depth		0 to 0.3 mm (0 to 0.012 in.)
Transmission case oil seal drive in depth		9.6 to 10.2 mm (0.378 to 0.402 in.)
Transmission clutch hub No.3 snap ring clearance		0.1 mm or less (0.004 in. or less)
Transmission clutch hub No.3 snap ring thickness	A	1.75 mm (0.0689 in.)
	B	1.80 mm.(0.0709 in.)
	C	1.85 mm (0.0728 in.)
	D	1.90 mm (0.0748 in.)
	E	1.95 mm (0.0768 in.)
	F	2.00 mm (0.0787 in.)
	G	2.05 mm (0.0807 in.)
	H	2.10 mm (0.0827 in.)
	J	2.15 mm (0.0846 in.)
Input shaft radial ball bearing snap ring clearance		0.1 mm or less (0.004 in. or less)
Input shaft radial ball bearing snap ring thickness	A	1.70 mm (0.0669 in.)
	B	1.75 mm (0.0689 in.)
	C	1.80 mm (0.0709 in.)
	D	1.85 mm (0.0728 in.)
	E	1.90 mm (0.0748 in.)
	F	1.95 mm (0.0768 in.)
	G	2.00 mm (0.0787 in.)
	H	2.05 mm (0.0807 in.)
	J	2.10 mm (0.0827 in.)
	K	2.15 mm (0.0846 in.)
	L	2.20 mm (0.0866 in.)
	M	2.25 mm (0.0886 in.)
Output shaft radial ball bearing snap ring clearance		0.1 mm or less (0.004 in. or less)
Output shaft radial ball bearing snap ring thickness	B	2.31 mm (0.0909 in.)
	C	2.37 mm (0.0933 in.)
	D	2.43 mm (0.0957 in.)
	E	2.49 mm (0.0980 in.)
	F	2.55 mm (0.1004 in.)
	G	2.61 mm (0.1028 in.)
	H	2.67 mm (0.1051 in.)
	J	2.73 mm (0.1075 in.)
	K	2.79 mm (0.1098 in.)
	L	2.85 mm (0.1122 in.)
	M	2.91 mm (0.1146 in.)
INPUT SHAFT ASSY (C59)
4th gear thrust clearance	STD	0.10 to 0.55 mm (0.0039 to 0.0217 in.)
4th gear thrust clearance	MAX	0.55 mm (0.0217 in.)
3rd gear thrust clearance	STD	0.10 to 0.35 mm (0.0039 to 0.0138 in.)
3rd gear thrust clearance	MAX	0.35 mm (0.0138 in.)
4th gear radial clearance	KOYO made STD	0.015 to 0.058 mm (0.0006 to 0.0023 in.)
	MAX	0.058 mm (0.0023 in.)
	NSK made STD	0.015 to 0.056 mm (0.0006 to 0.0022 in.)
	MAX	0.056 mm (0.0022 in.)
3rd gear radial clearance	KOYO made STD	0.015 to 0.058 mm (0.0006 to 0.0023 in.)
	MAX	0.058 mm (0.0023 in.)
	NSK made STD	0.015 to 0.056 mm (0.0006 to 0.0022 in.)
	MAX	0.056 mm (0.0022 in.)
Input shaft run out	MAX	0.015 mm (0.0006 in.)
Input shaft outer diameter	STD: A	24.885 to 24.900 mm (0.9797 to 0.9803 in.)
	B	28.985 to 29.000 mm(1.1411 to 1.1417 in.)
	C	30.985 to 31.000 mm (1.2198 to 1.2204 in.)
	D	24.985 to 25.000 mm (0.9836 to 0.9842 in.)
	MIN: A	24.885 mm (0.9797 in.)
	B	28.985 mm(1.1411 in.)
	C	30.985 mm (1.2198 in.)
	D	24.985 mm (0.9836 in.)
4th gear inside diameter	STD	34.015 to 34.031 mm (1.3391 to 1.3398 in.)
4th gear inside diameter	MAX	34.031 mm (1.3398 in.)
3rd gear inside diameter	STD	36.015 to 36.031 mm (1.4179 to 1.4185 in.)
3rd gear inside diameter	MAX	36.031 mm (1.4185 in.)
4th gear synchronizer ring back and 4th gear spline end clearance	MIN	0.65 mm (0.0256 in.)
3rd gear synchronizer ring back and 3rd gear spline end clearance	MIN	0.75 mm (0.0295 in.)
Gear shift fork No.2 claw and glove of the transmission hub sleeve No.2		0.15 to 0.35 mm (0.0059 to 0.0137 in.) clearance
Transmission clutch hub No.2 snap ring thickness	0	2.30 mm (0.0906 in.)
	1	2.36 mm (0.0929 in.)
	2	2.42 mm (0.0953 in.)
	3	2.48 mm (0.0976 in.)
	4	2.54 mm (0.1000 in.)
	5	2.60 mm (0.1024 in.)
Input shaft rear radial ball bearing snap ring	0	2.29 mm (0.0901 in.)
	1	2.35 mm (0.0925 in.)
	2	2.41 mm (0.0948 in.)
	3	2.47 mm (0.0972 in.)
	4	2.53 mm (0.0996 in.)
	5	2.59 mm (0.1019 in.)
INPUT SHAFT ASSY (C60)
4th gear thrust clearance	STD	0.10 to 0.55 mm (0.0039 to 0,0217 in.)
3rd gear thrust clearance	STD	0.10 to 0.35 mm (0.0039 to 0.0138 in.)
4th gear radial clearance	KOYO made	0.015 to 0.058 mm (0.0006 to 0.0023 in.)
4th gear radial clearance	NSK made	0.015 to 0.056 mm (0.0006 to 0.0022 in.)
3rd gear radial clearance	KOYO made	0.015 to 0.058 mm (0.0006 to 0.0023 in.)
3rd gear radial clearance	NSK made STD	0.015 to 0.056 mm (0.0006 to 0.0022 in.)
Input shaft run out	MAX	0.015 mm (0.0006 in.)
Input shaft outer diameter	New shaft part A	21.991 to 21.006 mm (0.8658 to 0.8270 in.)
	B	24.885 to 24.900 mm (0.9797 to 0.9803 in.)
	C	28.985 to 29.000 mm (1.1411 to 1.1417 in.)
	D	30.985 to 31.000 mm (1.2199 to 1.2205 in.)
	Min part A	21.991 mm (0.8658 in.)
	B	24.885 mm (0.9797 in.)
	C	28.985 mm (1.1411 in.)
	D	30.985 mm (1.2199 in.)
4th gear inside diameter	STD	34.015 to 34.031 mm (1.3391 to 1.3398 in.)
4th gear inside diameter	MAX	34.031 mm (1.3398 in.)
3rd gear inside diameter	STD	36.015 to 36.031 mm (1.4179 to 1.4185 in.)
3rd gear inside diameter	MAX	36.031 mm (1.4185 in.)
4th gear synchronizer ring back and 4th gear spline end clearance	MIN	0.75 mm (0.0295 in.)
3rd gear synchronizer ring back and 3rd gear spline end clearance	MIN	0.65 mm (0.0256 in.)
Gear shift fork No.2 claw and glove of the transmission hub sleeve No.2 clearance		0.15 to 0.35 mm (0.0059 to 0.0137 in.)
Transmission clutch hub No.2 snap ring clearance		0.1 mm (0.004 in.) or less
Transmission clutch hub No.2 snap ring thickness	0	2.30 mm (0.0906 in.)
	1	2.36 mm (0.0929 in.)
	2	2.42 mm (0.0953 in.)
	3	2.48 mm (0.0976 in.)
	4	2.54 mm (0.1000 in.)
	5	2.60 mm (0.1024 in.)
Input shaft bearing snap ring clearance		0.1 mm (0.004 in.) or less
Input shaft rear radial ball bearing snap ring	0	2.29 mm (0.0901 in.)
	1	2.35 mm (0.0925 in.)
	2	2.41 mm (0.0948 in.)
	3	2.47 mm (0.0972 in.)
	4	2.53 mm (0.0996 in.)
	5	2.59 mm (0.1019 in.)
OUTPUT SHAFT ASSY (C59)
1st gear thrust clearance	STD	0.10 to 0.40 mm (0.0039 to 0.0157 in.)
2nd gear thrust clearance	STD	0.10 to 0.45 mm (0.0039 to 0.0177 in.)
1st gear radial clearance	KOYO made	0.015 to 0.058 mm (0.0006 to 0.0023 in.)
1st gear radial clearance	NSK made	0.015 to 0.056 mm (0.0006 to 0.0022 in.)
1st gear radial clearance	KOYO made	0.015 to 0.058 mm (0.0006 to 0.0023 in.)
1st gear radial clearance	NSK made	0.015 to 0.056 mm (0.0006 to 0.0022 in.)
Output shaft maximum run out		0.015 mm (0.0006 in.)
Output shaft outer diameter	Part: A	31.985 mm (1.2592 in.)
	B	37.985 mm (1.4955 in.)
	C	32.985 mm (1.2986 in.)
2nd gear inside diameter	New	38.015 to 38.031 mm (1.4967 to 1.4973 in.)
2nd gear inside diameter	MAX	38.031 mm (1.4973 in.)
1st gear inside diameter	New	44.015 to 44.031 mm (1.7329 to 1.7335 in.)
1st gear inside diameter	MAX	44.031 mm (1.7335 in.)
1st gear thrust washer thickness	New	5.975 to 6.025 mm (0.2352 to 0.2372 in.)
1st gear thrust washer thickness	MIN	5.975 mm (0.2352 in.)
Synchronizer ring set No.2 back and 2nd gear spline end clearance		0.7 to 1.3 mm (0.0276 to 0.0512 in.)
Synchronizer ring No.1 back and 1st gear spline end clearance		0.75 to 1.65 mm (0.0295 to 0.065 in.)
Reverse gear groove and reverse shift fork claw clearance		0.15 to 0.35 mm (0.0059 to 0.0138 in.)
Output shaft front bearing snap ring thickness	7	1.85 to 1.90 mm (0.728 to 0.0748 in.)
	8	1.90 to 1.95 mm (0.748 to 0.0768 in.)
	1	1.95 to 2.00 mm (0.768 to 0.0787 in.)
	2	2.00 to 2.05 mm (0.787 to 0.0807 in.)
	3	2.05 to 2.10 mm (0.807 to 0.0827 in.)
	4	2.10 to 2.15 mm (0.827 to 0.0846 in.)
	5	2.15 to 2.20 mm (0.846 to 0.0866 in.)
	6	2.20 to 2.25 mm (0.866 to 0.0886 in.)
Transmission clutch hub No.1 snap ring thickness	A	2.50 mm (0.0984 in.)
	B	2.56 mm (0.1008 in.)
	C	2.62 mm (0.1031 in.)
	D	2.68 mm (0.1055 in.)
	E	2.74 mm (0.1079 in.)
	F	2.80 mm (0.1102 in.)
OUTPUT SHAFT ASSY (C60)
2nd gear thrust clearance	STD	0.10 to 0.40 mm (0.0039 to 0.0157 in.)
2nd gear thrust clearance	STD	0.10 to 0.55 mm (0.0039 to 0.0217 in.)
1st gear radial clearance	KOYO made	0.015 to 0.058 mm (0.0006 to 0.0023 in.)
1st gear radial clearance	NSK made	0.015 to 0.056 mm (0.0006 to 0.0022 in.)
1st gear radial clearance	KOYO made	0.015 to 0.058 mm (0.0006 to 0.0023 in.)
1st gear radial clearance	NSK made	0.015 to 0.056 mm (0.0006 to 0.0022 in.)
Output shaft maximum run out		0.015 mm (0.0006 in.)
Output shaft outer diameter	New shaft A	31.985 to 32.000 mm (1.2592 to 1.2598 in.)
	B	37.985 to 38.000 mm (1.4955 to 1.4961 in.)
	MIN A	31.985 mm (1.2592 in.)
	B	37.985 mm (1.4955 in.)
2nd gear inside diameter	New	38.015 to 38.031 mm (1.4967 to 1.4973 in.)
2nd gear inside diameter	MAX	38.031 mm (1.4973 in.)
1st gear inside diameter	New	44.015 to 44.031 mm (1.7329 to 1.7335 in.)
1st gear inside diameter	MAX	44.031 mm (1.7335 in.)
1st gear thrust washer thickness	New	5.975 to 6.025 mm (0.2352 to 0.2372 in.)
1st gear thrust washer thickness	MIN	5.975 mm (0.2352 in.)
Synchronizer ring set No.2 back and 2nd gear spline end clearance		0.7 to 1.3 mm (0.0276 to 0.0512 in.)
Synchronizer ring No.1 back and 1st gear spline end clearance		0.75 to 1.65 mm (0.0295 to 0.065 in.)
Reverse gear groove and reverse shift fork claw clearance		0.15 to 0.35 mm (0.0059 to 0.0138 in.)
Transmission clutch hub No.1 snap ring clearance		0.1 mm (0.004 in.) or less
Transmission clutch hub No. 1 snap ring thickness	A	2.50 mm (0.0984 in.)
	B	2.56 mm (0.1008 in.)
	C	2.62 mm (0.1031 in.)
	D	2.68 mm (0.1055 in.)
	E	2.74 mm (0.1079 in.)
	F	2.80 mm (0.1102 in.)
SHIFT & SELECT LEVER SHAFT ASSY (C60)
Control shaft cover oil seal drive in depth		0.2 to 1.2 mm (0.0079 to 0.0473 in.)
Shift lever inner No. 1 slotted pin drive in depth		0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
Shift lever inner No.2 slotted pin drive in depth		3.0 to 4.0 mm (0.1181 to 0.1575 in.)
DIFFERENTIAL CASE ASSY (MTM)
Front differential side gear backlash		0.05 to 0.20 mm (0.0020 to 0.0079 in.)
Front differential pinion thrust washer thickness		0.92 mm (0.0362 in.)
Front differential pinion shaft No.1 outer diameter		16.982 mm (0.6686 in.)
Front differential side gear thrust washer		0.95 mm (0.0374 in.)
		1.00 mm (0.0394 in.)
		1.05 mm (0.0413 in.)
		1.10 mm (0.0433 in.)
		1.15 mm (0.0453 in.)
		1.20 mm (0.0472 in.)
SHIFT & SELECT LEVER SHAFT ASSY (C59)
Control shaft cover oil seal drive in depth		0.2 to 1.2 mm (0.079 to 0.0473 in.)
Select inner lever slotted pin drive in depth		3.0 to 4.0 mm (0.1181 to 0.1575 in.)
Shift lever inner No.1 slotted pin drive in depth		0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
Shift lever inner No.2 slotted pin drive in depth		0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

Service Specifications - Manual Transmission / Transaxle

Pedal height from asphalt sheet	W/o Trun over	135.8 - 145.8 mm (5.346 - 5.740 in.)
Pedal height from asphalt sheet	W/Trun over	131.6 - 141.6 mm (5.182 - 5.575 in.)
Clutch pedal free play		5.0 - 15.0 mm (0.197 - 0591 in.)
Clutch pedal push rod play at pedal top		1.0 - 5.0 mm (0.039 - 0.197 in.)
Slotted spring pin protrusion	Maximum	1.5 - 3.5 mm (0.059 - 0.138 in.)
Disc rivet head depth	Maximum	0.3 mm (0.012 in.)
Disc runout	Minimum	0.8 mm (0.031 in.)
Diaphragm spring finger wear	Maximum depth	0.5 mm (0.020 in.)
Diaphragm spring finger wear	Maximum width	6.0 mm (0.236 in.)
Flywheel sub-assy runout	Maximum	0.1 mm (0.004 in.)
Diaphragm spring finger wear	Maximum depth	0.5 mm (0.020 in.)
Clutch release point from pedal full stroke end position		25 mm (0.98 in.) or more

Service Specifications - Clutch

STEERING SYSTEM
Steering wheel freeplay	Maximum	30 mm (1.18 in.)

SERVICE SPECIFICATIONS - STEERING COLUMN

POWER STEERING FLUID
	Fluid level rise	Maximum	5 mm (0.20 in.)
	Fluid pressure at idle speed with valve closed		7,300 to 7,800 kPa (75 to 80 kgf/cm 2 , 1,067 to 1,138 psi)
STEERING WHEEL
	Steering effort at idle speed	(Reference)	6.0 N.m (60 kgf.cm, 53 in..lbf)
VANE PUMP ASSY
	Vane pump rotating torque		0.27 N-m (2.8 kgf.cm, 2.4 in..lbf) or less
	Vane pump shaft and vane pump housing oil clearance	STD	0.021 to 0.043 mm (0.0008 to 0.0017 in.)
	Vane pump shaft and vane pump housing oil clearance	Maximum	0.07 mm (0.0028 in.)
	Vane plate thickness	Minimum	1.405 mm (0.0553 in.)
	Clearance between the rotor groove and plate	Maximum	0.03 mm (0.0012 in.)
	Spring free length	Minimum	36.9 mm (1.453 in.)
RACK & PINION POWER STEERING GEAR ASSY
	Steering rack runout	Maximum	0.1 mm (0.004 in.)
	Tie rod assy stad bolt torque	(Turning)	0.49 to 3.43 N.m (5.0 to 35.0 kgf.cm, 4.34 to 30.38 in..lbf)
	Total preload (Control valve rotating torque)	(Turning)	1.0 to 1.8 N.m(10 to 18 kgf.cm, 8.6 to 15.7 in..lbf)
	Rack boot clamp clearance		2.0 mm (0.079 in.) or less

Service Specifications - Power Steering

Refrigerant charge volume	Standard	490 +/- 30 g (17.28 +/- 1.06 oz.)
Magnetic clutch clearance	2ZZ-GE	0.35 - 0.60 mm (0.013 - 0.023 in.)
Magnetic clutch clearance	1ZZ-FE	0.35 - 0.60 mm (0.013 - 0.023 in.)

SERVICE SPECIFICATIONS - HEATER AND AIR CONDITIONER

Accelerator auto drive cable clearance	(1ZZ-FE) Standard	2 - 6 mm (0.079 - 0.236 in.)
Accelerator auto drive cable clearance	(2ZZ-GE) Standard	2 - 6 mm (0.079 - 0.236 in.)

SERVICE SPECIFICATIONS - CRUISE CONTROL

Service Specifications: Other Toyota Matrix E130

SERVICE DATA

SERVICE DATE

Scheme 3

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