Page 1079 of 2543

SERVICE SPECIFICATIONS
SERVICE DATA
 Pedal height from asphalt sheet 146.2±156.2 mm (5.76±6.15 in.) 
 Pedal freeplay
 
 5.0±15.0 mm (0.197±0.591 in.)
 Push rod play at pedal top 1.0±5.0 mm (0.039±0.197 in.)
 Full pedal stroke 132.0±138.0 mm (5.20±5.43 in.)
 Clutch release point from pedal full stroke end position 25 mm (0.98 in.) or more 
 Disc rivet head depth                                                 Maximum
 
 0.3 mm (0.012 in.)
 Disc runout                                                                Maximum 0.8 mm (0.031 in.)
 Diaphragm spring out non±alignment                        Maximum 0.5 mm (0.020 in.)
 Diaphragm spring finger wear                         Depth Maximum 0.6 mm (0.024 in.) 
 Diaphragm spring finger wear                          Width Maximum
 
 5.0 mm (0.197 in.)
 Flywheel runout                                                         Maximum 0.1 mm (0.004 in.)
 Flywheel damper rotational freeplay (2JZ±GTE)         Standard 105 mm (4.134 in.)
TORQUE SPECIFICATIONS
 Part tightened NVm kgfVcm ftVlbf
 Clutch cover x Flywheel 19 195 14 
 Master cylinder set nut
 
 12
 
125
 
 9
 Release cylinder set bolt 12 120 9
 Clutch tube bracket (2JZ±GE) 4.9 50 43 in.Vlbf
 Clutch line union 15 155 11 
 Bleeder plug
 
 11
 
11 0
 
 8
 Flywheel set bolt 49 500 36
 Release fork support (2JZ±GTE) 25 260 18
 Release fork support (2JZ±GE) 39 400 29 Clutch housing cover LH (2JZ±GTE) 12 120 9
CL±22± CLUTCHSERVICE SPECIFICATIONS 
     
        
        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 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 1260 of 2543

(b)  Place matchmarks on the flywheel and clutch cover.
(c)  Remove the 6 bolts.
Torque: 19 NVm (195 kgfVcm, 14 ftVlbf)
15.  JACK UP TRANSMISSION SLIGHTLY
Using a transmission jack, support the transmission.
16.  REMOVE REAR ENGINE MOUNTING MEMBER
Remove the 4 nuts, bolts and rear engine mounting member.
Torque:
VNut: 13 NVm (135 kgfVcm, 10 ftVlbf)
Bolt: 25 NVm (260 kgfVcm, 19 ftVlbf)
17. REMOVE STARTER
Lower the engine rear side and remove the 2 bolts and start-
er.
Torque: 39 NVm (400 kgfVcm, 29 ftVlbf)
18. REMOVE TRANSMISSION
Remove the transmission mounting 5 bolts and transmission
from the engine.
Torque: 72 NVm (730 kgfVcm, 53 ftVlbf)
19.  REMOVE SHIFT LEVER RETAINER
Remove the 4 bolts and shift lever retainer from the transmis-
sion.
Torque:
Bolt A: 19 NVm (195 kgfVcm, 14 ftVlbf)
Bolt B: 25 NVm (250 kgfVcm, 18 ftVlbf)
20.  REMOVE ENGINE REAR MOUNTING
Remove the 4 bolts and engine rear mounting from the trans-
mission.
Torque: 25 NVm (250 kgfVcm, 18 ftVlbf)
± V160 MANUAL TRANSMISSIONASSEMBLY REMOVAL AND INSTALLATIONMT2±7 
     
        
        Page 1265 of 2543

SERVICE SPECIFICATIONS
SERVICE DATA 
 
 
 
 
 
 Companion flange adjusting shim thickness 
 
 
 
 
 
1.15±1.20 mm (0.0453±0.0472 in.)
1.25±1.30 mm (0.0492±0.0512 in.)
1.45±1.50 mm (0.0571±0.0591 in.)
1.65±1.70 mm (0.0650±0.0669 in.)
1.85±1.90 mm (0.0729±0.0748 in.)
1.95±2.00 mm (0.0768±0.0787 in.)
TORQUE SPECIFICATIONS
 Part tightened N±m kgfVcm ftVlbf
 Engine rear mounting x Transmission 25 250 18 Shift lever retainer x Transmission 19 195 14 
 Transmission x Engine
 
 72
 
 730
 
 53
 Starter x Transmission 39 400 29
 Rear engine mounting member x Body 25 260 19
 Rear engine mounting member x Transmission 13 135 10
 Clutch cover x Flywheel 19 195 14
 Service hole cover set bolt 12 120 9
 Clutch release cylinder set bolt 12 120 9 Shift lever x Control rod 19 195 14 Crossmember brace x Body 13 130 9 
 Heat insulator x Body
 
 5.4
 
 55
 
 48in.Vlbf
 Exhaust center pipe x Tail pipe 19 195 14
 Exhaust front pipe x Exhaust center pipe 43 440 32
 Pipe support bracket x Transmission 37 380 27
 Exhaust front pipe x Exhaust manifold 58 590 43
 Oxygen sensor set bolt 18 180 13
 Shift lever x Shift lever retainer 7.8 80 69 in.Vlbf Clutch release fork support x Transmission 26 260 19 
 Vehicle speed sensor set bolt
 
 11
 
 11 0
 
 8
 Companion flange lock nut 120 1,220 88
 Front bearing retainer set bolt 10 100 7
 Clutch release fork support set bolt 26 260 19
 Vehicle speed sensor set bolt 11 11 0 8
MT2±12± V160 MANUAL TRANSMISSIONSERVICE SPECIFICATIONS 
     
        
        Page 1409 of 2543
6. 2JZ±GTE M/T:
REMOVE CLUTCH COVER SET BOLTS
(a)  Remove the 2 bolts and service hole cover.
(b)  Place the matchmarks on the flywheel and clutch cover.
(c)  Remove the 6 bolts.
7. A/T:
REMOVE TORQUE CONVERTER CLUTCH MOUNTING
BOLTS
(a)  Remove the hole plug.
(b)  Turn the crankshaft to gain access to each bolt.
Remove the 6 bolts.
8.  SEPARATE ENGINE AND TRANSMISSION
Remove the 6 bolts and transmission.
HINT: The º17º is 17 mm head bolt, and º14º is 14 mm head
bolt.
9. 2JZ±GE M/T:
REMOVE CLUTCH COVER AND DISC
(a)  Place matchmarks on the flywheel and clutch cover.
(b)  Loosen  each bolt one turn at a time until spring tension is
released.
(c)  Remove the bolts, and pull off the clutch cover with the clutch
disc.
NOTICE: Do not drop the clutch disc.
± ENGINEENGINE MECHANICALEG±95 
     
        
        Page 1436 of 2543

8.  INSTALL FUEL PIPE SUPPORT
Torque: 14 NVm (145 kgfVcm, 10 ftVlbf)
9.  INSTALL LH ENGINE MOUNTING BRACKET AND
INSULATOR ASSEMBLY
HINT: LH mounting bracket is marked ºA u INº.
Torque: 58 NVm (590 kgfVcm, 43 ftVlbf)
10.  INSTALL OIL FILTER BRACKET
(a)  Check and clean the oil filter bracket installation.
(b)  Place a new O±ring in position on the oil filter bracket.
(c)  Apply clean engine oil to the O±ring.
(d)  Install a new gasket to the union bolt.
(e)  Install the oil filter braket with the union bolt.
Torque: 88 NVm (900 kgfVcm, 65 ftVlbf)
11.  INSTALL NO.2 WATER BYPASS PIPE
(a)  Install a new gasket to the water pump.
(b) 2JZ±GE:
Install the water bypass pipe with the bolt and 2 nuts.
Torque: 21 NVm (210 kgfVcm, 15 ftVlbf)
(c) 2JZ±GTE:
Install the water bypass pipe with the 2 bolts and 2 nuts.
Torque: 21 NVm (210 kgfVcm, 15 ftVlbf)
12. 2JZ±GTE:
INSTALL OIL COOLER
(See oil cooler installation in Lubrication System)
13.  INSTALL OIL FILTER
(See oil and filter replacement in Lubrication System)
14.  INSTALL CYLINDER HEAD
(See cylinder head installation)
15.  INSTALL TIMING PULLEYS AND BELT
(See timing belt installation)
16. INSTALL GENERATOR
(See generator installation in Charging System)
17.  REMOVE ENGINE STAND FROM ENGINE
18. M/T:
INSTALL FLYWHEEL
HINT: The flywheel bolts are tightened in 2 progressive step,
(b) and (d).
(a)  Install the flywheel on the crankshaft.
(b)  Install and uniformly tighten the 8 bolts, in several passes, in
the sequence shown.
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
EG±122± ENGINEENGINE MECHANICAL 
     
        
        Page 1437 of 2543
(c)  Mark the flywheel bolt with paint.
(d)  Retighten the flywheel bolts by an additional 90°.
(e)  Check that the painted mark is now at a 90° angle to (d).
19. A/T:
INSTALL DRIVE PLATE
(a)  Install the front spacer, drive plate and rear plate on the
crankshaft.
Adhesive:
Part No. 08833±00070, THREE BOND 1324 or equivalent
(b)  Apply adhesive to 2 or 3 threads of the mounting bolt end.
(c)  Install and uniformly tighten the 8 bolts, in several passes, in
the sequence shown.
Torque: 83 NVm (850 kgfVcm, 61 ftVlbf)
± ENGINEENGINE MECHANICALEG±123