SPECIFICATIONS
Precautions
SUMMARY
SPECIFICATIONS
FA20 ENGINE MECHANICAL
SERVICE DATA
| Ignition timing |
-5 to 10° BTDC at idle (Transmission in neutral) |
||
| Idle speed |
Automatic transmission (in neutral) |
600 to 800 r/min |
|
| Manual transmission |
550 to 750 r/min |
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| Compression |
Compression pressure |
1150 to 1750 kPa (11.7 to 17.8 kgf/cm2, 167 to 254 psi) |
|
| Difference between each cylinder |
200 kPa (2.0 kgf/cm2, 29 psi) or less |
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| Cam clearance |
Standard (Cold) |
Intake |
0.10 to 0.16 mm (0.0039 to 0.0063 in.) |
| Exhaust |
0.21 to 0.27 mm (0.0083 to 0.0106 in.) |
||
| Camshaft |
Circle runout |
Maximum |
0.020 mm (0.00079 in.) |
| Cam lobe height |
Intake |
40.82 to 40.92 mm (1.6083 to 1.6110 in.) |
|
| Exhaust |
40.72 to 40.82 mm (1.6031 to 1.6071 in.) |
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| For fuel pump |
40.55 to 40.65 mm (1.5965 to 1.6004 in.) |
||
| Cam base circle |
Intake |
34.0 mm (1.3386 in.) |
|
| Exhaust |
34.0 mm (1.3386 in.) |
||
| Journal diameter |
25.946 to 25.963 mm (1.02149 to 1.02216 in.) |
||
| Thrust clearance |
0.068 to 0.116 mm (0.00027 to 0.00457 in.) |
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| Oil clearance |
0.037 to 0.072 mm (0.00146 to 0.00283 in.) |
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| Cylinder head sub-assembly |
Warpage |
Maximum |
0.035 mm (0.00138 in.) |
| Cylinder head height |
Standard |
98.5 mm (3.878 in.) |
|
| Minimum |
98.4 mm (3.874 in.) |
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| Intake valve |
Overall length |
103.3 mm (4.067 in.) |
|
| Margin thickness |
0.8 to 1.2 mm (0.0315 to 0.0472 in.) |
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| Valve stem diameter |
5.455 to 5.470 mm (0.2148 to 0.2154 in.) |
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| Valve seat width |
0.8 to 1.6 mm (0.032 to 0.063 in.) |
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| Exhaust valve |
Overall length |
95.1 mm (3.744 in.) |
|
| Margin thickness |
1.0 to 1.4 mm (0.039 to 0.055 in.) |
||
| Valve stem diameter |
5.445 to 5.460 mm (0.21437 to 0.21496 in.) |
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| Valve seat width |
1.1 to 1.7 mm (0.043 to 0.067 in.) |
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| Intake valve guide bush |
Inside diameter |
5.500 to 5.512 mm (0.21654 to 0.21701 in.) |
|
| Oil clearance |
0.030 to 0.057 mm (0.00118 to 0.00224 in.) |
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| Protrusion height |
11.4 to 11.8 mm (0.449 to 0.466 in.) |
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| Exhaust valve guide bush |
Inside diameter |
5.500 to 5.512 mm (0.21654 to 0.21701 in.) |
|
| Oil clearance |
0.040 to 0.067 mm (0.00157 to 0.00264 in.) |
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| Protrusion height |
11.4 to 11.8 mm (0.449 to 0.466 in.) |
||
| Valve adjusting shim |
Valve stem end diameter |
Intake |
5.455 to 5.470 mm (0.21476 to 0.21535 in.) |
| Exhaust |
5.445 to 5.460 mm (0.21437 to 0.21496 in.) |
||
| Valve adjusting shim inside diameter |
5.500 to 5.560 mm (0.21654 to 0.21890 in.) |
||
| Oil clearance |
0.030 to 0.115 mm (0.00118 to 0.00453 in.) |
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| Valve spring |
Free length |
41.06 mm (1.617 in.) |
|
| Deviation |
Maximum |
Less than 1.8 mm (0.0710 in.) |
|
| Angle |
Maximum |
2.5° |
|
| Cylinder block |
Warpage |
Maximum |
0.025 mm (0.00098 in.) |
| Cylinder block height |
Standard |
205.0 mm (8.071 in.) |
|
| Minimum |
204.9 mm (8.067 in.) |
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| Cylinder bore diameter |
Mark A |
86.005 to 86.015 mm (3.38602 to 3.38641 in.) |
|
| Mark B |
85.995 to 86.005 mm (3.38562 to 3.38602 in.) |
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| Maximum (When boring) |
86.505 mm (3.40570 in.) |
||
| Cylinder bore |
Taper |
0.030 mm (0.00118 in.) |
|
| Out-of-runout |
0.010 mm (0.00039 in.) |
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| Piston |
Piston diameter |
Distance from piston head |
39.4 mm (1.551 in.) |
| A grade |
85.985 to 85.995 mm (3.38523 to 3.38562 in.) |
||
| B grade |
85.975 to 85.985 mm (3.38484 to 3.38523 in.) |
||
| 0.25 mm (0.0098 in.) over size |
86.225 to 86.245 mm (3.39468 to 3.39547 in.) |
||
| 0.50 mm (0.0197 in.) over size |
86.475 to 86.495 mm (3.40452 to 3.40531 in.) |
||
| Oil clearance |
0.010 to 0.030 mm (0.00039 to 0.00118 in.) |
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| Piston pin |
Piston pin oil clearance |
0.004 to 0.008 mm (0.00016 to 0.00031 in.) |
|
| Connecting rod bushing oil clearance |
0.006 to 0.026 mm (0.00024 to 0.00102 in.) |
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| Piston ring |
Piston ring end gap |
No. 1 |
0.20 to 0.25 mm (0.00784 to 0.00984 in.) |
| No. 2 |
0.60 to 0.70 mm (0.02362 to 0.02756 in.) |
||
| Oil ring |
0.10 to 0.35 mm (0.00394 to 0.01378 in.) |
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| Groove clearance |
No. 1 |
0.030 to 0.080 mm (0.00118 to 0.00315 in.) |
|
| No. 2 |
0.030 to 0.070 mm (0.00118 to 0.00276 in.) |
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| Connecting rod |
Bend |
Maximum |
0.10 mm (0.0039 in.) per 100 mm (3.937 in.) in length |
| Twist |
Maximum |
0.10 mm (0.0039 in.) per 100 mm (3.937 in.) in length |
|
| Thrust clearance |
0.070 to 0.330 mm (0.00276 to 0.01299 in.) |
||
| Oil clearance |
0.025 to 0.055 mm (0.00098 to 0.00217 in.) |
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| Bearing size (Thickness at center) |
Standard |
1.492 to 1.508 mm (0.05874 to 0.05937 in.) |
|
| 0.03 mm (0.0012 in.) Undersize |
1.511 to 1.515 mm (0.05949 to 0.05965 in.) |
||
| 0.05 mm (0.0020 in.) Undersize |
1.521 to 1.525 mm (0.05988 to 0.06004 in.) |
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| 0.25 mm (0.0098 in.) Undersize |
1.621 to 1.625 mm (0.06382 to 0.06398 in.) |
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| Crank pin diameter |
Standard |
49.976 to 50.000 mm (1.96756 to 1.96850 in.) |
|
| 0.03 mm (0.0012 in.) Undersize |
49.946 to 49.970 mm (1.96637 to 1.96732 in.) |
||
| 0.05 mm (0.0020 in.) Undersize |
49.926 to 49.950 mm (1.96559 to 1.96653 in.) |
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| 0.25 mm (0.0098 in.) Undersize |
49.726 to 49.750 mm (1.95771 to 1.95866 in.) |
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| Crankshaft |
Circle runout |
Maximum |
0.035 mm (0.00138 in.) |
| Crank pin taper |
Maximum |
0.006 mm (0.00024 in.) |
|
| Crank pin out-of-runout |
Maximum |
0.005 mm (0.00020 in.) |
|
| Crankshaft journal taper |
Maximum |
0.006 mm (0.00024 in.) |
|
| Crankshaft journal out-of-runout |
Maximum |
0.005 mm (0.00020 in.) |
|
| Crank pin diameter |
Minimum |
47.726 mm (1.87897 in.) |
|
| Crankshaft journal diameter |
Minimum |
67.735 mm (2.66673 in.) |
|
| Connecting rod bearing thickness (at center) |
Standard |
1.492 to 1.508 mm (0.05874 to 0.05937 in.) |
|
| 0.03 mm (0.0012 in.) Undersize |
1.511 to 1.515 mm (0.05949 to 0.05965 in.) |
||
| 0.05 mm (0.0020 in.) Undersize |
1.521 to 1.525 mm (0.05988 to 0.06004 in.) |
||
| 0.25 mm (0.0098 in.) Undersize |
1.621 to 1.625 mm (0.06382 to 0.06398 in.) |
||
| No. 1 to No. 4 crank bearing thickness (at center) |
Standard |
2.495 to 2.513 mm (0.09823 to 0.09894 in.) |
|
| 0.03 mm (0.0012 in.) Undersize |
2.519 to 2.522 mm (0.09917 to 0.09929 in.) |
||
| 0.05 mm (0.0020 in.) Undersize |
2.529 to 2.532 mm (0.09957 to 0.09968 in.) |
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| 0.25 mm (0.0098 in.) Undersize |
2.629 to 2.632 mm (0.10350 to 0.10362 in.) |
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| No. 5 crank bearing thickness (at center) |
Standard |
2.493 to 2.511 mm (0.09815 to 0.09886 in.) |
|
| 0.03 mm (0.0012 in.) Undersize |
2.517 to 2.520 mm (0.09909 to 0.09921 in.) |
||
| 0.05 mm (0.0020 in.) Undersize |
2.527 to 2.530 mm (0.09949 to 0.09961 in.) |
||
| 0.25 mm (0.0098 in.) Undersize |
2.627 to 2.630 mm (0.10342 to 0.10354 in.) |
||
| Crank pin outer diameter |
Standard |
49.976 to 50.000 mm (1.96756 to 1.96850 in.) |
|
| 0.03 mm (0.0012 in.) Undersize |
49.946 to 49.970 mm (1.96637 to 1.96734 in.) |
||
| 0.05 mm (0.0020 in.) Undersize |
49.926 to 49.950 mm (1.96559 to 1.96653 in.) |
||
| 0.25 mm (0.0098 in.) Undersize |
49.726 to 49.750 mm (1.95771 to 1.95866 in.) |
||
| Crankshaft journal diameter |
Standard |
67.985 to 68.009 mm (2.67657 to 2.67751 in.) |
|
| 0.03 mm (0.0012 in.) Undersize |
67.955 to 67.979 mm (2.67539 to 2.67633 in.) |
||
| 0.05 mm (0.0020 in.) Undersize |
67.935 to 67.959 mm (2.67460 to 2.67555 in.) |
||
| 0.25 mm (0.0098 in.) Undersize |
67.735 to 67.759 mm (2.66673 to 2.66767 in.) |
||
| Thrust clearance |
0.130 to 0.308 mm (0.00512 to 0.01213 in.) |
||
| Oil clearance |
0.013 to 0.031 mm (0.00051 to 0.00122 in.) |
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FA20 FUEL
FA20 COOLING
SERVICE DATA
| Radiator Cap |
Pumping speed: 1 pump per second Standard valve (for brand-new cap): 93 to 123 kPa (0.95 to 1.25 kgf/cm2, 14 to 18 psi) Minimum standard valve (after suing cap): 83 kPa (0.85 kgf/cm2, 12 psi) |
| Thermostat (for Engine Coolant) |
Valve opening temperature: 86 to 90°C (187 to 194°F) |
| Valve lift: 8.0 mm (0.315 in.) or more at 95°C (203°F) |
|
| Thermostat (for Automatic Transmission) |
Valve opening temperature: 48 to 52°C (118 to 126°F) |
| Valve lift: 6.0 mm (0.236 in.) or more at 63°C (145°F) |
FA20 LUBRICATION
FA20 STARTING
SERVICE DATA
| Starter assembly |
Standard current |
Below 90 A at 11.5 V |
|
| Starter armature assembly |
Standard runout |
for Manual Transmission |
0.05 mm (0.002 in.) |
| for Automatic Transmission |
0.02 mm (0.0008 in.) |
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| Maximum runout |
for Manual Transmission |
0.10 mm (0.004 in.) |
|
| for Automatic Transmission |
0.05 mm (0.002 in.) |
||
| Standard depth Segment - Mold |
for Manual Transmission |
0.05 mm (0.002 in.) |
|
| for Automatic Transmission |
0.7 mm (0.0276 in.) |
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| Minimum depth Segment - Mold |
for Automatic Transmission |
0.20 mm (0.0079 in.) |
|
| Standard diameter |
for Automatic Transmission |
29 mm (1.1417 in.) |
|
| Minimum diameter |
for Automatic Transmission |
28 mm (1.1024 in.) |
|
| Brush length |
Standard length |
for Manual Transmission |
12.3 mm (0.484 in.) |
| for Automatic Transmission |
14.4 mm (0.5669 in.) |
||
| Minimum length |
for Manual Transmission |
7.0 mm (0.276 in.) |
|
| for Automatic Transmission |
9.0 mm (0.3543 in.) |
||
| Standard brush spring force |
for Manual Transmission |
15.9 to 19.5 N (1.6 to 2.0 kgf, 3.6 to 4.4 lbf) |
|
| Minimum brush spring force |
for Manual Transmission |
2.5 N (0.3 kgf, 0.6 lbf) |
|
TX6A AUTOMATIC TRANSMISSION / TRANSAXLE
SERVICE DATA
| Line pressure (Fluid temperature): 50 to 80°C (122 to 176°F) Engine idling |
D position |
350 to 430 kPa (3.6 to 4.4 kgf/cm2, 51 to 62 psi) |
| R position |
760 to 950 kPa (7.7 to 9.7 kgf/cm2, 110 to 138 psi) |
|
| Line pressure (Fluid temperature): 50 to 80°C (122 to 176°F) At stall speed (Throttle valve fully open) |
D position |
1200 to 1380 kPa (12.5 to 14.0 kgf/cm2, 174 to 200 psi) |
| R position |
1410 to 1630 kPa (14.4 to 16.6 kgf/cm2, 204 to 236 psi) |
|
| Engine stall speed |
D position |
2350 +/- 250 r/min |
| Time lag |
N → D position |
Less than 1.2 seconds |
| N → R position |
Less than 1.5 seconds |
|
| Drive plate runout |
Maximum |
0.30 mm (0.0118 in.) |
SERVICE DATA (Automatic Transmission Unit:)
| 1st and reverse return spring free length |
Standard: 23.74 mm (0.935 in.) |
| Rear planetary gear pinion thrust clearance |
Standard: 0.2 to 0.6 mm (0.00788 to 0.0236 in.) |
| Rear planetary gear bushing inside diameter |
Standard: 18.025 mm (0.710 in.) |
| 1st and reverse brake pack clearance |
0.5 to 0.8 mm (0.0197 to 0.0315 in.) |
| Flange thickness (1st and reverse brake) |
Mark 0: 0 mm (0 in.) Mark 2: 0.2 mm (0.00787 in.) Mark 4: 0.4 mm (0.0157 in.) Mark 6: 0.6 mm (0.0236 in.) Mark 8: 0.8 mm (0.0315 in.) Mark 10: 1.0 mm (0.0394 in.) Mark 12: 1.2 mm (0.0472 in.) Mark 14: 1.4 mm (0.0551 in.) |
| Intermediate shaft runout |
Standard: 0.03 mm (0.00118 in.) |
| Intermediate shaft diameter |
Standard A: 22.962 to 22.975 mm (0.9041 to 0.9045 in.) Standard B: 27.759 to 27.775 mm (1.0929 to 1.0935 in.) |
| Center planetary gear pinion thrust clearance |
Standard: 0.12 to 0.68 mm (0.00473 to 0.0267 in.) |
| No. 2 brake pinion return spring free length |
Standard: 22.66 mm (0.892 in.) |
| No. 2 brake piston piston stroke |
0.6 to 0.9 mm (0.0237 to 0.0354 in.) |
| Flange thickness ( No. 2 brake piston) |
Mark 0: 2.0 mm (0.0787 in.) Mark 1: 2.1 mm (0.0827 in.) Mark 2: 2.2 mm (0.0866 in.) Mark 3: 2.3 mm (0.0906 in.) Mark 4: 2.4 mm (0.0945 in.) Mark 5: 2.5 mm (0.0984 in.) Mark 6: 2.6 mm (0.102 in.) Mark 7: 2.7 mm (0.106 in.) |
| Brake piston return spring free length |
Standard: 17.05 mm (0.671 in.) |
| Front planetary gear pinion thrust clearance |
Standard: 0.20 to 0.60 mm (0.00788 to 0.0236 in.) |
| Front planetary gear bushing inside diameter |
Standard: 48.78 mm (1.92 in.) |
| No. 1 brake piston piston stroke |
0.42 to 0.72 mm (0.0166 to 0.0283 in.) |
| No. 3 brake piston return spring free length |
Standard: 15.72 mm (0.619 in.) |
| Flange thickness ( No. 1 brake piston) |
Mark 0: 2.0 mm (0.0787 in.) Mark 1: 2.2 mm (0.0866 in.) Mark 2: 2.4 mm (0.0945 in.) Mark 3: 2.6 mm (0.102 in.) |
SERVICE DATA (Clutch Drum And Input Shaft:)
| Direct clutch return spring free length |
Standard: 20.02 mm (0.788 in.) |
| Reverse clutch return spring free length |
Standard: 21.03 mm (0.828 in.) |
| Direct clutch pack clearance |
0.5 to 0.8 mm (0.0197 to 0.0314 in.) |
| Flange thickness (Direct clutch) |
Mark 0: 3.0 mm (0.118 in.) Mark 1: 3.1 mm (0.122 in.) Mark 2: 3.2 mm (0.126 in.) Mark 3: 3.3 mm (0.130 in.) Mark 4: 3.4 mm (0.134 in.) Mark 5: 3.5 mm (0.138 in.) Mark 6: 3.6 mm (0.142 in.) Mark 7: 3.7 mm (0.146 in.) Mark 8: 3.8 mm (0.150 in.) |
| Reverse clutch pack clearance |
0.4 to 0.7 mm (0.0158 to 0.0275 in.) |
| Flange thickness (Reverse clutch) |
Mark 0: 2.4 mm (0.0945 in.) Mark 1: 2.5 mm (0.0984 in.) Mark 2: 2.6 mm (0.102 in.) Mark 3: 2.7 mm (0.106 in.) Mark 4: 2.8 mm (0.110 in.) Mark 5: 2.9 mm (0.114 in.) Mark 6: 3.0 mm (0.118 in.) Mark 7: 3.1 mm (0.122 in.) Mark 8: 3.2 mm (0.126 in.) Mark 9: 3.3 mm (0.130 in.) Mark A: 3.4 mm (0.134 in.) Mark B: 3.5 mm (0.138 in.) |
| Forward clutch return spring free length |
Standard: 26.29 mm (1.04 in.) |
| Forward clutch pack clearance |
0.56 to 0.86 mm (0.0221 to 0.0338 in.) |
| Flange thickness (Forward clutch) |
Mark 0: 3.0 mm (0.118 in.) Mark 1: 3.1 mm (0.122 in.) Mark 2: 3.2 mm (0.126 in.) Mark 3: 3.3 mm (0.130 in.) Mark 4: 3.4 mm (0.134 in.) Mark 5: 3.5 mm (0.138 in.) Mark 6: 3.6 mm (0.142 in.) Mark 7: 3.7 mm (0.146 in.) Mark 8: 3.8 mm (0.150 in.) Mark 9: 3.9 mm (0.154 in.) |
| Coast clutch pack clearance |
0.4 to 0.7 mm (0.0158 to 0.0275 in.) |
| Flange thickness (Coast clutch) |
Mark 0: 3.0 mm (0.118 in.) Mark 1: 3.1 mm (0.122 in.) Mark 2: 3.2 mm (0.126 in.) Mark 3: 3.3 mm (0.130 in.) Mark 4: 3.4 mm (0.134 in.) Mark 5: 3.5 mm (0.138 in.) Mark 6: 3.6 mm (0.142 in.) Mark 7: 3.7 mm (0.146 in.) Mark 8: 3.8 mm (0.150 in.) Mark 9: 3.9 mm (0.154 in.) |
| Forward clutch hub inside diameter |
Standard: 23.037 to 23.062 mm (0.9070 to 0.9079 in.) |
| Reverse clutch hub inside diameter |
Standard: 33.312 to 33.337 mm (1.3115 to 1.3125 in.) |
SERVICE DATA (Accumulator:)
| Spring |
Free Length/Outer diameter mm (in.) |
Color |
|---|---|---|
| B1 (Outer) |
46.36 (1.825)/17.10 (0.673) |
Natural |
| C2 |
65.07 (2.562)/16.2 (0.638) |
Pink |
| B3 |
70.5 (2.776)/19.7 (0.776) |
Purple |
| C3 (Inner) |
44.0 (1.732)/14.0 (0.551) |
Yellow |
| C3 (Outer) |
76.65 (3.0178)/20.10 (0.7913) |
White |
SERVICE DATA (Output Shaft Bearing:)
| Clearance |
0.02 to 0.12 mm (0.000787 to 0.00472 in.) |
| Flange thickness |
No. 1: 3.80 mm (0.150 in.) No. 2: 3.85 mm (0.152 in.) No. 3: 3.90 mm (0.154 in.) No. 4: 3.95 mm (0.156 in.) No. 5: 4.00 mm (0.157 in.) No. 6: 4.05 mm (0.159 in.) No. 7: 4.10 mm (0.161 in.) No. 8: 4.15 mm (0.163 in.) No. 9: 4.20 mm (0.165 in.) No. 10: 4.25 mm (0.167 in.) No. 11: 4.30 mm (0.169 in.) No. 12: 4.35 mm (0.171 in.) |
CLUTCH
TL70 MANUAL TRANSMISSION / TRANSAXLE
SERVICE DATA
| Manual transmission extension housing oil seal installation depth |
- |
0.1 to 1.1 mm (0.00394 to 0.0433 in.) |
| Reverse idler gear radial clearance |
Standard Maximum |
0.040 to 0.082 mm (0.00157 to 0.00323 in.) 0.082 mm (0.00323 in.) |
| No. 4 gear shift fork slotted spring pin drive in depth |
- |
0 mm (0 in.) (from the end surface of the No. 4 gear shift fork) |
| No. 1 gear shift head slotted spring pin drive in depth |
- |
0 mm (0 in.) (from the end surface of the No. 1 gear shift head) |
| No. 2 gear shift head slotted spring pin drive in depth |
- |
0 mm (0 in.) (from the end surface of the No. 2 gear shift head) |
| No. 3 gear shift head slotted spring pin drive in depth |
- |
0 mm (0 in.) (from the end surface of the No. 3 gear shift head) |
| Transmission front bearing retainer oil seal installation depth |
- |
11.1 to 11.9 mm (0.437 to 0.469 in.) |
| Transmission Extension housing oil seal installation depth |
- |
0.1 to 1.1 mm (0.0394 to 0.0433 in.) |
| Extension housing rear oil seal installation depth |
- |
1.0 to 2.0 mm (0.0394 to 0.0787 in.) |
| Counter shaft 6th gear thrust clearance |
Standard Maximum |
0.10 to 0.40 mm (0.00394 to 0.0157 in.) 0.40 mm (0.0157 in.) |
| Counter shaft 6th gear radial clearance |
Standard Maximum |
0.015 to 0.068 mm (0.000590 to 0.00268 in.) 0.068 mm (0.00268 in.) |
| Input shaft radial clearance |
Standard Maximum |
0.029 to 0.072 mm (0.00114 to 0.00283 in.) 0.072 mm (0.00283 in.) |
| 1st gear thrust clearance |
Standard Maximum |
0.15 to 0.40 (0.00590 to 0.0157 in.) 0.40 (0.0157 in.) |
| 1st gear radial clearance |
Standard Maximum |
0.015 to 0.066 (0.000590 to 0.00260 in.) 0.066 (0.00260 in.) |
| 2nd gear thrust clearance |
Standard Maximum |
0.10 to 0.45 (0.000394 to 0.0177 in.) 0.45 (0.0177 in.) |
| 2nd gear radial clearance |
Standard Maximum |
0.015 to 0.066 (0.000590 to 0.00260 in.) 0.066 (0.00260 in.) |
| Reverse gear thrust clearance |
Standard Maximum |
0.10 to 0.45 (0.000394 to 0.0177 in.) 0.45 (0.0177 in.) |
| Reverse gear radial clearance |
Standard Maximum |
0.015 to 0.066 (0.000590 to 0.00260 in.) 0.066 (0.00260 in.) |
| Counter shaft 3rd gear thrust clearance |
Standard Maximum |
0.10 to 0.35 (0.00393 to 0.0138 in.) 0.35 (0.0138 in.) |
| Counter shaft 3rd gear radial clearance |
Standard Maximum |
0.015 to 0.068 (0.000590 to 0.00268 in.) 0.068 (0.00268 in.) |
| Counter shaft 4th gear thrust clearance |
Standard Maximum |
0.10 to 0.35 (0.00393 to 0.0138 in.) 0.35 (0.0138 in.) |
| Counter shaft 4th gear radial clearance |
Standard Maximum |
0.065 to 0.115 (0.002559 to 0.00453 in.) 0.115 (0.00453 in.) |
| No. 1 gear shift head clearance |
Standard Maximum |
15.2 to 15.4 mm (0.59843 to 0.60630 in.) 15.4 mm (0.60630 in.) |
| No. 2 gear shift head clearance |
Standard Maximum |
15.2 to 15.4 mm (0.59843 to 0.60630 in.) 15.4 mm (0.60630 in.) |
| No. 3 gear shift head clearance |
Standard Maximum |
15.2 to 15.4 mm (0.59843 to 0.60630 in.) 15.4 mm (0.60630 in.) |
| Shift shaft |
Standard width Minimum width |
14.8 to 15.0 mm (0.583 to 0.591 in.) 14.8 mm (0.583 in.) |
| No. 1 shift inter lock block |
Standard width Minimum width |
14.8 to 15.0 mm (0.583 to 0.591 in.) 14.8 mm (0.583 in.) |
| No. 4 gear shift fork |
Standard Maximum |
15.2 to 15.4 mm (0.59843 to 0.60630 in.) 15.4 mm (0.60630 in.) |
| 5th shift head |
Standard Maximum |
15.2 to 15.4 mm (0.59843 to 0.60630 in.) 15.4 mm (0.60630 in.) |
| No. 2 synchronizer ring and counter shaft 6th gear clearance |
Standard Minimum |
0.88 to 1.52 mm (0.0346 to 0.0598 in.) 0.88 mm (0.0346 in.) |
| Counter shaft 6th gear inside diameter |
Standard Maximum |
34.015 to 34.040 mm (1.33917 to 1.34016 in.) 34.040 mm (1.34016 in.) |
| No. 4 gear shift fork claw |
Standard Minimum |
7.9 to 8.0 mm (0.311 to 0.315 in.) 7.9 mm (0.311 in.) |
| No. 4 gear shift fork claw and glove of the No. 4 transmission hub sleeve clearance |
Standard Maximum |
0.15 to 0.35 mm (0.00590 to 0.0138 in.) 0.35 mm (0.0138 in.) |
| Reverse idler gear inside diameter |
Standard Maximum |
22.040 to 22.061mm (0.86771 to 0.86854 in.) 22.061mm (0.86854 in.) |
| Reverse idler gear shaft outer diameter |
Standard Minimum |
21.979 to 22.000 mm (0.86531 to 0.86614 in.) 21.979 mm (0.86531 in.) |
| No. 4 transmission clutch hub shaft snap ring |
Mark A |
2.80 mm (0.11023 in.) |
| B |
2.85 mm (0.11220 in.) |
|
| C |
2.90 mm (0.11417 in.) |
|
| D |
2.95 mm (0.11614 in.) |
|
| E |
3.00 mm (0.11811 in.) |
|
| F |
3.05 mm (0.12007 in.) |
|
| No. 2 synchronizer ring and 3rd gear clearance |
Standard Minimum |
0.8 to 1.6 mm (0.0314 to 0.0629 in.) 0.8 mm (0.0314 in.) |
| Front input shaft bearing shaft snap ring thickness |
Standard Maximum |
0 mm (0 in.) 0.1 mm (0.00394 in.) |
| Front input shaft bearing shaft snap ring |
Mark 0 |
1.95 mm (0.07677 in.) |
| 1 |
2.00 mm (0.07874 in.) |
|
| 2 |
2.05 mm (0.08070 in.) |
|
| 3 |
2.10 mm (0.08267 in.) |
|
| 4 |
2.15 mm (0.08464 in.) |
|
| 5 |
2.20 mm (0.08661 in.) |
|
| Output shaft outer diameter |
Standard A |
31.984 to 32.000 mm (1.25921 to 1.25984 in.) |
| B |
42.984 to 43.000 mm (1.69228 to 1.69291 in.) |
|
| C |
40.984 to 41.000 mm (1.61354 to 1.61417 in.) |
|
| Minimum A |
31.984 mm (1.25921 in.) |
|
| B |
42.984 mm (1.69228 in.) |
|
| C |
40.984 mm (1.61354 in.) |
|
| Output shaft runout |
Standard |
0.03 mm (0.00118 in.) or less |
| Reverse gear inside diameter |
Standard Maximum |
47.015 to 47.040 mm (1.85098 to 1.85197 in.) 47.040 mm (1.85197 in.) |
| 1st gear inside diameter |
Standard Maximum |
46.315 to 46.340 mm (1.82343 to 1.82441 in.) 46.340 mm (1.82441 in.) |
| 2nd gear inside diameter |
Standard Maximum |
49.015 to 49.040 mm (1.92972 to 1.93071 in.) 49.040 mm (1.93071 in.) |
| 1st gear bearing inner race outer diameter |
Standard Minimum |
40.284 to 40.300 mm (1.58598 to 1.58661 in.) 40.284 mm (1.58598 in.) |
| No. 1 gear shift fork claw |
Standard Minimum |
7.9 to 8.0 mm (0.311 to 0.315 in.) 7.9 mm (0.311 in.) |
| No. 1 gear shift fork claw and glove of the No. 1 transmission hub sleeve clearance |
Standard Maximum |
0.15 to 0.35 mm (0.00590 to 0.0138 in.) 0.35 mm (0.0138 in.) |
| No. 3 gear shift fork claw |
Standard Minimum |
7.9 to 8.0 mm (0.311 to 0.315 in.) 7.9 mm (0.311 in.) |
| No. 3 gear shift fork claw and glove of the No. 3 transmission hub sleeve clearance |
Standard Maximum |
0.15 to 0.35 mm (0.00590 to 0.0138 in.) 0.35 mm (0.0138 in.) |
| No. 1 synchronizer ring set and 1st gear clearance |
Standard inner |
0.48 to 1.12 mm (0.0189 to 0.0441 in.) |
| Middle |
0.38 to 1.22 mm (0.0150 to 0.0480 in.) |
|
| Outer |
0.8 to 1.8 mm (0.0315 to 0.0709 in.) |
|
| No. 1 synchronizer ring set and 2nd gear clearance |
Standard inner |
0.48 to 1.12 mm (0.0189 to 0.0441 in.) |
| Middle |
0.38 to 1.22 mm (0.0150 to 0.0480 in.) |
|
| Outer |
0.8 to 1.8 mm (0.0315 to 0.0709 in.) |
|
| No. 3 transmission clutch hub shaft snap ring thickness |
Standard |
0 to 0.1 mm (0 to 0.00394 in.) |
| No. 3 transmission clutch hub shaft snap ring |
Mark A |
1.80 mm (0.07086 in.) |
| B |
1.85 mm (0.07283 in.) |
|
| C |
1.90 mm (0.07480 in.) |
|
| D |
1.95 mm (0.07677 in.) |
|
| E |
2.00 mm (0.07874 in.) |
|
| F |
2.05 mm (0.08070 in.) |
|
| 6th gear shaft snap ring thickness |
Standard |
0 to 0.11 mm (0 to 0.00433 in.) |
| 6th gear shaft snap ring |
Mark A |
2.67 mm (0.10511 in.) |
| B |
2.73 mm (0.10748 in.) |
|
| C |
2.79 mm (0.10984 in.) |
|
| D |
2.85 mm (0.11220 in.) |
|
| E |
2.91 mm (0.11456 in.) |
|
| F |
2.97 mm (0.11692 in.) |
|
| G |
3.03 mm (0.11929 in.) |
|
| H |
3.09 mm (0.12165 in.) |
|
| J |
3.15 mm (0.12401 in.) |
|
| K |
3.21 mm (0.12638 in.) |
|
| L |
3.27 mm (0.12874 in.) |
|
| No. 2 gear shift fork claw |
Standard Minimum |
7.9 to 8.0 mm (0.311 to 0.315 in.) 7.9 mm (0.311 in.) |
| No. 2 gear shift fork claw and glove of the No. 2 transmission hub sleeve clearance |
Standard Maximum |
0.15 to 0.35 mm (0.00590 to 0.0138 in.) 0.35 mm (0.0138 in.) |
| No. 1 synchronizer ring and 4rd gear clearance |
Standard Maximum |
0.8 to 1.6 mm (0.0314 to 0.0629 in.) 1.6 mm (0.0629 in.) |
| No. 3 synchronizer ring set and counter shaft 3rd gear clearance |
Standard inner |
0.4 to 1.2 mm (0.0157 to 0.0472 in.) |
| Middle |
0.3 to 1.3 mm (0.0118 to 0.0512 in.) |
|
| Outer |
0.8 to 1.8 mm (0.0315 to 0.0709 in.) |
|
| Counter shaft outer diameter |
Standard A |
39.284 to 39.300 mm (1.54661 to 1.54721 in.) |
| B |
37.984 to 38.000 mm (1.49543 to 1.49606 in.) |
|
| C |
24.987 to 25.000 mm (0.98374 to 0.98425 in.) |
|
| Minimum A |
39.284 mm (1.54661 in.) |
|
| B |
37.984 mm (1.49543 in.) |
|
| C |
24.987 mm (0.98374 in.) |
|
| Counter shaft runout |
Standard |
0.03 mm (0.00118 in.) or less |
| Counter shaft 3rd gear inside diameter |
Standard Maximum |
43.015 to 43.040 mm (1.69350 to 1.69448 in.) 43.040 mm (1.69448 in.) |
| Counter shaft 4th gear inside diameter |
Standard Maximum |
46.315 to 46.340 mm (1.82425 to 1.82441 in.) 46.340 mm (1.82441 in.) |
| 4th gear bearing inner race outer diameter |
Standard Minimum |
46.225 to 46.250 mm (1.81988 to 1.82087 in.) 46.225 mm (1.81988 in.) |
| 4th inner race thrust washer thickness |
Standard |
0 to 0.1 mm (0 to 0.00394 in.) |
| 4th inner race thrust washer |
Mark A |
3.75 mm (0.14763 in.) |
| B |
3.80 mm (0.14960 in.) |
|
| C |
3.85 mm (0.15157 in.) |
|
| D |
3.90 mm (0.15354 in.) |
|
| E |
3.95 mm (0.15551 in.) |
|
| F |
4.00 mm (0.15748 in.) |
|
| G |
4.05 mm (0.15944 in.) |
|
| H |
4.10 mm (0.16141 in.) |
|
| Counter drive gear shaft snap ring thickness |
Standard |
0 to 0.1 mm (0 to 0.00394 in.) |
| Counter drive gear shaft snap ring |
Mark A |
1.80 mm (0.07086 in.) |
| B |
1.85 mm (0.07283 in.) |
|
| C |
1.90 mm (0.07480 in.) |
|
| D |
1.95 mm (0.07677 in.) |
|
| E |
2.00 mm (0.07874 in.) |
|
| F |
2.05 mm (0.08070 in.) |
|
| Front counter gear bearing shaft snap ring thickness |
Standard |
0 to 0.1 mm (0 to 0.00394 in.) |
| Front counter gear bearing shaft snap ring |
Mark 1 |
2.05 mm (0.08070 in.) |
| 2 |
2.10 mm (0.08267 in.) |
|
| 3 |
2.15 mm (0.08464 in.) |
|
| 4 |
2.20 mm (0.08661 in.) |
|
| 5 |
2.25 mm (0.08858 in.) |
|
| 6 |
2.30 mm (0.09055 in.) |
DRIVE SHAFT / PROPELLER SHAFT
AXLE AND DIFFERENTIAL
SERVICE DATA (Axle)
| Front axle hub bearing looseness |
Maximum: 0.05 mm (0.00196 in.) |
| Front axle hub runout |
Maximum: 0.05 mm (0.00196 in.) |
| Rear axle hub bearing looseness |
Maximum: 0.05 mm (0.00196 in.) |
| Rear axle hub runout |
Maximum: 0.05 mm (0.00196 in.) |
SERVICE DATA (Differential)
| Rear differential carrier oil seal drive in depth |
1.55 to 2.45 mm (0.062 to 0.098 in.) |
| Rear differential side gear shaft oil seal drive in depth |
-0.5 to 0.5 mm (-0.02 to 0.02 in.) |
| Differential ring gear runout |
Maximum: 0.07 mm (0.003 in.) |
| Rear differential case sub-assembly runout |
Maximum: 0.07 mm (0.003 in.) |
| Differential ring gear backlash |
0.13 to 0.18 mm (0.005 to 0.007 in.) |
| Differential side gear backlash |
0 mm (0 in.) |
| Rear drive pinion companion flange runout |
Maximum: 0.09 mm (0.004 in.) |
| Differential drive pinion preload (at starting) |
New bearing: 1.49 to 2.59 N*m (15.2 to 26.4 kgf*cm, 1.1 to 1.91 ft*lbf) Reused bearing: 1.11 to 1.91 N*m (11.3 to 19.5 kgf*cm, 0.82 to 1.41 ft*lbf) |
| Total preload (Drive pinion preload plus) |
New differential case bearing x New rear drive pinion tapered roller bearing: 2.57 to 4.26 N*m (26.2 to 43.4 kgf*cm, 1.9 to 3.14 ft*lbf) New differential case bearing x Reused rear drive pinion tapered roller bearing: 2.19 to 3.58 N*m (22.3 to 36.5 kgf*cm, 1.62 to 2.64 ft*lbf) Reused differential case bearing x New rear drive pinion tapered roller bearing: 1.98 to 3.37 N*m (20.2 to 34.4 kgf*cm, 1.46 to 2.49 ft*lbf) Reused differential case bearing x Reused rear drive pinion tapered roller bearing: 1.60 to 2.69 N*m (16.3 to 27.4 kgf*cm, 1.18 to 1.98 ft*lbf) |
| Rear differential side gear shaft plate washer thickness mm (in.) |
2.57 to 2.59 (0.1012 to 0.1020) 2.59 to 2.61 (0.1020 to 0.1028) 2.61 to 2.63 (0.1028 to 0.1035) 2.63 to 2.65 (0.1035 to 0.1043) 2.65 to 2.67 (0.1043 to 0.1051) 2.67 to 2.69 (0.1051 to 0.1059) 2.69 to 2.71 (0.1059 to 0.1067) 2.71 to 2.73 (0.1067 to 0.1075) 2.73 to 2.75 (0.1075 to 0.1083) 2.75 to 2.77 (0.1083 to 0.1091) 2.77 to 2.79 (0.1091 to 0.1098) 2.79 to 2.81 (0.1098 to 0.1106) 2.81 to 2.83 (0.1106 to 0.1114) 2.83 to 2.85 (0.1114 to 0.1122) 2.85 to 2.87 (0.1122 to 0.1130) 2.87 to 2.89 (0.1130 to 0.1138) 2.89 to 2.91 (0.1138 to 0.1146) 2.91 to 2.93 (0.1146 to 0.1154) 2.93 to 2.95 (0.1154 to 0.1161) 2.95 to 2.97 (0.1161 to 0.1169) 2.97 to 2.99 (0.1169 to 0.1177) 2.99 to 3.01 (0.1177 to 0.1185) 3.01 to 3.03 (0.1185 to 0.1193) 3.03 to 3.05 (0.1193 to 0.1201) 3.05 to 3.07 (0.1201 to 0.1209) 3.07 to 3.09 (0.1209 to 0.1217) 3.09 to 3.11 (0.1217 to 0.1224) 3.11 to 3.13 (0.1224 to 0.1232) 3.13 to 3.15 (0.1232 to 0.1240) 3.15 to 3.17 (0.1240 to 0.1248) 3.17 to 3.19 (0.1248 to 0.1256) 3.19 to 3.21 (0.1256 to 0.1264) 3.21 to 3.23 (0.1264 to 0.1272) 3.23 to 3.25 (0.1272 to 0.1280) 3.25 to 3.27 (0.1280 to 0.1287) 3.27 to 3.29 (0.1287 to 0.1295) 3.29 to 3.31 (0.1295 to 0.1303) 3.31 to 3.33 (0.1303 to 0.1311) 3.33 to 3.35 (0.1311 to 0.1319) 3.35 to 3.37 (0.1319 to 0.1327) 3.37 to 3.39 (0.1327 to 0.1335) 3.39 to 3.41 (0.1335 to 0.1343) 3.41 to 3.43 (0.1343 to 0.1350) 3.43 to 3.45 (0.1350 to 0.1358) 3.45 to 3.47 (0.1358 to 0.1366) 3.47 to 3.49 (0.1366 to 0.1374) |
| Rear differential drive pinion plate washer thickness mm (in.) |
1.69 to 1.71 (0.0665 to 0.0673) 1.72 to 1.74 (0.0677 to 0.0685) 1.75 to 1.77 (0.0689 to 0.0697) 1.78 to 1.80 (0.0701 to 0.0709) 1.81 to 1.83 (0.0713 to 0.0720) 1.84 to 1.86 (0.0724 to 0.0732) 1.87 to 1.89 (0.0736 to 0.0744) 1.90 to 1.92 (0.0748 to 0.0756) 1.93 to 1.95 (0.0760 to 0.0768) 1.96 to 1.98 (0.0772 to 0.0780) 1.99 to 2.01 (0.0783 to 0.0791) 2.02 to 2.04 (0.0795 to 0.0803) 2.05 to 2.07 (0.0807 to 0.0815) 2.08 to 2.10 (0.0819 to 0.0827) 2.11 to 2.13 (0.0831 to 0.0839) 2.14 to 2.16 (0.0843 to 0.0850) 2.17 to 2.19 (0.0854 to 0.0862) 2.20 to 2.22 (0.0866 to 0.0874) 2.23 to 2.25 (0.0878 to 0.0886) 2.26 to 2.28 (0.0890 to 0.0898) 2.29 to 2.31 (0.0902 to 0.0909) 2.32 to 2.34 (0.0913 to 0.0921) |
ALIGNMENT / HANDLING DIAGNOSIS
SERVICE DATA (Vehicle Height (Unloaded Vehicle))
| Front B - A |
Rear C |
Rear D |
Rear E |
|---|---|---|---|
| 146 mm (5.75 in.) |
195 mm (7.68 in.) |
375 mm (14.76 in.) |
372 mm (14.65 in.) |
Measurement points:
A: Ground clearance of front lower suspension arm set front bolt centerB: Ground clearance of front wheel center
C: Ground clearance of lower control arm set bolt center
D: Front wheel arch height of front wheel center
E: Rear wheel arch height of rear wheel center
SERVICE DATA (Camber (Unloaded Vehicle))
| - |
Camber Inclination |
Right-left Difference |
|---|---|---|
| Front |
0 +/- 45' |
30' or less |
| Rear |
-1°12' +/- 45' |
45' or less |
SERVICE DATA (Caster (Unloaded Vehicle))
| - |
Caster Inclination (Reference) |
|---|---|
| Front |
5°54' (5.90°) |
SERVICE DATA (Wheel Turning Angle (Unloaded Vehicle))
| - |
Inside Wheel (Reference) |
Outside Wheel (Reference) |
|---|---|---|
| Front |
36°54' |
31°12' |
SERVICE DATA (Toe-in (Unloaded Vehicle))
| - |
Specified Condition |
|---|---|
| Front |
Toe angle (sum of wheels) : 0°00' +/- 0°15' (0.00° +/- 0.25°) |
| 0 +/- 3.0 mm (0 +/- 0.12 in.) |
|
| Rear |
Toe angle (sum of wheels) : 0°10' +/- 0°15' (0.16° +/- 0.25°) |
| 2.0 +/- 3.0 mm (0.08 +/- 0.12 in.) |
SERVICE DATA (Distance between the centers of the 2 installation bolts of the rear No. 2 suspension arm assembly LH and RH)
| - |
Standard distance |
|---|---|
| Rear |
457.5 +/- 3 mm (18.01 +/- 0.12 in.) |
SERVICE DATA (Distance between the centers of the 2 installation bolts of the rear No. 2 suspension arm assembly)
| - |
Standard distance |
|---|---|
| Rear |
450.9 +/- 2 mm (17.75 +/- 0.08 in.) |
TIRE / WHEEL
SERVICE DATA (Cold Tire Inflation Pressure)
| Tire Size |
Cold Tire Inflation Pressure kPa (kgf/cm2, psi) |
|
|---|---|---|
| 205/55R16 89V |
240 (2.4, 35) |
240 (2.4, 35) |
| 215/45R17 87W |
240 (2.4, 35) |
240 (2.4, 35) |
| Maximum wheel runout |
Steel wheel |
1.5 mm (0.059 in.) (Vertical and lateral) |
| Aluminum wheel |
1.0 mm (0.039 in.) (Vertical and lateral) |
| Maximum wheel imbalance after adjustment |
10.0 g (0.35 oz) |
|
BRAKE SYSTEM (OTHER)
SERVICE DATA
| Brake pedal height from floor mat |
for Manual Transmission |
145mm (5.709in.) |
| for Automatic Transmission |
150mm (5.906in.) |
|
| Brake pedal free play (when the brake pedal is pushed to move with a force of less than 10 N (1 kgf, 2.2 lbf).) |
0.2 mm (0.008in.) to 2mm (0.079in.) or less |
|
| Brake pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110 lbf) |
for Manual Transmission |
More than 55 mm (2.165 in.) |
| for Automatic Transmission |
More than 55 mm (2.165 in.) |
|
| Vacuum of the vacuum pump assembly |
With the engine idling |
More than 93 kPa (698 mmHg, 13.5 psi) of vacuum |
BRAKE (FRONT)
BRAKE (REAR)
SERVICE DATA (for for Solid Disc Brake)
| Pad lining thickness |
Standard |
9.0 mm (0.354 in.) |
| Minimum |
1.5 mm (0.059 in.) |
|
| Disc thickness |
Standard |
10.0 mm (0.394 in.) |
| Minimum |
8.5 mm (0.335 in.) |
|
| Disc runout |
Maximum |
0.05 mm (0.002 in.) |
SERVICE DATA (for Ventilated Disc Brake)
| Pad lining thickness |
Standard |
11.0 mm (0.433 in.) |
| Minimum |
1.5 mm (0.059 in.) |
|
| Disc thickness |
Standard |
18.0 mm (0.709 in.) |
| Minimum |
16.0 mm (0.630 in.) |
|
| Disc runout |
Maximum |
0.05 mm (0.002 in.) |
PARKING BRAKE
STEERING COLUMN
SERVICE DATA
| Maximum steering free play |
30 mm (1.18 in.) |
| Steering column assembly preload |
1.6 to 2.1 N*m (16.3 to 21.4 kgf*cm, 1.2 to 1.5 ft*lbf) |
| Steering intermediate shaft assembly turn torque (rack and pinion power steering gear assembly side) |
6.6 N (0.67 kgf, 1.48 lbf) or less |
| Steering intermediate shaft assembly turn torque (steering column assembly side) |
6.0 N (0.61 kgf, 1.35 lbf) or less |
STEERING GEAR / LINKAGE
FA20 BATTERY / CHARGING