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 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 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 
     
        
        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