Page 3929 of 4770
PP0M4±01
PP±78
± PREPARATIONAUTOMATIC TRANSAXLE (A541E)
130 Author: Date:
LUBRICANT
ItemCapacityClassification
Automatic transaxle fluid
(w/o Differential oil)
Dry fill
Drain and refill
8.0 liters (8.5 US qts, 7.0 Imp. qts)
3.9 liters (4.1 US qts, 3.4 Imp. qts)ATF D±II or DEXRON®III (DEXRON®II)
Page 3930 of 4770
PP1WM±01
± PREPARATIONSUSPENSION AND AXLE
PP±79
131 Author: Date:
SUSPENSION AND AXLE
SST (Special Service Tools)
09223±56010Crankshaft Rear Oil Seal
ReplacerFront drive shaft
09240±00020Wire Gauge SetFront drive shaft
09309±36010Transmission Rear Bearing
ReplacerFront drive shaft
09310±35010Countershaft Bearing ReplacerFront axle hub
09316±20011Transfer Bearing ReplacerFront drive shaft
09316±60011Transmission & Transfer Bearing
ReplacerFront axle hub
Front suspension
(09316±00011)Replacer Pipe
(09316±00041)Replacer ºCº
09506±35010Differential Drive Pinion Rear
Bearing ReplacerFront drive shaft
09520±00031Rear Axle Shaft PullerFront axle hub
09521±24010Drive Shaft Boot Clamping ToolFront drive shaft
09527±17011Rear Axle Shaft Bearing RemoverFront axle hub
Page 3931 of 4770
PP±80
± PREPARATIONSUSPENSION AND AXLE
132 Author: Date:
09555±55010Differential Drive Pinion
Bearing ReplacerFront drive shaft
09608±16042Front Hub Bearing Adjusting ToolFront drive shaft
(09608±02021)Bolt & Nut
(09608±02041)Retainer
09608±32010Steering Knuckle Oil Seal
ReplacerFront axle hub
Front suspension
09610±20012Pitman Arm PullerFront axle hub
09628±10011Ball Joint PullerFront axle hub
Rear axle hub
09628±62011Ball Joint PullerFront axle hub
Front suspension
09727±30021Coil Spring CompressorFront suspension
Rear suspension
09729±22031Front Spring Upper Seat HolderFront suspension
09950±00020Bearing RemoverFront axle hub
Front drive shaft
09950±60010Replacer SetFront axle hub
(09951±00400)Replacer 40
Page 3941 of 4770
PP0DB±03
PP±90
± PREPARATIONSTEERING
142 Author: Date:
STEERING
SST (Special Service Tools)
09249±63010Torque Wrench AdaptorPS vane pump
09521±24010Drive Shaft Boot Clamping ToolPS gear
09527±20011Rear Axle Shaft Bearing RemoverPS gear
09612±00012Rack & Pinion Steering Rack
Housing StandPS gear
09612±22011Tilt Handle Bearing ReplacerPS gear
09612±24014Steering Gear Housing Overhaul
Tool Set
(09613±22011)Steering Rack Shaft Bushing
PullerPS gear
09616±00010Steering Worm Bearing Adjusting
SocketPS gear
09631±10021Rack Stopper WrenchPS gear
09631±12071Steering Rack Oil Seal Test ToolPS gear
09631±20081Seal Ring ToolPS gear
09631±22020Power Steering Hose Nut
14 x 17 mm Wrench SetPS vane pump
PS gear
Page 3954 of 4770
PP0L0±01
± PREPARATIONBODY ELECTRICAL
PP±103
155 Author: Date:
EQUIPMENT
Voltmeter
Ammeter
Ohmmeter
Test lead
SyphonBrake fluid level warning switch
Bulb (3.4 W)Fuel sender gauge, Seat belt warning relay
Bulb (21 W)Turn signal flasher relay
Dry cell batteryFuel sender gauge
Torque wrench
Masking tapeRear window defogger wire
Tin foilRear window defogger wire
Page 3962 of 4770
PP0B9±02
± PREPARATIONAIR CONDITIONING
PP±111
163 Author: Date:
LUBRICANT
ItemCapacityClassification
Compressor oil±ND±OIL 8 or equivalent
When replacing receiver20 cc (0.71 fl.oz.)
When replacing condenser40 ± 50 cc (1.4 ± 1.7 fl.oz.)
When replacing evaporator40 ± 50 cc (1.4 ± 1.7 fl.oz.)
When replacing compressor120 cc (4.1 fl.oz.)
Page 3968 of 4770

SS0AD±03
SS±6
± SERVICE SPECIFICATIONSENGINE MECHANICAL (5S±FE)
169 Author: Date:
ENGINE MECHANICAL (5S±FE)
SERVICE DATA
Compression
pressureat 250 rpm STD
Minimum
Difference of pressure between each cylinder1,226 kPa (12.5 kgf/cm2, 178 psi) or more
981 kPa (10.0 kgf/cm2, 142 psi)
98 kPa (1.0 kgf/cm2, 14 psi) or less
Valve
clearanceat cold Intake
Exhaust
Adjusting shim (for repair part) Mark 2.500
Mark 2.550
Mark 2.600
Mark 2.650
Mark 2.700
Mark 2.750
Mark 2.800
Mark 2.850
Mark 2.900
Mark 2.950
Mark 3.000
Mark 3.050
Mark 3.100
Mark 3.150
Mark 3.200
Mark 3.250
Mark 3.3000.19 ± 0.29 mm (0.007 ± 0.011 in.)
0.28 ± 0.38 mm (0.011 ± 0.015 in.)
2.500 mm (0.0984 in.)
2.550 mm (0.1004 in.)
2.600 mm (0.1024 in.)
2.650 mm (0.1043 in.)
2.700 mm (0.1063 in.)
2.750 mm (0.1083 in.)
2.800 mm (0.1102 in.)
2.850 mm (0.1122 in.)
2.900 mm (0.1142 in.)
2.950 mm (0.1161 in.)
3.000 mm (0.1181 in.)
3.050 mm (0.1201 in.)
3.100 mm (0.1220 in.)
3.150 mm (0.1240 in.)
3.200 mm (0.1260 in.)
3.250 mm (0.1280 in.)
3.300 mm (0.1299 in.)
Ignition timingw/ Terminals TE1 and E1 connected of DLC18 ± 12° BTDC @ idle
Idle speed±700 ± 50 rpm
Idler pulley
tension springFree length
Installed load at 50.5 mm (1.988 in.)42.0 mm (1.654 in.)
32 ± 37 N (3.25 ± 3.75 kgf, 7.2 ± 8.3 lbf)
Cylinder headWarpage
Cylinder block side Maximum
Manifold sideMaximum
Valve seat
Refacing angle
Contacting angle
Contacting width
0.05 mm (0.0020 in.)
0.08 mm (0.0031 in.)
30°, 45°, 75°
45°
1.0 ± 1.4 mm (0.039 ± 0.055 in.)
Valve guide
bushingInside diameter
Outside diameter (for repair part) STD
O/S 0.056.010 ± 6.030 mm (0.2366 ± 0.2374 in.)
11.048 ± 11.059 mm (0.4331 ± 0.4342 in.)
11.050 ± 11.077 mm (0.4350 ± 0.4361 in.)
ValveValve overall length STD Intake
Exhaust
Minimum Intake
Exhaust
Vale face angle
Stem diameterIntake
Eh t
97.40 ± 97.80 mm (3.8346 ± 3.8504 in.)
98.25 ± 98.65 mm (3.8681 ± 3.8839 in.)
97.1 mm (3.823 in.)
98.0 mm (3.858 in.)
44.5°
5.970 ± 5.985 mm (0.2350 ± 0.2356 in.)
5 965 5 980 (0 2348 0 2354 i )Exhaust
Stem oil clearance STD Intake
Exhaust
Maximum Intake
Exhaust
Margin thickness STD
Minimum5.965 ± 5.980 mm (0.2348 ± 0.2354 in.)
0.025 ± 0.060 mm (0.0010 ± 0.0024 in.)
0.030 ± 0.065 mm (0.0012 ± 0.0026 in.)
0.08 mm (0.0031 in.)
0.10 mm (0.0039 in.)
0.8 ± 1.2 mm (0.031 ± 0.047 in.)
0.5 mm (0.020 in.)
Valve springDeviation Maximum
Free length
Installed tension at 34.7 mm (1.366 in.)2.0 mm (0.079 in.)
40.95 ± 42.80 mm (1.6122 ± 1.6850 in.)
164 ± 189 N (16.7 ± 19.3 kgf, 36.8 ± 42.5 lbf)
Page 3969 of 4770

± SERVICE SPECIFICATIONSENGINE MECHANICAL (5S±FE)
SS±7
170 Author: Date:
Valve lifterLifter diameter
Lifter bore diameter
Oil clearance STD
Maximum30.966 ± 30.976 mm (1.2191 ± 1.2195 in.)
31.000 ± 31.018 mm (1.2205 ± 1.2212 in.)
0.024 ± 0.052 mm (0.0009 ± 0.0020 in.)
0.07 mm (0.0028 in.)
ManifoldWarpage Maximum0.30 mm (0.0118 in.)
CamshaftThrust clearance STD Intake
Exhaust
Maximum Intake
Exhaust
Journal oil clearance STD
Maximum
Journal diameter
Circle runout Maximum
Cam lobe height STD Intake
Exhaust
Minimum Intake
Exhaust
Camshaft gear backlash STD
Maximum
Camshaft gear spring end free distance0.045 ± 0.100 mm (0.0018 ± 0.0039 in.)
0.030 ± 0.085 mm (0.0012 ± 0.0033 in.)
0.12 mm (0.0047 in.)
0.10 mm (0.0039 in.)
0.025 ± 0.062 mm (0.0010 ± 0.0024 in.)
0.10 mm (0.0039 in.)
26.959 ± 26.975 mm (1.0614 ± 1.0620 in.)
0.04 mm (0.0016 in.)
42.01 ± 42.11 mm (1.6539 ± 1.6579 in.)
40.06 ± 40.16 mm (1.5772 ± 1.5811 in.)
41.90 mm (1.6496 in.)
39.95 mm (1.5728 in.)
0.020 ± 0.200 mm (0.0008 ± 0.0079 in.)
0.30 mm (0.0188 in.)
22.5 ± 22.9 mm (0.886 ± 0.902 in.)
Cylinder blockCylinder head surface warpage Maximum
Cylinder bore diameter STD Mark 1
Mark 2
Mark 3
Maximum STD
O/S 0.500.05 mm (0.0020 in.)
87.000 ± 87.010 mm (3.4252 ± 3.4256 in.)
87.010 ± 87.020 mm (3.4256 ± 3.4260 in.)
87.020 ± 87.030 mm (3.4260 ± 3.4264 in.)
87.23 mm (3.4342 in.)
87.73 mm (3.4350 in.)
Piston and
piston ringPiston diameter STD Mark 1
Mark 2
Mark 3
O/S 0.50
Piston oil clearance STD
Maximum
Piston ring groove clearance No.1, No.2
Piston ring end gap STD No.1
No.2
Oil (side rail)
Maximum No.1
No.2
Oil (side rail)86.815 ± 86.825 mm (3.4179 ± 3.4183 in.)
86.825 ± 86.835 mm (3.4183 ± 3.4186 in.)
86.835 ± 86.845 mm (3.4201 ± 3.4205 in.)
87.350 ± 87.380 mm (3.4375 ± 3.4387 in.)
0.175 ± 0.195 mm (0.0068 ± 0.0076 in.)
0.215 mm (0.0085 in.)
0.030 ± 0.070 mm (0.0012 ± 0.0028 in.)
0.270 ± 0.490 mm (0.0106 ± 0.0192 in.)
0.450 ± 0.670 mm (0.0177 ± 0.0263 in.)
0.100 ± 0.470 mm (0.0039 ± 0.0185 in.)
1.09 mm (0.0429 in.)
1.27 mm (0.0499 in.)
1.07 mm (0.0421in.)
Connecting rodThrust clearance STD
Maximum
Connecting rod bearing center wall thickness
Reference STD Mark 1
Mark 2
Mark 3
Connecting rod oil clearance STD STD
U/S 0.25
Maximum
Rod bend Maximum per 100 mm (3.94 in.)
Rod twist Maximum per 100 mm (3.94 in.)
Bushing inside diameter
Piston pin diameter
Piston pin oil clearance STD
Maximum
Connecting rod bolt outside diameter STD
Minimum0.160 ± 0.312 mm (0.0063 ± 0.0123 inb.)
0.35 mm (0.0138 in.)
1.484 ± 1.488 mm (0.0584 ± 0.0586 in.)
1.488 ± 1.492 mm (0.0586 ± 0.0587 in.)
1.492 ± 1.496 mm (0.0587 ± 0.0589 in.)
0.024 ± 0.055 mm (0.0009 ± 0.0022 in.)
0.023 ± 0.069 mm (0.0009 ± 0.0027 in.)
0.08 mm (0.0031 in.)
0.05 mm (0.0020 in.)
0.15 mm (0.0059 in.)
22.005 ± 22.017 mm (0.8663 ± 0.8668 in.)
21.997 ± 22.009 mm (0.8660 ± 0.8665 in.)
0.005 ± 0.011 mm (0.0002 ± 0.0004 in.)
0.05 mm (0.0020 in.)
7.860 ± 8.000 mm (0.3094 ± 0.3150 in.)
7.60 mm (0.2992 in.)