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
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
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
(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
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
11. REMOVE CLUTCH RELEASE CYLINDER AND GROUND
CABLE
(a) Remove the 2 bolts and clutch release cylinder.
Torque: 13 NVm (130 kgfVcm, 9 ftVlbf)
(b) Remove the bolt, ground cable and flexible hose bracket.
Torque: 37 NVm (380 kgfVcm, 27 ftVlbf)
12. REMOVE STARTER
(a) Remove the nut and disconnect the starter wire.
(b) Disconnect the starter wire connector.
(c) Remove the 2 bolts and starter.
Torque: 39 NVm (400 kgfVcm, 29 ftVlbf)
13. DISCONNECT BACK±UP LIGHT SWITCH CONNECTOR
14. DISCONNECT VEHICLE SPEED SENSOR CONNECTOR
15. REMOVE TRANSMISSION MOUNTING BOLTS
Remove the 3 transmission mounting bolts.
Torque:
Bolt A: 72 NVm (730 kgfVcm, 53 ftVlbf)
Bolt B: 37 NVm (380 kgfVcm, 27 ftVlbf)
16. JACK UP TRANSMISSION SLIGHTLY
Using a transmission jack, support the transmission.
17. REMOVE REAR ENGINE MOUNTING MEMBER
(a) Remove the 4 bolts and nuts.
Torque:
Nut: 13 NVm (135 kgfVcm, 10 ftVlbf)
Bolt: 25 NVm (260 kgfVcm, 19 ftVlbf)
(b) Remove the rear engine mounting member.
18. REMOVE ENGINE REAR MOUNTING
Remove the 3 bolts and engine rear mounting from the trans-
mission.
Torque: 25 NVm (250 kgfVcm, 18 ftVlbf)
19. REMOVE TRANSMISSION
(a) Remove the 3 remaining transmission mounting bolts.
Torque: 72 NVm (730 kgfVcm, 53 ftVlbf)
(b) Lower the engine rear side and remove the transmission from
the engine. MT1±10
± W58 MANUAL TRANSMISSIONASSEMBLY REMOVAL AND INSTALLATION
Rear bearing Mark 7 2.26±2.31 mm (0.0890±0.0909 in.)
Oil seal drive in depth
Front bearing retainer (from retainer end) 11.4±12.0 mm (0.449±0.472 in.)
Control shift lever retainer 55.4±56.0 mm (2.181±2.205 in.)
TORQUE SPECIFICATIONS
Part tightened NVm kgfVcm ftVlbf
Transmission x Engine
12 mm bolt 72 730 53 10 mm bolt 37 380 27 Engine rear mounting x Transmission 25 250 18 Rear engine mounting member
Nut 13 135 10 Bolt 25 260 19 Transmission x Starter 39 400 29 Clutch release cylinder set bolt 13 130 9
Transmission shift lever x Transmission
19
195
14
Propeller shaft x Differential
93
950
69
Propeller shaft center bearing
49
500
36
Crossmember brace set bolt 13 130 9
Heat insulator set nut 5.4 55 48 in.Vlbf
Exhaust center pipe x Tail pipe 19 195 14
Exhaust front pipe x Exhaust center pipe 43 440 32
Exhaust pipe support bracket set bolt 37 380 27
Exhaust No.2 front pipe x Exhaust front pipe 43 440 32
Oxygen sensor set nut 18 180 13
Shift lever x Control shift lever arm 7.8 80 69 in.Vlbf
Shift fork set bolt 20 200 14
Straight screw plug 25 250 18
Reverse idler gear shaft stopper bolt 25 250 18
Oil separator x Intermediate plate 18 185 13
Front bearing retainer set bolt 25 250 18
Extension housing x Intermediate plate 37 380 27
Restrict pin 40 410 30
Shift lever housing x Shift and select lever shaft 39 400 29
Control shift lever retainer x Extension housing 18 185 13
No.2 inner shift lever x Control shaft 39 400 29
No.1 control shift yoke x Control shaft 19 195 14 Drain and filler plugs 39 400 29 Back±up light switch 40 410 30 Control shift lever arm x Control shift lever retainer 25 250 18 Control shift lever arm x Extension housing 19 195 14 Clutch housing x Transmission case 37 380 27 Rear bearing retainer x Intermediate plate 18 185 13
MT1±48± W58 MANUAL TRANSMISSIONSERVICE SPECIFICATIONS
ENGINE
EG±1