Page 1249 of 2543

22. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY
Tighten the following parts:
wFront seat±to±body mounting bolts
Torque: 37 NVm (375 kgfVcm, 27 ftVlbf).
wFront suspension member±to±body mounting bolt
Torque:
Front side
125 NVm (1,280 kgfVcm, 92 ftVlbf)
Rear side
200 NVm (2,040 kgfVcm, 148 ftVlbf)
wRear suspension member±to±body mounting bolts.
Torque: 175 NVm (1,790 kgfVcm, 129 ftVlbf)
wRear suspension member rear cushion±to±body
mounting bolts
Torque: 58 NVm (590 kgfVcm, 43 ftVlbf)
23. BODY INSPECTION
(a) Check the body exterior for dents, scratches and rust.
(b) Check the underbody for rust and damage.
If necessary, replace or repair.
24. ROAD TEST
(a) Check the engine and chassis for abnormal noises.
(b) Check that the vehicle does not wander or pull to one side.
(c) Check that the brakes work properly and do not drag.
(d) Perform setting of the parking brake shoes and drum.
25. FINAL INSPECTION
(a) Check the operation of the body parts:
wHood
Auxiliary catch operates properly
Hood locks securely when closed
wFront and rear doors
Door locks operate properly
Doors close properly
wLuggage compartment door
Door lock operates properly
wSeats
Seat adjusts easily and locks securely in any position
Front seat back locks securely in any position
Folding±down rear seat backs lock securely
(b) Be sure to deliver a clean car. Especially check:
wSteering wheel
wShift lever knob
wAll switch knobs
wSeats MA±16
± MAINTENANCEMAINTENANCE OPERATIONS
Page 1250 of 2543

There are some maintenance and inspection
items which are considered to be the owner's re-
sponsibility. They can be performed by the owner
or be can have them done at a service shop.
These items include those which should be
checked on a daily basis, those which, in most
cases, do not require (special) tools and those
which are considered to be reasonable for the
owner to perform. Items and procedures for gen-
eral maintenance are as follows:
OUTSIDE VEHICLE
1. TIRES
(a) Check the pressure with a gauge. Adjust if
necessary.
(b) Check for cuts, damage, uneven or excessive
wear.
2. WHEEL NUTS
When checking the tires, check the nuts for
looseness or for missing nuts. If necessary,
tighten them.
3. WINDSHIELD WIPER BLADES
Check for wear or cracks whenever they do not
wipe clean. Replace if necessary.
4. FLUID LEAKS
(a) Check underneath for leaking fuel, oil, water or
other fluid.
(b) If you smell gasoline fumes or notice any leak,
have the cause found and corrected.
5. DOORS AND ENGINE HOOD
(a) Check that all doors including the trunk lid
operate smoothly, and that all latches lock
securely.
(b) Check that the engine hood secondary latch
secures the hood from opening when the
primary latch is released.
INSIDE VEHICLE
6. LIGHTS
(a) C h e c k t h a t t h e headlights, stop lights,
tail±lights, turn signal lights, and other lights
are all working.
(b) Check the headlight aiming.7. WARNING LIGHT AND BUZZERS
Check that all warning lights and buzzers
function properly.
8. HORN
Check that it is working.
9. WINDSHIELD GLASS
Check for scratches, pits or abrasions.
10. WINDSHIELD WIPER AND WASHER
(a) Check operation of the wipers and washer.
(b) Check that the wipers do not streak.
11. WINDSHIELD DEFROSTER
Check that the air comes out from the defrost-
er outlet when operating the heater air condi-
tioner at defroster mode.
12. REAR VIEW MIRROR
Check that it is mounted securely.
13. SUN VISORS
Check that they move freely and are
mounted securely.
14. STEERING WHEEL
Check that it has the specified freeplay. Be
alert for changes in steering condition, such
as excessive steering effort, excessive free-
play or strange noise.
15. SEATS
(a) Check that all front seat controls such as seat
adjusters, seatback recliner, etc. operate
smoothly.
(b) Check that all latches lock securely in any
position.
(c) Check that the locks hold securely in any
latched position.
(d) Check that the head restraints move up and
down smoothly and that the locks hold
securely in any latched position.
(e) For folding±down rear seat backs, check that
the latches lock securely.
16. SEAT BELTS
(a) Check that the seat belt system such as
buckles, retractors and anchors operate
properly and smoothly.
(b) Check that the belt webbing is not cut, frayed,
worn or damaged.
17. ACCELERATOR PEDAL
Check the pedal for smooth operation and
uneven pedal effort or catching.
GENERAL MAINTENANCE
± MAINTENANCEGENERAL MAINTENANCEMA±17
Page 1251 of 2543

18. BRAKE PEDAL
(a) Check that pedal for smooth operation.
(b) Check that the pedal has the proper reserve
distance and freeplay.
(c) Check the brake booster function.
19. BRAKES
At a safe place, check that the brakes do not
pull to one side when applied.
20. PARKING BRAKE
(a) Check that the pedal has the proper travel.
(b) On a safe incline, check that the vehicle is
held securely with only the parking brake
applied.
21. AUTOMATIC TRANSMISSION PARK
MECHANISM
(a) Check the lock release button of the selector
lever for proper and smooth operation.
(b) On a safe incline, check that the vehicle is
held securely with the selector lever in the ºPº
position and all brakes released.
UNDER HOOD
22. WINDSHIELD WASHER FLUID
Check that there is sufficient fluid in the tank.
23. ENGINE COOLANT LEVEL
Check that the coolant level is between the
LEVEL lines on the see±through reservoir at
normal temperature (20°C (68°F)).
24. RADIATOR AND HOSES
(a) Check that the front of the radiator is clean
and not blocked with leaves, dirt or bugs.
(b) Check the hoses for cracks, kinks, rot or
loose connections.
25. BATTERY ELECTROLYTE LEVEL
Check the indicator.
When the indicator color is blue, the condition
is satisfactory. A red color indicates that dis-
tilled water must be added, and white indi-
cates that charging is necessary.
26. BRAKE FLUID LEVEL
Check that the brake fluid level is near the up-
per level line on the see±through reservoir.27. ENGINE DRIVE BELT
Check drive belt for fraying, cracks, wear or
oil contamination.
28. ENGINE OIL LEVEL
Check that level on the dipstick with the en-
gine turned off.
29. POWER STEERING FLUID LEVEL
Check the level on the dipstick.
The level should be in the ºHOTº or ºCOLDº
range depending on the fluid temperature.
30. A U TO M AT I C TRANSMISSION FLUID
LEVEL
(a) Park the vehicle on a level surface.
(b) With the engine idling and the parking and
foot brake applied, shift the selector into all
positions from ºPº to ºLº, and then shift into ºPº
position.
(c) Turn and pull out the dipstick and wipe off the
fluid with a clean rag.
Re±insert the dipstick fully and check that the
fluid level is in the ºHOTº range.
(d) Perform this check with the fluid at normal
driving temperature (70±80°C (158±176°F)).
If the level is at the low side, add fluid.
NOTICE: Do not overfill.
HINT: Wait about 30 minutes before checking
the fluid level after extended driving at high
speeds in hot weather, driving in heavy traffic
or with a trailer.
31. EXHAUST SYSTEM
Visually inspect for cracks, holes or loose
supports.
If any change in the sound of the exhaust or
smell of the exhaust fumes is noticed, have
the cause located and correted. MA±18
± MAINTENANCEGENERAL MAINTENANCE
Page 1252 of 2543

SERVICE SPECIFICATIONS
SERVICE DATA
Engine
Spark plug
Recommended spark plug 2JZ±GE ND
NGK
2JZ±GTE ND
NGK
Correct electrode gap
Firing order
Valve clearance Intake
Exhaust
PK16R11
BKR5EP11
PK20R11
BKR6EP11
1.1 mm (0.043 in.)
1±5±3±6±2±4
0.15±0.25 mm (0.006±0.010 in.)
0.25±0.35 mm (0.010±0.014 in.)
Brake
Front and rear brakes
Pad thickness Minimum
Disc thickness Minimum Front 2JZ±GE
2JZ±GTE
Rear
Disc runout Maximum
Parking brake
Lining thickness Maximum
Drum inside diameter Maximum
1.0 mm (0.039 in.)
30.0 mm (1.181 in.)
28.0 mm (1.102 in.)
15.0 mm (0.591 in.)
0.05 mm (0.0020 in.)
1.0 mm (0.039 in.)
191 mm (7.520 in.)
Chassis
Steering linkage
Steering wheel freeplay Maximum
Ball joint
Vertical play Maximum
30 mm (1.18 in.)
0.3 mm (0.012 in.)
TORQUE SPECIFICATIONS
Part tightened NVm kgfVcm ftVlbf
Spark plug x Cylinder head
18
180
13
Front seat x Body 37 375 27
Front suspension member x Body Front side
Rear side
125
200
1,280
2,040
92
148
Rear suspension member x Body 175 1,790 129
Rear suspension member rear cushion x Body 58 590 43
± MAINTENANCESERVICE SPECIFICATIONSMA±19
Page 1253 of 2543
V160 MANUAL TRANSMISSION
MT2±1
Page 1254 of 2543
09308±10010
09308±14010
09309±14040
09330±00021
09950±30010
(09951±03010)
(09953±03010)
(09955±03030)
(09956±03030)
(09954±03010)
Adaptor 20
Lower Plate 130
Arm
Center Bolt
Upper Plate
Puller A Set
Companion Flange Holding Tool
Remover & Replacer D
Replacer Pipe A
Oil Seal Puller
PREPARATION
SST (SPECIAL SERVICE TOOLS)
EQUIPMENT
Calipers
Torque wrench
LUBRICANT
Item Capacity Oil type
Manual transmission oil
1.8 liters (1.9 US qts, 1.6 lmp.qts)
TOYOTA GEAR OIL V160 or
ESSO ATF DEXRON[D 21065
MT2±2± V160 MANUAL TRANSMISSIONPREPARATION
Page 1255 of 2543
MT2±8MT2±4
Noise
Jumps out of gear
Trouble
Parts
Name
See page
Hard to shift or will not shift
Oil leakage
Oil (Level low)Oil seal (Worn or damaged)Gasket (Damaged)Oil (Level too high)Oil (Wrong)Locking ball spring (Damaged)Control cable (Family)Shift key spring (Damaged)O±Ring (Worn or damaged)Gear (Worn or damaged)Shift fork (Worn)Bearing (Worn or damaged)Synchronizer ring (Worn or damaged)Flywheel damper
MT2±8CL
Section
SSM (SPECIAL SERVICE MATERIALS)
08833±00080
Adhesive 1344,
THREE BOND 1344,
LOCTITE 242 or equivalent
Companion flange lock nut
Vehicle speed sensor set bolt
TROUBLESHOOTING
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
± V160 MANUAL TRANSMISSIONPREPARATIONMT2±3
Page 1256 of 2543
MT2±8MT2±4
Noise
Jumps out of gear
Trouble
Parts
Name
See page
Hard to shift or will not shift
Oil leakage
Oil (Level low)Oil seal (Worn or damaged)Gasket (Damaged)Oil (Level too high)Oil (Wrong)Locking ball spring (Damaged)Control cable (Family)Shift key spring (Damaged)O±Ring (Worn or damaged)Gear (Worn or damaged)Shift fork (Worn)Bearing (Worn or damaged)Synchronizer ring (Worn or damaged)Flywheel damper
MT2±8CL
Section
SSM (SPECIAL SERVICE MATERIALS)
08833±00080
Adhesive 1344,
THREE BOND 1344,
LOCTITE 242 or equivalent
Companion flange lock nut
Vehicle speed sensor set bolt
TROUBLESHOOTING
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
± V160 MANUAL TRANSMISSIONTROUBLESHOOTINGMT2±3