
CYLINDER BLOCK
EM-125
< DISASSEMBLY AND ASSEMBLY >
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If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Refer to EM-
132, "MainBearing".
CRANKSHAFT PIN JOURNAL DIAMETER
Measure the outer diameter of crankshaft pin journal with a
micrometer (A).
If out of the standard, measure the connecting rod bearing oil
clearance. Then use undersize bearing. Refer to EM-130,
"ConnectingRodBearing".
CRANKSHAFT OUT-OF-ROUND AND TAPER
Measure the dimensions at four different points as shown in the
figure on each main journal and pin journal with a micrometer.
Out-of-round is indicated by the difference in the dimensions
between (d) and (c) at (a) and (b).
Taper is indicated by the difference in the dimensions between.
If the measured value exceeds the limit, correct or replace crank-
shaft.
If corrected, measure the bearing oil clearance of the corrected
main journal and/or pin journal. Then select the main bearing and/
or connecting rod bearing. Refer to EM-132, "
MainBearing" and/
or EM-130, "
ConnectingRodBearing".
CRANKSHAFT RUNOUT
Place V-block on precise flat table, and support the journals on the both end of crankshaft.
Place a dial indicator straight up on the No. 3 journal.
While rotating crankshaft, read the movement of the pointer on a
dial indicator. (Total indicator reading)
If it exceeds the limit, replace crankshaft.
CONNECTING ROD BEARING OIL CLEARANCE
Method by Calculation
Install connecting rod bearings (1) to connecting rod (2) and con-
necting rod cap, and tighten connecting rod bolts to the specified
torque. Refer to EM-110, "
Disassembly and Assembly" for the
tightening procedure.
Measure the inner diameter of connecting rod bearing with an
inside micrometer.
(Oil clearance) = (Connecting rod bearing inner diameter) – (Crank-
shaft pin journal diameter)Standard : Refer to EM-143, "
CylinderBlock".
JPBIA0228ZZ
Limit : Refer to EM-143, "CylinderBlock".
JPBIA0229ZZ
Standard and limit : Refer to EM-143, "CylinderBlock".
SEM346D
Standard and limit : Refer to EM-147,
"ConnectingRodBearing".JPBIA0230ZZ

CYLINDER BLOCK
EM-127
< DISASSEMBLY AND ASSEMBLY >
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Remove main bearing caps and bearings, and using the scale on
the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.
MAIN BEARING CRUSH HEIGHT
When main bearing cap is removed after being tightened to the
specified torque with main bearings (1) installed, the tip end of
bearing must protrude. Refer to EM-110, "
Disassembly and
Assembly" for the tightening procedure.
If the standard is not met, replace main bearings.
CONNECTING ROD BEARING CRUSH HEIGHT
When connecting rod bearing cap is removed after being tightened
to the specified torque with connecting rod bearings (1) installed,
the tip end of bearing must protrude. Refer to EM-110, "
Disassem-
bly and Assembly" for the tightening procedure.
If the standard is not met, replace connecting rod bearings.
MAIN BEARING CAP BOLT OUTER DIAMETER
Measure the outer diameters (c), (d) at two positions as shown in
the figure.
If reduction appears in (a) range, regard it (c).
If it exceeds the limit (large difference in dimensions), replace main
bearing cap bolt with new one.
CONNECTING ROD BOLT OUTER DIAMETER
JPBIA0231ZZ
A : Crush height
Standard : There must be crush height.
JPBIA0233ZZ
A : Crush height
Standard : There must be crush height.
JPBIA0233ZZ
a : 20 mm (0.79 in)
b : 30 mm (1.18 in)
e : 10 mm (0.39 in)
Limit [(d) – (c)] : 0.11 mm (0.0043 in)
JPBIA0234ZZ

SERVICE DATA AND SPECIFICATIONS (SDS)
EM-139
< SERVICE DATA AND SPECIFICATIONS (SDS)
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Cylinder HeadINFOID:0000000003802306
CYLINDER HEAD
Unit: mm (in)
VALVE DIMENSIONS
820P 8.20 (0.3228)
822P 8.22 (0.3236)
824P 8.24 (0.3244)
826P 8.26 (0.3252)
828P 8.28 (0.3260)
830P 8.30 (0.3268)
832P 8.32 (0.3276)
834P 8.34 (0.3283)
836P 8.36 (0.3291)
838P 8.38 (0.3299)
840P 8.40 (0.3307) Identification (stamped) mark Thickness
SEM758G
Items Standard Limit
Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004)
Normal cylinder head height “H” 126.3 - 126.5 (4.97 - 4.98) —
PBIC0924E

GI-1
GENERAL INFORMATION
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CONTENTS
GENERAL INFORMATION
HOW TO USE THIS MANUAL ......................3
HOW TO USE THIS MANUAL ............................3
Description ................................................................3
Terms ........................................................................3
Units ..........................................................................3
Contents ....................................................................3
Relation between Illustrations and Descriptions .......4
Components ..............................................................4
HOW TO FOLLOW TROUBLE DIAGNOSES .....6
Description ................................................................6
How to Follow Test Groups in Trouble Diagnosis ......6
Key to Symbols Signifying Measurements or Pro-
cedures .....................................................................
7
HOW TO READ WIRING DIAGRAMS ................9
Connector Symbols ...................................................9
Sample/Wiring Diagram -Example- .........................10
Description ..............................................................11
ABBREVIATIONS ..............................................13
Abbreviation List ......................................................13
TIGHTENING TORQUE OF STANDARD
BOLTS ................................................................
14
Description ..............................................................14
Tightening Torque Table (New Standard Includ-
ed) ...........................................................................
14
TERMINOLOGY .................................................17
SAE J1930 Terminology List ...................................17
FEATURES OF NEW MODEL .....................21
IDENTIFICATION INFORMATION .....................21
Model Variation .......................................................21
Information About Identification or Model Code ......21
Dimensions .............................................................23
Wheels & Tires ........................................................23
PRECAUTION ..............................................24
PRECAUTIONS .................................................24
Description ...............................................................24
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" .................................................................
24
Precautions For Xenon Headlamp Service .............24
Precaution Necessary for Steering Wheel Rota-
tion after Battery Disconnect ...................................
24
Precaution for Procedure without Cowl Top Cover ....25
General Precautions ................................................25
Three Way Catalyst .................................................27
Multiport Fuel Injection System or Engine Control
System .....................................................................
27
Hoses ......................................................................27
Engine Oils ..............................................................28
Air Conditioning .......................................................28
Fuel ..........................................................................29
LIFTING POINT .................................................30
Commercial Service Tools .......................................30
Garage Jack and Safety Stand and 2-Pole Lift .......30
Board-On Lift ...........................................................31
TOW TRUCK TOWING .....................................32
Tow Truck Towing ...................................................32
Vehicle Recovery (Freeing a Stuck Vehicle) ...........32
BASIC INSPECTION ...................................34
SERVICE INFORMATION FOR ELECTRICAL
INCIDENT ..........................................................
34
Work Flow ................................................................34
Control Units and Electrical Parts ............................34
Intermittent Incident .................................................35
Circuit Inspection .....................................................37
CONSULT-III/GST CHECKING SYSTEM .........43
Description ...............................................................43
CONSULT-III Function and System Application*1 ....43
CONSULT-III/GST Data Link Connector (DLC)
Circuit ......................................................................
43

IDENTIFICATION INFORMATION
GI-23
< FEATURES OF NEW MODEL >
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P CVT Unit (RE0F10A)
CVT Unit (RE0F09B)
DimensionsINFOID:0000000003852774
Unit: mm (in)
*1: 205/65R16 tire model
*2: 215/55R17 tire model
Wheels & TiresINFOID:0000000003852775
: Vehicle front
SAIA1496E
: Unit front
SAIA0360E
Overall length 4,850 (190.9)
Overall width 1,795 (70.7)
Overall height 1,475 (58.1)
Front tread 1,560 (61.4)*1, 1,550 (61.0)*2
Rear tread 1,560 (61.4)*1, 1,550 (61.0)*2
Wheelbase 2,775 (109.3)
Application Conventional Spare
Road wheel/offset mm (in)16 X 6-1/2J/40 (1.57)
17 X 7J/45 (1.77)
Conventional
Tire size205/65R16 95H
215/55R17 94V

ST-1
STEERING
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STEERING SYSTEM
SYMPTOM DIAGNOSIS ..... ..........................2
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ........................ .....
2
NVH Troubleshooting Chart ................................ ......2
PRECAUTION ...............................................3
PRECAUTIONS .............................................. .....3
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ............................................................. ......
3
Precaution Necessary for Steering Wheel Rota-
tion after Battery Disconnect .....................................
3
Service Notice or Precautions for Steering System
......
3
PREPARATION ............................................5
PREPARATION .............................................. .....5
Special Service Tools .......................................... ......5
ON-VEHICLE MAINTENANCE .....................7
POWER STEERING FLUID ........................... .....7
Inspection ............................................................ ......7
STEERING WHEEL .............................................9
Inspection ............................................................ ......9
ON-VEHICLE REPAIR .................................12
STEERING WHEEL ........................................ ....12
Exploded View .................................................... ....12
Removal and Installation .........................................12
STEERING COLUMN .........................................13
Exploded View .................................................... ....13
Removal and Installation .........................................13
Inspection ................................................................14
LOWER SHAFT ................................................16
Exploded View ..................................................... ....16
Removal and Installation .........................................16
Inspection ................................................................17
STEERING GEAR AND LINKAGE ...................18
Exploded View .........................................................18
Removal and Installation .........................................19
Disassembly and Assembly .....................................20
Inspection ................................................................26
POWER STEERING OIL PUMP .......................28
Exploded View .........................................................28
Removal and Installation .........................................29
Disassembly and Assembly .....................................29
Inspection ................................................................32
HYDRAULIC LINE ............................................34
Exploded View .........................................................34
Removal and Installation .........................................35
SERVICE DATA AND SPECIFICATIONS
(SDS) ............... .............................................
37
SERVICE DATA AND SPECIFICATIONS
(SDS) .................................................................
37
General Specifications ......................................... ....37
Steering Wheel Axial End Play and Play .................37
Steering Wheel Turning Force .................................37
Steering Angle .........................................................37
Steering Column Length ..........................................37
Steering Column Mounting Dimensions ..................37
Steering Column Operating Range .........................37
Lower Shaft Sliding Range ......................................38
Rack Sliding Force ..................................................38
Rack Stroke .............................................................38
Socket Swing Force and Rotating Torque ...............38
Socket Axial End Play .............................................38
Inner Socket Length ................................................38
Relief Oil Pressure ...................................................38

SERVICE DATA AND SPECIFICATIONS (SDS)
ST-37
< SERVICE DATA AND SPECIFICATIONS (SDS)
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SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
General SpecificationsINFOID:0000000003806332
Steering Wheel Axial End Play and PlayINFOID:0000000003806333
Unit: mm (in)
Steering Wheel Turning ForceINFOID:0000000003806334
Unit: N·m (kg-m, in-lb)
Steering AngleINFOID:0000000003806335
Unit: Degree minute (Decimal degree)
Steering Column LengthINFOID:0000000003826226
Unit: mm (in)
Steering Column Mounting DimensionsINFOID:0000000003826227
Unit: mm (in)
Steering Column Operating RangeINFOID:0000000003806336
Steering gear modelPR26AF
Fluid capacity (Approx.)
(lmp qt)1.0 (7/8)
Item Standard
Steering wheel axial end play 0 (0)
Steering wheel play on the outer circumference 0 – 35 (0 – 1.38)
Item Standard
Steering wheel turning force 7.45 (0.76, 66)
ItemStandard
Tire size: 205/65R16 Tire size: 215/55R17
Inner wheelMinimum 38°00′ (38.0°)34°00′ (34.0°)
Nominal 41°00′ (41.0°)37°00′ (37.0°)
Maximum 42°30′ (42.5°)38°30′ (38.5°)
Outer wheel Nominal 33°00′ (31.0°)31°00′ (31.0°)
Item Standard
Column length484 – 486 (19.06 – 19.13)
Item Standard
Mounting dimension 19.5 (0.768) or less
Item Standard
Tilt operating range 37 mm (1.46 in)
Rotating torque 0.49 N·m (0.05 kg-m, 4 in-lb)