ENGINE MECHANICAL
STANDARD AND REPAIR LIMIT
Distortion limit mm
- - Intake manifold
Intake manifold collector
1 -5-3-6-2-4
1.20 (1
2.2)/300
0.90 (9.2)/300
0.1 (1.0)/300
Firing order
-- - 0.1
0.1
- -- - ( Cylinder block 0.1
Compression
pressure
MPa
(kg/cm2)/rpm
Exhaust manifold
Cvlinder head
Engine oil capacity Standard
Limit
-
Limit of variation between cylinders
0.3
0.2
- - -- - Spark plug I ~akerfl~~e/~~ark plug gap mm r NGKPFRGG-11/1.0 - 1.1
Without
filter
'with
filter
ignition advance device
I Electronically-controlled ignition advance
Approx.
3.9
Aoorox.
4.3
Engine idling speed
rPm
Idle
base speed (during no feed back control)
Pm
650-e50
(N or P position for
A/T)
600 (N or P position for AQ
Density of COIHC at idling speed
Wppm
Ignition timing (during no feed back control)
BTDCO/rpm Less
thanbl~ess than 50
15dY600
Valve clearance
(INT/EXH) mm
Deflection amount of accessory V-belt Hot
engine
Cold engine (at ambient temperature)
Measured
with tension gauge
(kg)
I
SEC.117 Power steering
Fan belt pump belt
0.36+0.062/0.53i0.062
0.3
1 20 .04/0.50a0.04
Fuel tank capacity
4
Engine coolant total capacity [with reservoir tank (max. level)] t
Thermostat opening temperature [start to open - full open]
OC
Radiator cap opening pressure
MPa (kg/cm2)
Power steering pump belt
Measured by pushing at 98
N (1 0 kg)
mm Approx.
65
Approx. 9.4
82
- 95
0.06
- 0.1 0 (0.6 - 1 .O)
New 1 Used 1 Limit
AfC
compressor belt
Fan belt
,
667 - 755
(68
- 77)
Power steering pump belt
' AfC compressor belt
Fan belt
559 - 637 284 (29)
(57 - 65)
667
- 755
(68
- 77)
667
- 755
(68
- 77)
559 - 637 284 (29)
(57 - 65)
559 - 637 284 (29) (57 - 65)
8-
10
6-8
3 - 5
- 10 - 12 16
7-9 12
4
- 6 7.5
ENGINE MECHANICAL pEZBq
TIGHTENING TORQUE
Engine cover
' Throttle body
Throttle position sensor
IAA unit
(ACC valve)
' Intake manifold collector
* Intake manifold
Engine coolant temperature
sensor
' Fuel tube
Pressure regulator
Fuel damper
Fuel hose clamp bolt
(in engine compartment)
Turbocharger Oil tube
Water tube (block side)
(turbocharger side)
Oxygen sensor
Exhaust manifold cover
' Exhaust manifold
Crank pulley
Cam pulley (INT)
Cam pulley
(EXH)
Timing belt cover
Timing belt rear cover
Tensioner pulley
Idler pulley
Crankshaft position sensor
' Oil pan
Oil strainer
Oil pan drain plug
Ignition coil
Spark plug
' Rocker cover
' Camshaft bracket
Camshaft baffle plate Unit:
N.m (kg-m)
5.0
- 6.5 (0.51 - 0.66)
1)
8.8
- 11 (0.9 - 1.1)
2)
18
- 22 (1 -8 - 2.2)
2.0
- 2.4 (0.20 - 0.24)
8.4
- 11 (0.86 - 1.1)
18
- 22 (1.8 - 2.2)
18
- 22 (1 -8 - 2.2)
20
- 29 (2.0 - 3.0)
5.1
- 6.5 (0.52 - 0.66)
20
- 29 (2.0 - 3.0)
1) 5.5
- 7.5 (0.56 - 0.76)
2) 5.5 - 7.5 (0.56 - 0.76)
(Tighten separately in twice.)
' Cylinder head boit
Cylinder head sub bolt
VTC solenoid
" Main bearing cap
Connecting rod
nut
Oil jet
Flywheel and drive plate
Engine coolant drain plug
Knock sensor
Radiator mounting bracket
Auxiliary electric fan
Water pump (M6 bolt)
(M8 bolt)
(MI
0 bolt)
Water inlet
Oil pump assembly
Accelerator cable lock nut
Fuel tank strap
Fuel sender unit lock
ring
Exhaust manifold to front
tube
Front tube to catalytic
converter
Catalytic converter to center
tube
Center tube to main
muffler
Alternator (main)
(stay side)
Starter motor Unit:
N.m (kg-m)
1) 29 (3.0)
2) 98 (10.0)
3) 0 (0)
4) 25 - 34 (2.5 - 3.5)
5) 95"
- 100"
(Angle tightening)
I%
9.0 - 12 (0.92 - 1.2)
25
- 34 (2.5 - 3.5)
49
- 59 (5.0 - 6.0) AT
1) 14 - 16 (1.4 - 1.6)
2) 60" - 65"
(Angle tightening) BR
30 - 40 (3.1 - 4.1)
93
- 103 (9.5 - 10.5)
34 - 44 (3.5 - 4.5) ST
25 - 34 (2.5 - 3.5)
3.8
- 4.5 (0.39 - 0.46) I%$
5.1 - 6.5 (0.52 - 0.66)
17
- 21 (1.7 - 2.1)
20
- 23 (2.0 - 2.3) kIA
35 - 47 (3.6 - 4.8)
16
- 21 (1.6 - 2.1)
9.0
- 12 (0.92 - 1.2) a=
': Tighten as specified tightening order.
1): Tighten separately in several times.
AUTOMATIC TRANSMISSION
LOCK-UP SPEED
Engine type (mode
Vehicle speed in
D, position
Vehicle speed in
D, position code)
Lock-up OFF krnh
Lock-up
ON
kmlh
Lock-up OFF kmlh Closed throttle
Half throttle
Closed throttle
Half throttle
Closed throttle Half throttle
Closed throttle Half throttle
--- - Closed throttle: Throttle opening of less than 118 with the closed throttle position switch off position
Half throttle: Throttle opening of 418
STALL SPEED
LINE PRESSURE
Engine type (model code) Stall engine speed rpm
- - -
At idle engine speed I 0.58 - 0.62 (5.9 - 6.3) I 0.47 - 0.51 (4.8 - 5.2)
Engine speed
At stall engine speed
1 1.71 - 1.78 (17.4 - 18.2) 1 1.22 - 1.29 (12.4 - 13.2)
Line pressure MPa (kg/cm2)
R position D, 2, and 1 positions (4AT)
D, 3, and 2 positions (M-AT)
CONTROL VALVE SPECIFICATIONS
Val ve loc
Upper body
Lower body :ation
L1
L2
L3
L4
L5
L6
CONTROL VALVE SPRING SPECIFICATIONS
L7
L8
L9
L10
L11
L13
L14
L15
L16
Unit: mm I 1 I I I I
Valve designation
Torque converter regulator valve
Pressure modifier valve
Pressure regulator valve
Overrun clutch control valve
Lower body Total
length mm
27.5
43.5
68.0
55.5
19.5
56.0
75.0
Accumulator control valve Parts
number
31780 41x01
31751 41x02
31741 80x00
3 1 772
4AXOO
3 1 772
4AX02
31 675 41 X07
31766
- 4AXOO
31766 51x03
4AX03
model
Except
4AX03 model
4AX03 model
Except
4AX03 model
Valve
spring location Throttle accumulator piston
Shift valve
B
Shift valve A
Upper body
Overrun clutch reducing
63.5
65.0
Overrun clutch reducing valve
Pilot valve
Torque converter clutch control valve
L1
L2 L3
L4
L5
L6
L7
Valve spring designation
Torque converter regulator valve spring
Pressure modifier valve spring
Pressure regulator valve spring
Throttle accumulator piston spring
A
Shift valve B spring
Shift valve
A spring
31 766 51 X04
31766 4AX02
54.5
38.5 58.0
57.0
67.0
37.5
37.5
41
.O
66.0 38.5
Shuttle shift valve S
Free length
36.0
31.95
31.8
30.5
23.5 25.0
23.6
38.3
Overrun clutch control valve
spring
4AX03 model
Pilot valve spring
r
Torque converter clutch control valve spring
31 772 41 X06
31772 41x01
31 832
4AX01
31766 51x05
31766 4AX01
31772 41x12
31772 4AX01
31772 71x00
31 772 41 X03
31772
21x00
4AX03
model
Except
4AX03 model
4AX03 model
Except
4AX03 model
/ L~ / valve spring
26.5
46.5
54.0
25.0
22.6
25.4
23.0
23.0
33.89
I
I I
Shuttle shift valve S spring
1 reducing valve spring Outer
diameter
'D"
9.0
6.8
15.0
9.8
11.0
7.0
7.0
8.0
Except 4AX03 model
32.5
4AX03
model
Except
4AX03 model
4AX00 model
Except
4AX00 model
1 reducing valve
9.0
6.5
5.65
7.0
6.7
6.75
6.7
6.7
6.95
3-2
timing
valve spring
Servo charger valve spring
Lock-up regulator valve spring
3-2 timing valve
Wire
diameter
"d"
1.4
0.8 1.3
1.3
0.8
0.65
0.6
0.55
35.5 7.0
4AX03
model
Except
4AX03 model
1.1
0.8
0.75
0.65 0.7
0.75
0.7
0.7
0.55
Servo charger valve
Lock-up regulator valve
Winding
direction Right
4
1
7
t
?
T
T
7.0 0.85
T
?
T
T
?
T
T
T
.. I
Parts
number
31742
4AXOO
3 1 742
41x19
31742
4AXO 1
31 742
41
XI 5
31742
4AX02
3
1762
41x01
3 1762
41x03
31762
4AXOO
0.9
T 31742
t
41 X63
31742
41x65
AUTOMATIC TRANSMISSIO
Standard 0.10 - 0.25 Low one-way clutch inner race to seal ring clearance mm
Limit 0.25
OIL PUMP AND LOW ONE-WAY CLUTCH
-
TOTAL END PLAY --
Total end play mm 0.25 - 0.55 I
0.1 5 - 0.22
0.11
- 0.18 Oil pump clearance mm
Thickness mm
Inner gear and outer gear to housing
0.03 - 0.05
Standard 0.1 0 - 0.25 Oil pump cover to seal ring clearance mm , Limit 0.25
Outer
gear to crescendo
Outer gear to housing
I Parts number
Bearing race
REVERSECLUTCHENDPLAY
Reverse clutch drum end play mm 0.55 - 0.90 I
Oil pump thrust washer
ADJUSTMENT OF TANDEM BRAKE BAND TENSION
Number of turns of anchor end pin back-off I 2.375 - 2.625
Anchor end pin tightening torque N.m (kg-m) 4.0 - 5.8
(0.4 - 0.6)
TIGHTENING TORQUE
Unit: N.m (kg-m)
Lock
nut tightening torque N-m
(kg-m)
Transmission to engine mounting bolt
41 - 50 (4.1 - 5.2)
I TIM side to engine side I 40 - 49 (4.0 - 5.0) - - - - - - -- - - - - - -
I Engine side to TIM side I 30 - 39 (3.0 - 4.0)
BRAKE
BRAKING FORCE
More than 10% of axle
weight
REAR DlSC BRAKE
Total braking force of rear wheels
Variation between right and left of
each wheel Brake
type
Less than 8% of axle weight ADllVC
9.3
Brake
pad
Disc rotor
Total
braking force OPZ11V
11.5
Standard
thickness (New) mm
Wear limit of thickness mm
Standard thickness (New) mm
Wear limit of thickness mm
Runout limit mm
More than 50%
of vehicle
weight at inspected
Note: The braking force when both front wheels are locked up can be considered to meet the total braking force.
2.0
16
14
BRAKE PEDAL
18
16
PARKING BRAKE
Free play (at pedal top surface)
mm I 3 - 11 Less than
0.07 Type DS17HD I
Brake
lining
Depressed pedal height under force
of 490 N (50 kg)
(from dash panel top surface)
mm
Brake
pedal height
(from dash panel top surface)
mm
Standard inner diameter
I (New) mm I
Standard thickness (New) mrn
Wear limit of thickness
mm M/T: 163 - 173 IVT: 170 - 180
172 dia. 3.0 1.5
M/T: More
than 85 A. More than 90 . . Drum I
I
Wear limit of inner diameter
mm I 173 dia.
Clearance between the edge of stop
lamp switch screw and pedal stopper
mm Operating
stroke
[under force of 196 N (20
kg)] 5 - 7 notches
CHECK VALVE I
I
Maximum stroke
19 notches
Number of notches when brake warning
lamp turns on
TIGHTENING TORQUE
Unit: N.m (kg-m)
Within 1 notch
Vacuum leakage
[at
vacuum Of 66'7 kPa (-500 mmHg)]
BRAKE BOOSTER
Within 1.3 kPa (10 mmHg) of
vacuum for 15 seconds
Master cylinder fixing nut
I 12 - 14 (1.2 - 1.5)
Vacuum leakage
[at vacuum of 66.7
kPa
(-500
mmHg)l
Within 3.3
kPa
(25
mmHg)
of
vacuum for 15 seconds Front
caliper mounting bolt
Brake tube flare nut -- - 152 - 154 (15.5 - 15.8)
15
- 17 (1.5 - 1.8)
FRONT DlSC BRAKE
Input rod standard length at installed
mm
Brake type
I AD25VB I CUSVD [OPZ~~VC
140
Standard thickness
Wear limit of
thickness
Standard thickness
mm
1 22 1 26 1 30
Disc rotor Wear limit of
thickness
Runout
limit Less than 0.07
STEERING
STEERING GEAR STEERING WHEEL
Steering wheel end play rnm -- -
Steering wheel free play rnm1 0-35 0
Steering gear type
Rack neutral position "L" mm
Amount of steering gear housing movement mm
I Within 22 PR29, PR26AD, PR26AF
68.5
STEERING
ANGLE
STEERING COLUMN
Inner wheel
Outer wheel 42"
33"
STC0101
D 88
Primary tightening torque 5.0 - 5.8 8T
Steering column length "L" mm
Retainer
adjustment
61
0
Re-tightening torque after loosening
once 5.0
- 5.8 Rs N.m (kg-m) (0.5 - 0.6)
MA
Range
within ill .5 mm from
STEERING LINKAGE Less than 98.0 EL (1 0.0)
(30.0)
Full range
Rack
sliding
force
Steering gear type
Oscillating torque 0.30
- 2.94
Nm
(kg-m)
(0.03 - 0.30) variations Less
than 147
Spring scale measurement
(at stud bolt hole) 6.48
- 64.6
N
(kg)
(0.66 - 6.59)
Tie-rod
ball joint
outer socket OIL PUMP Sliding torque 0.30 - 2.94
End play
Oscillating torque
1 .O - 7.8
Maximum oil pump pressure
MPa (kg/cm2) 8.822: (90)
(Without HICAS)
7.842:; (80)
(With HICAS)
STEERING FLUID Tie-rod ball joint
inner socket Spring
scale measurement (at
arrow position in figure below) 19.0 - 152
N (kg) (1.90 - 15.5)
Fluid capacity P I Approx. 1.0
End play mm Less than 0.2
mm 173.3
TIGHTENING TORQUE Tie-rod length "L"
Unit: N.m (kq-m)
Steering wheel nut
Steering gear to suspension member
Hydraulic tube (high pressure side) to oil
/ 50 - 68 (5.0 - 7.0)
Pump
30
- 39
(3.0 - 4.0)
89
- 91 (9.0 - 9.3)
24
- 29 (2.4 - 3.0)
30
- 39 (3.0 - 4.0)
79
- 98 (8.0 - 10.0)
32 - 42 (3.2 - 4.3)
14
- 17 (1.4 - 1.8)
Steering gear
to steering column
Outer socket to steering knuckle
Tie-rod lock nut
Oil pump fixing bolt
Hydraulic tube to
steering gear Large
Small
High pressure side
Low pressure side 15
- 24 (1.5 - 2.5)
28
- 39 (2.8 - 4.0)
SUPER HlCAS
POWER CYLINDER --
Oscillating torque 0.98 - 7.80 Power cylinder ball N.m (kg-m) (0.1 - 0.8) joint
End play
POWER CYLINDER LOWER LINK
Power cylinder lower link length mm 1 290.4t1.0
/ Lock nut
-- -- Clearance at power cylinder stroke mm 1 3.6k0.1
--- Outer link to axle housing 1 46 - 59 (4.6 - 6.1)
--- - - - - - -
TIGHTENING TORQUE
Unit: N-m (kg-m)
HlCAS actuator assembly fixing bolt 84.4 - 107
(8.60 - 11 .O)