SPECIFICATIONS SERVICE A-1

Transcription

1 A-1 SERVICE SPECIFICATIONS Page MAl NTENANCE... A-2 ENGINE MECHANICAL A-3 EFI SYSTEM A-5 FUEL SySTEM... A-7 COOLING SYSTEM A-7 LUBRICATION SySTEM... A-7 IGNITION SySTEM... A-8 STARTING SYSTEM A-8 CHARGING SYSTEM A-9 CLUTCH... A-9 MANUAL TRANSMiSSiON... A-10 AUTOMATIC TRANSMiSSiON... A-14 TRANSFER... A-19 PROPE LLER SHAFT A-20 FRONT AXLE AND SUSPENSiON... A-21 REAR AXLE AND SUSPENSION A-25 BRAKE SySTEM... A-28 STEERING A-30 WiNCH... A-33 LUBRICANTS A-34

2 A-2 SERVICE SPECI FICATIONS - Maintenance MAINTENANCE Engine Drive belt tension New belt Used belt Coolant capacity wlheater or air conditioner Engine oil capacity drain and refill with oil filter change Spark plug Type NO NGK Gap Firing order Valve clearance (hot) Intake Exhaust Idle speed 22R 22R-E Fast idle speed 22R 125 ± 25 Ib 80 ± 20 Ib 8.4 liters 4.6 liters W16EXR-U BPR5EY 0.8mm mm 0.30 mm 8.9 US qts 4.9 US qts 7.4 Imp. qts 4.0 Imp. qts in in in. 700 rpm MIT 750 rpm AIT 750 rpm 2600 rpm (EG R system OF F and choke opener OF F) Chassis Front brake Pad thickness Disc thickness Limit 2WD 4WD Limit 1/2 ton 1 ton, C&C Limit 1.0mm 21.0 mm 24.0 mm 11.5 mm in in in in. Disc runout Limit 0.15 mm in. Rear brake Lining thickness Drum inner diameter Front axle and suspension Limit Limit 1.0 mm mm in in. Ball joint vertical play Wheel bearing friction preload (at starting) Limit 2WD 4WD 2.3mm kg kg in Ib N Ib N Steering wheel freeplay Tightening torque Less than 30mm 1.18 in. Seat mounting bolts 375 kg-cm 27 ft-ib 37 N'm Leaf spring U-bolt 2WD 1,000 kg-cm 72 ft-ib 98 N'm 4WD 1,250 kg-cm 90 ft-ib 123 N'm Strat bar bracket x frame 530 kg-cm 38 ft-ib 52 N'm

3 SERVICE SPECIFICATIONS - Engine Mechanical A-3 ENGINE MECHANICAL ~pecifications Compression STD More than 12.0 kg/cm psi 1,177 kpa pressure Limit 10.0 kg/cm psi 981 kpa Differential of pressure between each cylinder Less than 1.0 kg/cm 2 14 psi 98 kpa Cylinder head Head surface warpage Limit 0.15 mm in. Valve seat Refacing angle IN 30,45,60 EX 30,45, 65 Contacting angle 45 Contacting width mm in. Valve guide Inner diameter Intake mm in. bushing Exhaust mm in. Outer diameter STD mm in. O/S type mm in. Protrusion from cylinder head 19 mm 0.75 in. Replacing temperature (cylinder head side) Normal temperature Valve Valve overall length STD Intake mm in. Exhaust mm in. Valve face angle IN & EX 44.5 Stem diameter STD Intake mm in. Exhaust mm in. Stem end refacing Limit IN & EX 0.5 mm in. Stem oil clearance STD Intake mm in. Exhaust mm in. Limit Intake 0.08 mm in. Exhaust 0.10 mm in. Valve head edge thickness Limit 0.6mm in. Valve spring Free length 45.8 mm in. Installed length 40.5 mm in. Installed load STD 25.0 kg 55.11b 245 N Limit 22.5 kg 49.61b 221 N Squareness Limit 1.6 mm in. Rocker arm Rocker shaft diameter mm in. and shaft Shaft to arm oil clearance STD mm in. Limit 0.08 mm in. Intake and Manifold surface warpage Limit Intake 0.20 mm in. exhaust manifold Exhaust 0.70 mm in. Chain and Crankshaft sprocket wear Limit 59.4 mm in. sprocket Camshaft sprocket wear Limit mm in. Tension and Tensioner head thickness Limit 11.0 mm in. damper Damper No.1 wear Limit 0.5 mm in. I Damper No.2 wear Limit 0.5 mm in.

4 I Rod A-4 SERVICE SPECI FICATIONS - Engine Mechanical Specifications (Cont'd) Camshaft Thrust clearance STD mm in. Limit 0.25 mm in. Journal oil clearance STD mm in. Limit 0.1 mm in. Journal diameter STD mm in. Circle runout Limit 0.2 mm in. Cam height Intake mm in. Exhaust mm in. Cylinder block Warpage Limit 0.05 mm in.. Cyl inder bore STD mm in. Cylinder bore wear Limit 0.2 mm in. Difference of bore limit between cylinder Less than 0.03 mm ( in.) Taper and out-of-round Limit 0.02 mm in. Piston and Piston diameter STD mm in. piston ring O/S type mm in. O/S type mm in. Piston to cylinder clearance mm in. Piston ring end gap Standard No mm in. No mm in. I Oil mm in. I Maximum No mm in. i No mm in. Oil 1.42mm in. Ring to ring groove clearance Limit No.1, No mm in. Piston pin installing temperature I 80 C 176 F Connecting rod Thrust clearance STD mm in. and bearing Limit 0.30 mm in. Bearing oil clearance STD mm in. Limit 0.10mm in. Pin to bushing oil clearance STD mm in. Limit mm in. Rod bend Limit 0.05 mm in. I twist Limit 0.15 mm in. I Crankshaft Thrust clearance STD mm in. Limit 0.30 mm in. Thrust washer th ickness STD 2.00 mm in. O/S type mm in. O/S type mm in. Main journal oil clearance STD mm in. Limit 0.08 mm in. Main journal diameter STD mm in. Bearing U/S type mm in. Bearing U/S type 0.25 mm in. Crank pin oil clearance STD mm in. Limit 0.08 mm in. Crank pin diameter STD mm in. Bearing U/S type mm in. Bearing U/S type 0.25 mm in. Circle runout Limit 0.1 mm in. Main journal taper and out-of-round Limit 0.01 mm in. Crank pin journal taper and out-of-round Limit 0.01 mm in. I

5 SERVICE SPECIFICATIONS - Engine Mechanical, EFI System A-5 Tightening Torque Tightening part kg-cm ft-ib N-m Cylinder head x Cylinder block Manifold x Cylinder head Intake Exhaust Crankshaft bearing cap x Cylinder block 1, Connecting rod cap x Connecting rod Crankshaft pulley x Crankshaft 1, Flywheel x Crankshaft 1, Camshaft bearing cap x Cylinder head Camshaft timing sprocket x Camshaft Oil pan x Cylinder block in.-ib 5.9 EFI SYSTEM Pressure Fuel pressure at No vacuum kg/cm psi kpa regulator Cold start Resistance 2-4Sl injector Leakage Less than one drop of fuel per minute Injector Resistance n Injection volume cc/15 sec ( cu in.) Difference between each injector Leakage Air flow meter Resistance E2- Vs n Less than 6 cc (0.37 cu in.) Less than one drop of fuel per minute (Measuring plate fully closed) 20-1,000 Sl E2- Vc n E2- VB Sl El- Fc (Measuring plate fully open) 00 (Measuring plate fully closed) o (Measuring plate open) E2- THA kn (-20 C, _4 F) 4-7 ksl (O C, 32 F) 2-3 kn (20 C, 68 F) kn (40 C, 104 F) ksl (60 C, 140 F) Auxiliary air Resistance n valve Temperature wi valve closed About 120 C (248 F) Throttle body Throttle valve fully closed angle 6 Throttle position sensor Clearance between lever and stop screw Between terminals Resistance Omm o in. VTA - E kn 0.57 mm in. IDL - E n 0.85 mm in. IDL - E2 Infinity Throttle valve fully opened position VTA - E kn - Vce - E2 3-7 kn

6 A-6 EFI SYSTEM (Cont'd) SERVICE SPECIFICATIONS - EFI System Main relay Resistance n Circuit opening Resistance STA - EI n relay +B - Fc n +B - Fp 00 Resistor Resistance 2-3 n each Start injector Resistance STA - STJ n (below 30 C, 86 F) time switch n (above 40 C, 104 F) STA - Ground n Temperature Resistance kn (-20 C, _4 F) sensor 4-7 kn (O C, 32 F) 2-3 kn (20 C, 68 F) kn (40 C, 104 F) kn (60 C, 140 F) kn (80 C, 176 F) ECU NOTE: 1. Perform all voltage and resistance measurements with the ECU connected. 2. Verify that the battery voltage is 11 V or above when the ignition switch is ON. 3. The testing probes must not make contact with the computer Ox and VF terminals. +B - E) Ignition switch ON BATT - E) IDL - Ez 4-10 Throttle valve open Throttle valve fully closed VTA - Ez. Ignition switch 4-5 Throttle valve fully open ON Vcc - Ez IGt - E) Idling STA - E) 6-12 Ignition switch ST position No.l0-E) 9-14 Ignition switch ON No E) W-E No trouble (CHECK ENGINE light go off) and engine running Vc - Ez Ignition switch Measuring plate fully closed ON Vs - Ez 5-8 Measuring plate fully open Idling THA - Ez 2-6 Ignition switch ON Intake air temperature 20 C or 68 F THW - Ez Ignition switch ON Coolant temperature 80 C or 176 F BIK - Ez 8-14 Stop Iight switch ON Resistance EI- Ez on EI- BODY EI- EOI on on EI - Eoz on Fuel cut rpm Cut MIT 2,130 rpm (Brake switch OFF) A/T 2,200 rpm Hysteresis rpm (Brake switch ON) rpm (Brake switch OFF) I

7 SERVICE SPECIFICATIONS - Fuel System, Coo~ing System, Lubrication System A-7 FUEL SYSTEM I Carburetor Float level Raised position (float top to air horn) Lowered position (float bottom to air horn) Float lip clearance (at float lowered) Throttle valve closed angle Throttle valve full open angle Secondary touch angle Fast idle angle Fast idle speed Unloader angle Choke breaker opening angle Choke heater Idle-up angle Dash pot touch angle Dash pot setting speed Idle speed Idle mixture adjusting screw presetting Idle mixture speed Primary Secondary Primary Secondary Resistance MIT AIT MIT A/T 9.8mm in. 48mm 1.89 in. 1 mm 0.04 in. 9? from horizontal plane 20 from horizontal plane 90 from horizontal plane 90 from horizontal plane 59 from horizontal plane 23 from horizontal plane 2,600 rpm 45 from horizontal plane 42 from horizontal plane n at 20 C (68 F) 16.5 from horizontal plane 24.5 from horizontal plane 3,000 rpm 700 rpm 750 rpm Screw out 3-1/2 turns 740 rpm 790 rpm ~OOLING SYSTEM Radiator Relief valve opening pressure STD kg/cm psi kpa Limit 0.6 kg/cm psi 59 kpa Thermostat Valve opening temperature Starts to open at 88 C 190 F Fully opens at e 212 F Valve opening travel 8mm 0.31 in. LUBRICATION SYSTEM Oil pressure (normal operating temperature) at idle speed More than 0.3 kg/cm 2 (4.3 psi, 29 kpa) at 3,000 rpm kg/cm 2 (36-71 psi, kpa) Oil pump Body clearance STD mm in. Tip clearance Limit 0.2 mm in. Drive gear to crescent STD mm in. Limit 0.3mm in. Drive gear to crescent STD mm in. Limit 0.3mm in. Side clearance STD mm in. Limit. O.1g;ni~ in. Relief valve operating pressure 4.5 kg/cm 2 64 psi 441 kpa

8 A-a SERVICE SPECIFICATIONS - Ignition System, Starting System IGNITION SYSTEM Spark plug Type NO W16EXR-U NGK BPR5EY Gap 0.8mm in. Distributor Air gap mm in. (22R Engine) Distributor Governor Distributor rpm Advance angle advance angle 600 Advance begins , , , Vacuum Ex. Calif. For Calif. - mmhg (in.hg, kpa) Advance angle mmhg (in.hg, kpa) Advance angle 80 (3.15,10.7) Advance begins 80 ( 3.15,10.7) Advance begins Main 132 (5.20, 17.6) ( 8.35, 28.3) (7048, 25.3) (13.00, 44.0) ( 7.87,26.7) Advance begins 200 ( 7.87,26.7) Advance begins Sub 246 ( 9.69,32.8) (11.81, 40.0) (11.81, 40.0) High tension wire Resistance Limit Less than 25 kn per cord 22R-E 22R IgniHon coil Primary coil resistance n n Secondary coil resistance kn kn Insulation resistance w/500v megohm meter 10 Mn or more STARTING SYSTEM Reduction type Rated voltage and output power 12V, 1.0 kw 12V, 1.4 kw starter No-load characteristic Ampere Less than 90A Less than 90A rpm More than 3,000 rpm More than 3,500 rpm at 11.5V at 11.5V Brush Length STD 13.0 mm in mm in. Limit 8.5 mm in mm in. Commutator Outer diameter STD 30mm 1.18in. +- Limit 29 mm 1.14 in. +- Mica depth STD mm in. Limit 0.2 mm in. +- Runout Limit 0.05 mm in. +- Spring installed load STD 1,785-2, b N A049'78 Limit 1,200 g b 12 N

9 SERVICE SPECIFICATIONS - Charging System, Clutch A-9 CHARGING SYSTEM I Battery specific gravity when fully charged at 20 C (68 F) Alternator Rated output ampere 60A Brush exposed length STD 10.5 mm 0.4~3 in. Limit 4.5mm in. Rotor coil resistance n Slip ring diameter STD 14.4 mm in. Limit 14.0 mm in. Alternator Regulator voltage V (at 25 C) regulator CLUTCH Specifications Pedal height (from asphalt sheet) 144mm 5.67 in. I Push rod play at pedal top Pedal freeplay Disc rivet head depth Disc runout Diaphragm spring tip alignment Diaphragm spring finger wear Flywheel runout mm in mm in. Limit 0.3mm in. Limit 0.8mm in. Limit 0.5 mm in. Limit Depth 0.6mm in. Width 5.0mm in. Limit 0.2 mm in. Tightening Torque Tightening part kg-cm ft-ib N-m Clutch cover x Flywheel Strap x Clutch pressure plate Master cylinder reservoir set bolt Master cylinder set nut A00989

10 A-10 SERVICE SPECIFICATIONS - Manual Transmission MANUAL TRANSMISSION Specifications (2WD AND 4WD) Manual transm ission (W46, 55, 56) Output shaft 2nd gear journal diameter Limit mm in. 3rd gear journal diameter Limit mm in. Flange thickness Limit 5.60 mm in. Runout Limit 0.06 mm in. 1st gear inner race flange thickness Limit 4.70 mm in. 1st gear inner race outer diameter Limit mm in. 1st and 2nd gear inner diameter Limit mm in. 3rd gear inner diameter Limit mm in. Counter 5th gear inner diameter Limit mm in. Reverse idler gear inner diameter Limit 20.2 mm in. Counter gear Center bearing journal outer diameter Limit mm in. 5th gear journal outer diameter Limit mm in. Reverse idler gear shaft outer diameter Limit 19.9 mm in. Reverse shift arm shoe to idler gear groove clearance Limit 0.9mm in. Gear thrust clearance 1st, 2nd & 3rd STD mm in. Limit 0.30 mm in. Counter 5th STD mm in. Limit 0.46 mm in. Gear oil clearance 1st & 2nd STD mm in. Limit 0.15 mm in. 3rd STD mm in. Limit 0.20 mm in. Counter 5th STD mm in. Limit 0.15 mm in. Shift fork to hub sleeve clearance Limit 1.0mm in. Synchronizer ring to gear clearance STD mm in. Limit 0.5mm in. A00990

11 SERVICE SPECIFICATIONS - Manual Transmission A-11 Specifications (2WD and 4WD)(Cont'd) Manual Input shaft snap ring thickness transmission (W46, 55, 56) Mark (Cont'd) mm in mm in mm in mm in mm in mm in. Output shaft snap ring thickness Front mm in. Mark D mm in mm in mm in mm in mm in. Rear mm in. Mark mm in mm in mm in mm in mm in mm in mm in. Reverse gear mm in. Mark mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in. I AOO mm in mm in.

12 A-12 SERVICE SPECIFICATIONS - Manual Transmission Specifications (2WD and 4WD){Cont'd) Manual transmission (W46, 55, 56) (Cont'd) Countershaft snap ring thickness Front Rear Clutch hub No.3 Mark mm in mm in mm in mm in mm in " mm in mm in. Mark mm in mm in mm in mm in mm in mm in mm in. Mark mm in mm in mm in mm in. Tightening Torque (2WD AND 4WD) Tightening part kg-em ft-ib N m Shift fork set bolt Strait screw plug Idler shaft stopper bolt Reverse restrict pin Front bearing retainer set bolt Extension housing x Intermediate plate Restrict pin Shift lever housing x Shift and select lever Shift lever retainer x Extension housing Drain and filler plugs Back-up light switch Clutch housing x Transmission case A00992

13 MANUAL TRANSMISSION ---~ecifications (4WD) SERVICE SPECIFICATIONS - Manual Transmission A-13 Manual transmission (G52) Output shaft 2nd gear journal diameter Limit mm in. 3rd gear journal diameter Limit mm in. Flange thickness Limit 4.80 mm in. Runout Limit 0.05 mm in. Inner race flange thickness Limit 3.99 mm in. Inner race outer diameter Limit mm in. Gear thrust clearance 1st, 2nd and 3rd STD mm in. Limit 0.25 mm in. Counter 5th STD mm in. Gear oil clearance Limit 0.30 mm in. 1st and cou nter 5th STD mm in. Limit mm in. 2nd and 3rd STD mm in. Limit mm in. Shift fork to hub sleeve clearance Limit 1.0 mm in. Synchronizer ring to gear clearance STD mm in. Input shaft snap ring thickness Limit 0.8mm in. Mark mm in mm in mm in mm in mm in. Output shaft snap ring thickness Front mm in. Mark C mm in. D mm in. D mm in. E mm in. E mm in. F mm in. F mm in. A00993

14 A-14 SERVICE SPECIFICATIONS - Manual Transmission Specifications (4WD) (Cont'd) Manual transmission (G52) (Cont'd) Rear Counter gear snap ring (Front Bearing) Mark A mm in. B mm in. C mm in mm in. E mm in. F mm in. G mm in. H mm in. J mm in. K mm in. L mm in. Mark mm in mm in mm in mm in mm in mm in. Tightening Torque (4WD) Tightening part kg-cm ft-ib N-m Straight screw plug Transfer adapter x Transmission case Restrict pin Shift lever retainer x Extension housing Front bearing retainer x Transmission case Rear bearing retainer x Intermediate plate Reverse shift arm bracket Counter gear rear lock nut 1, Reverse idler gear shaft stopper bolt Clutch housing x Transmission case Shift lever housing bolt A00994

15 SERVICE SPECI FICATIONS - AUTOMATIC TRANSMISSION (A43D) 'pacifications Automatic Transmission A 15 Governor pressure (Vehicle speed reference) kg/cm 2 psi kpa Output shaft rpm 22 R 22R-E 22R-E (C & C) 1,000 (32 km/h, 20 mph) (33 km/h, 21 mph) (29 km/h, 18mph) ,800 (58 km/h, 36 mph) (59 km/h, 37 mph) (52 km/h, 32 mph) ,500 (114 km/h, 71 mph)(115 km/h, 71 mph)(100 km/h,62mph) Line pressure (22R Engine) Idling "0" range "R" range Stall "0" range ,079 "R" range ,344-1,667 Line pressure (22R-E Engine) Idling "0" range "R" range Stall "0" range ,167 "R" range ,471-1,863 Engine stall revolution 22R Engine 1,850 ± 150 rpm 22R-E Engine 1,900 ± 150 rpm Engine idle speed (A/C OFF) "N" range "0" range 750 rpm 700 rpm Time lag "N" range -+ "0" range Less than 1.2 seconds "N" range -+ "R" range Less than 1.5 seconds Throttle cable adjustment Throttle valve fully opened Between boot end face and inner cable stopper 0-1mm in. Torque converter runout Limit 0.30 mm in. Drive plate runout Limit 0.20 mm in. Shift point "0" range (throttle valve fully open) "L" range schedule (22R Engine) km/h (mph) No shift (35-45) (65-77) *1 *2 (60-71) (24-34) (28-39) * shift up point with closed throttle valve is km/h (22-30 mph). * down-shift is possible up to maximum speed. Shift point "0" range (throttle valve fully open) "L" range schedule ( 22R-E Engine) Ex. C & C No shift km/h (mph) (37-47) (68-79) *1 *2 (62-73) (25-35) (29-40) * shift up point with closed throttle valve is at km/h (24-34 mph). * down-shift is possible up to maximum speed.

16 A-16 SERVICE SPECIFICATIONS - Automatic Transmission Specifications (Cont'd) Shift point schedule 22R-E Engine) ( C&C km/h (mph) 1 ~ (32-41) 2 ~ (59-69) "0" range (throttle valve fully open) 3 ~ 00 No shift *1 00 ~ 3 *2 3 ~ (53-63) 2 ~ (22-30) ill" range 2 ~ (25-35) * 1 3 ~ 00 shift up point with closed throttle valve is at km/h (21-29 mph). *2 00 ~ 3 down-shift is possible up to maximum speed. Valve body spring mm (in.) Spring Lower valve body Free length Coil outer diameter No. coils Wire diameter Primary regulator valve (22R) Primary regulator valve (22R-E) 1-2 shift valve 3-4 shift valve Oil cooler by-pass valve Pressure relief valve ball Damping check ball (2.8866) (2.4094) (1.3630) (1.3248) (1.3118) (1.2654) (0.7874) (0.6583) (0.6772) 7.56 (0.2976) (0.4173) (0.5441) (0.5173) 4.95 (0.1949) (0.0626) 1.80 (0.0709) 0.56 (0.0220) 1.10 (0.0433) 1.32 (0.0520) 2.03 (0.0799) 0.38 (0.0150) Upper rear valve body Low coast modulator valve Sequence valve Governor modulator valve 2-3 shift timing valve Detent regulator valve Intermediate modulator valve (1.6673) (1.4783) (1.4201) (1.3819) (1.1783) (1.0732) 9.24 (0.3638) 9.17 (0.3610) 9.09 (0.3579) 8.96 (0.3528) 8.85 (0.3484) 9.04 (0.3559) (0.0331) (0.0461) (0.0280) (0.0299) (0.0354) (0.0433) Upper front valve body Secondary regu lator valve Down shift plug Throttle valve (2.8059) (1.5634) (0.8638) (0.6862) (0.4287) 8.58 (0.3378) (0.0760) (0.0469) (0.0280) Clutch and brake return spring (Co, C 11 C 2 ) Free length Coil outer diameter No. of coils mm 8.0mm in in. Clutch and brake return spring (8 0,8 1,8 2,8 3 ) Free length Coil outer diameter No. of coils 16.12mm 8.0mm in in. Oil pump Side clearance Body clearance Tip clearance Driven gear STD Limit STD Limit STD Limit mm 0.1 mm mm 0.3mm mm 0.3mm in in in in in in.

17 Spacifications (Cant'd) SERVICE SPECI FICATIONS - Automatic Transmission A-17 Clutch and brake Front clutch (C 1 ) STO mm in. piston stroke Rear clutch (C 2 ) STO mm in. 00 clutch (Co) STO mm in. No.1 brake (B 1 ) STO mm in. No.2 brake (B 2 ) STO mm in. Brake clearance No.3 brake (B 3 ) STO mm in. 00 brake (Bo ) STO mm in. Accumulator Length Outer diameter piston 8 2 Front 48.5 (1.909) 34.8 (1.370) mm (in.) C 2 Center 45.0 (1.772) 31.8 (1.252) C 1 Rear 49.5 (1.949) 31.8 (1.252) Accumulator ~ Engine Free length Coil outer diameter No. Wire diameter coils piston spring mm (in.) 22R (2.6180) (0.7051) (0.1024) 8 2 Front 22R-E (2.6252) (0.6441) (0.1024) C 2 Center All (2.1724) (0.6248) (0.0787) C 1 Rear 22R (2.6992) (0.6902) (0.0800) 22R-E (2.5512) (0.6772) (0.0787) Bushing bore Bushing name Length Finished bore Bore limit mm(in.) Front (0.3819) ( ) (0.8495) Stator support Rear (0.6870) ( ) (0.8495) Oil pump body 00 sun gear Front & Rear 00 input shaft (0.5299) ( ) (1.5035) (0.3819) ( ) (0.9109) (0.3543) ( ) (0.4437) Sun gear Center support Transmission case Output shaft Extension housing Front & Rear (0.5315) ( ) (0.8495) (2.3650) ( ) (1.4355) (0.5299) ( ) (1.5035) (0.3819) ( ) (0.7117) (1.1713) ( ) (1.4990)

18 A-18 Tightening Torque SERVICE SPECIFICATIONS - Automatic Transmission Tightening part kg-cm ft-ib N-m Engine x Transmission Transmission housing x Converter housing 17 mm mm Extension housing Drive plate Torque converter Oil pump Center support Upper valve body x Lower valve body in.-ib 5.4 Valve body Oil strainer in.-ib 5.4 Oil pan in.-ib 4.4 Cooler pipe union nut Testing plug in.-ib 7.4 Parking lock pawl bracket in.-ib 7.4 Drain plug Governor body in.-ib 3.9

19 SERVICE SPECI FICATIONS - Transfer A-19 TRANSFER -pecifications Output shaft bearing thrust clearance Output shaft snap ring thickness Output shaft runout Low gear to output shaft oil clearance Low gear thrust clearance Transfer drive gear to output shaft oil clearance Transfer drive gear thrust clearance Input shaft bearing thrust clearance Input shaft snap ring thickness Counter shaft bearing thrust clearance Counter shaft snap ring thickness Idler gear shaft bearing thrust clearance Idler gear shaft snap ring thickness Shift fork to hub sleeve clearance Less than 0.1 mm (0.004 in.) Mark mm in mm in mm in mm in mm in mm in. Limit 0.03 mm in. STD mm in. Limit mm in. STD mm in. Limit 0.30 mm in. STD mm in. Limit mm in. STD mm in. Limit 0.32 mm in. Less than 0.15 mm ( in.) Mark mm in mm in mm in. Less than 0.15 mm ( in.) Mark mm in mm in. Less than 0.15 mm ( in.) Mark A mm in. B mm in. Limit 1.0mm in. A00995

20 A 20 SERVICE SPECIFICATIONS - Transfer, Propeller Shaft Tightening Torque Tightening part kg-em ft-ib N m Adapter x Reduction case Reduction case x Front case x Rear case Rear case x Extension housing Front case x Rear case Reduction case x Front case Reduction case x Transfer cover in.-ib 6.5 Reduction case x Shift lever retainer Output shaft x Companion flange 1, Front drive gear bearing retainer x Front case Front case x Bearing retainer PROPELLER SHAFT Specifications Spider axial play Spider bearing selection Less than 0.05 mm ( in.) Mark Bearing cup outer diameter None Ex. RN50L-KRA RN50L-KRA Bearing hole inner diameter None Ex.RN50L-KRA RN50L-KRA Bearing cup outer diameter Red Ex. RN50L-KRA RN50L-KRA Bearing hole inner diameter Drill Ex.RN50L-KRA RN50L-KRA Snap ring thickness Color mm mm mm mm mm mm mm mm in in in in in in in in. Runout None Ex. RN50L-KRA mm RN50L-KRA mm Brown Ex. RN50L-KRA mm RN50L-KRA mm Blue Ex. RN50L-KRA mm RN50L-KRA mm Limit 0.8mm in in in in in in in. Tightening Torque Tightening part kg-em ft-ib N-m Intermediate shaft x Propeller shaft Propeller shaft x Differential (2WD) Propeller shaft x Transfer (4WD) Propeller shaft x Differential (4WD) Intermediate shaft x Center bearing x Joint flange 1st 1, AOO996 2nd Loosen nut 3rd

21 SERVICE SPECI FICATIONS - FRONT AXLE AND SUSPENSION ~pecifications (2WD) Front Axle and Suspension A-21 Cold tire Tire size kg/cm 2 (psi, kpa) inflation pressure Front 2.0 (28, 196) 205/70 SR 14 Rear 2.25 (32, 221) PR P195/75 R R14 LT8PR Front 1.7 (24, 167) Rear 2.5 (36, 245) Front 2.0 (28, 196) Rear 2.45 (35, 240) Front 1.8 (26, 177) Rear 4.5 (64,441) Do not drive over 120 km/h (75 mph) with cargo above 400 kg (882 Ib). Vehicle height Body type and Vehicle height mm (in.) Tire size Suspension type Front Rear STD Short PR 270 (10.63) 299 (11.77)! STD Long PR 275 (10.83) 290(11.42) Long Soft ride suspension Extra cab Soft ride suspension P195/75R (10.24) 277 (10.91) t 250 ( 9.84) 275 (10.83) Extra cab STD suspension t t 273 (10.75) 1 ton 185R 14-LT8PR 262(10.31) 295 (11.61) C&C 185R 14-LT8PR 259 (10.20) 242 ( 9.53) SR-5 Short SR-5 Long Extra cab SR-5 Long P195/75 R ( 9.80) 277(10.91) 205/70 SR (10.04) 280 (11.02) P195/75 R ( 9.96) 275 (10.83) 205/70 SR (10.20) 278 (10.94) P195/75 R ( 9.84) 274 (10.79) 205/70 SR (10.08) 278 (10.94)

22 A-22 SERVICE SPECIFICATIONS - Front Axle and Suspension Specifications (2WD) (Cont'd) Front wheel Inspection STD Adjustment STD. alignment Toe-in 1/2 ton Short Bias tire 4 ± 4 mm (0.16 ± 0.16 in.) 4 ± 1 mm (0.16 ± 0.04 in.) Radial tire 1 ± 4 mm (0.04 ± 0.16 in.) 1 ± 1 mm (0.04 ± 0.04 in.) 1 ton, C & C Radial tire 4 ± 4 mm (0.16 ± 0.16 in.) 4 ± 1 mm (0.16 ± 0.04 in.) 1/2 ton Long Bias tire 6 ± 4 mm (0.24 ± 0.16 in.) 6 ± 1 mm (0.24 ± 0.04 in.) Radial tire 3 ± 4 mm (0.12 ± 0.16 in.) 3 ± 1 mm (0.12 ± 0.04 in.) Camber 0 30' ± 45' 0 30' ± 30' Left-right error 30' 30' Steering axis inclination 10 Caster 1/2 ton Short 0 40' ± 45' 0 40' ± 30' 1/2 ton Long 1 10' ± 45' 1 10' ± 30' 1 ton 0 35' ± 45' 0 35' ± 30' C&C 0 05' ± 45' 0 05' ± 30' Left-right error 30' 30' Slide slip Less than 3.0 mm/m (0.118 in./3.3 tt) Wheel angle Inside wheel 34 ~~: Outside wheel 30 At 20 wheel angle 22 15' Disc wheel lateral runout Limit 1.0 mm in. Wheel bearing preload Frictional force kg Ib N (rotating load at hub bolt) of oil seal plus Hub axial play Limit 0.05 mm in. Ball joint vertical play Limit 2.3mm in. Ball joint rotation condition Lower ball joint kg-cm (22-43 in.-ib, N m) Upper ball joint kg-cm (18-34 in.-ib, N m)

23 SE RVICE SPECI FICATIONS - FRONT AXLE AND SUSPENSION -~ecifications (4WD) Front Axle and Suspension A-23 Cold tire Inflation pressure kg/cm 2 (psi, kpa) inflation Tire Size pressure Front Rear P225/75R (26, 177) 2.0 (28, 196) Front wheel Inspection STD Adjustment STD alignment Toe-in 1 ± 4 mm (0.04 ± 0.16 in.) 1 ± 1 mm (0.04 ± 0.04 in.) Camber 1 ± 45' Steering axis inclination 9 30' ± 45' Caster Side slip TRUCK 2 15' ± 1 4-RUNNER 3 00' ± 1 0 Less than 3.0 mm/m (0.118 in.l3.3 ft) Wheel angle Inside wheel 30030'~~: Max. Outside wheel 29 ~ ~ At 20 wheel angle Inside wheel 20 30' Outside wheel 20 Disc wheel lateral runout Limit 1.0 mm in. Wheel bearing preload Frictional force of kg Ib N (rotating load at hub bolt) oil seal plus Steering knuckle bearing preload kg Ib N (rotating load at knuckle arm end, before install dust seal) Steering knuckle preload adjusting shim thickness 0.1 mm in. 0.2 mm in. 0.5mm 1.0mm in in.

24 A 24 SERVICE SPECIFICATIONS - Front Axle and Suspension Tightening Torque (2WD) Tightening part kg-cm ft-ib N m Steering knuckle x Upper ball joint 1, Steering knuckle x Lower ball joint 1, Steering knuckle x Knuckle arm x Dust cover 1, Upper ball joint x Upper arm Lower ball joint x Lower arm Shock absorber x Lower arm Shock absorber x Upper bracket lock nut Lower arm x Frame 2, Lower arm x Torque arm Upper arm x Frame 1, Upper arm shaft x Upper arm 1, Strut bar x Lower arm Strut bar x Strut bar bracket (F ront nut) 1, Stabilizer bar bracket x Body Stabilizer x Lower arm Wheel hub nut 1, Disc brake cylinder x Torque plate Torque plate x Steering knuckle 1, Tie rod clamp bolt Tightening Torque (4WD) Tightening part kg-cm ft-ib N m Tie rod clamp bolt Free wheeling hub body x Axle hub Brake assembly x Adjusting nut in.-ib 6.9 Inner hub x Axle shaft Steering knuckle arm x Housing Bearing cap x Housing Knuckle spindle x Housing Torque plate x Steering knuckle 1, Disc brake cylinder x Steering knuckle Spring U bolt x Axle housing 1, Front spring bracket x Hanger pin Rear spring shackle x Leaf spring Front shock absorber x Axle housing Front shock absorber x Frame Torque rod x Axle housing 1, Torque rod x Frame 1, Stabilizer bar x Axle housing Stabilizer x Frame Wheel nut 1,

25 SERVICE SPECIFICATIONS - REAR AXLE AND SUSPENSION ~pecifications Rear Axle and Suspension A in. Drive pinion bearing preload at Starting Differential 2WD 1/2 ton New bearing kg-cm in.-ib N m Reused bearing 6-10 kg-cm in.-ib N m Total preload at Starting Add drive pinion bearing preload New and reused bearing 4-6 kg-cm in.-ib N m Drive pinion to ring gear backlash mm in. Pinion gear to side gear backlash mm in. Ring gear runout limit 0.07 mm in. Companion flange runout limit Radial 0.10 mm in. Lateral 0.10 mm in. Ring gear installing temperature C F Side gear thrust washer thickness 1.0 mm in. 1.1mm in. 1.2 mm in. 1.3 mm in. Drive pinion adjusting plate washer thickness 2.24 mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in.

26 A-26 SERVICE SPECIFICATIONS - Rear Axle and Suspension Specifications (Cont'd) 8.0 in. Differential 1 ton, C & C and 4WD Drive pinion bearing preload at Starting New bearing Reused bearing Total preload at Starting New and resued bearing Drive pinion to ring gear backlash Pinion gear to side gear backlash Ring gear runout Limit Companion flange runout Limit Radial Lateral Ring gear installing temperature Side gear thrust washer thickness Drive pinion adjusting plate washer thickness kg-cm in.-ib N m 9-13 kg-cm in.-ib N m Add drive pinion bearing preload 4-6 kg-cm in.-ib N m mm in mm in mm in mm in mm in C F 1.6 mm in. 1.7 mm in. 1.8mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm iin mm in mm in mm in mm in mm in.

27 Tightening Torque SERVICE SPECIFICATIONS - Rear Axle and Suspension A-27 Differential Tightening part kg-cm ft-ib N m Propeller shaft x Companion flange Drive pinion x Companion flange 7.5 in. 1,100-2, in. 2,000-3, Ring gear x Differential case Bearing cap x Differential carrier Differential carrier x Axle housing Rear axle and Rear axle housing x Bearing retainer suspension Spring center bolt Spring U bolt x Axle housing 2WD 1, WD 1, Front spring bracket x Hanger pin Rear spring shackle x Leaf spring Rear shock absorber x U-bolt seat 2WD WD Rear shock absorber x Body 2WD WD

28 A 28 BRAKE SYSTEM Specifications SERVICE SPECIFICATIONS - Brake System Brake Pedal height (from asphalt sheet) mm in. Pedal freeplay 3-6mm in. Pedal reserve distance at 50 kg (110 Ib) (from asphalt sheet) 2WD 1/2 ton More than 65 mm (2.56 in.) 1 ton, C & C More than 55 mm (2.17 in.) 4WD More than 60 mm (2.36 in.) Brake booster Booster push rod to piston clearance at Idling vacuum mm in. at No vacuum mm in. w/sst Omm o in. Front brake Disc thickness STD 25.0 mm in. (PD60 Type Limit 24.0 mm in. disc) (2WD) Disc runout Limit 0.15 mm in. Pad thickness STD 10.0 mm in. Limit 1.0mm in. Front brake Disc thickness STD 22.0 mm in. (FS-17 Type Limit 21.0 mm in. disc) (2WD) Disc runout Limit 0.15 mm in. Pad thickness STD 10.0 mm in. Limit 1.0mm in. Front brake Disc thickness STD 12.5 mm in. (S-12+8 Type Limit 11.5 mm in. disc) (4WD) Disc runout Limit 0.15 mm in. Pad thickness STD 9.7mm in. Limit 1.0mm in. Rear brake Drum inner diameter STD mm in. (Drum) Limit mm in. Lining thickness STD 5.0mm in. Limit 1.0 mm in. Parking brake Lever travel at 20 kg (44 Ib) 2WD clicks 4WD 7-15 clicks

29 SERVICE SPECI FICATIONS - Brake System A-29 Tightening Torque Tightening part kg-cm ft-ib N m Brake booster clevis lock nut Brake booster x Pedal bracket Master cylinder x Brake booster Master cylinder fluid outlet plug 16 mm I 18 mm I Piston stopper bolt x Master cylinder Brake tube union nut x Master cylinder Disc brake cylinder x Torque plate (2WD) FS PD Torque plate x Steering knuckle (2WD) 1, Disc Brake cylinder x Steering knuckle (4WD) Brake tube union nut Bleeder plug Front disc x Front axle hub (2WD) (4WD) Flexible hose bracket x Disc brake cylinder (2WD) Drum brake backing plate x Rear axle housing Rear brake wheel cylinder x Backing plate (Leading-trailing type - 2WD 1/2 ton) Rear brake wheel cylinder x Backing plate (Duo-servo type - 4WD, 2WD 1 ton) Rear brake bleeder plug Brake tube x Wheel cylinder Bellcrank bracket x Backing plate LSP & BV (LSPV) bracket x Frame LSP & BV (LSPV) x LSP & BV (LSPV) bracket LSP & BV (LSPV) spring x LSP & BV (LSPV) bracket LSP & BV (LSPV) spring x Shackle LSP & BV (LSPV) shackle lock nut LSP & BV (LSPV) shackle x Shackle bracket LSP & BV (LSPV) shackle bracket x Rear axle housing

30 A-30 SERVICE SPECIFICATIONS - Steering STEERING Specifications Steering Steering wheel freeplay Less than 30 mm (1.18 in.) Joint radial play Less than 0.06 mm ( in.) Bearing block width Punch mark Yes mm in. No mm in. Spider axial play Less than 0.05 mm ( in.) Hole snap ring thickness Color None mm in. Brown mm in. Blue mm in. Steering gear Gear housing oil level mm ( in.) from top housing Sector shaft thrust clearance Less than 0.05 mm ( in.) (2WD) Thrust washer thickness 2.00 mm in mm in mm in. 2.12mm 2.16mm Worm bearing preload at Starting kg-cm in in mm in. Total preload at Starting kg-cm in.-ib N m in.-ib N m Steering gear Gear housing oil level mm ( in.) from top housing Sector shaft thrust clearance Less than 0.05 mm ( in.) (4WD) Thrust washer thickness 2.00 mm in mm in mm in mm in mm in. Sector shaft outer diameter Limit mm in. Sector shaft oil clearance Limit 0.10mm in. End cover shim thickness 0.05 mm in. Worm bearing preload at Starting kg-em 0.06 mm in mm in mm in mm in mm in mm in mm in. Total preload at Starting kg-em in.-ib N m in.-ib N m

31 SERVICE SPECIFICATIONS - Steering A-31 Specifications (Cont'd) Power steering Drive belt tension [wi Nippondenso BTG-20 ( ) or Borroughs drive belt tension gauge No. BT-33-73F] New belt 125 ± 25 Ib Used belt 80 ± 20 Ib Maximum rise of oil level 5mm 0.20 in. Oil pressure (at Idle speed) 2WD More than 75 kg/cm 2 (1,067 psi, 7,355 kpa) 4WD More than 65 kg/cm 2 ( 924 psi, 6,374 kpa) Steering effort at steering wheel Less than 4 kg (8.8 Ib, 39 N) Vane plate Height Limit 7.8 mm in. Thickness Limit 1.7 mm in. Length Limit mm in. Vane plate to rotor groove clearance Limit 0.06 mm in. Vane plate length Rotor and cam ring mark None mm in mm in mm in mm in mm in. Shaft to bushing clearance STD mm in. Limit 0.07 mm in. Flow control spring length STD 50.0 mm in. Limit 47.0 mm in. Pump rotating torque Less than 2.8 kg-em (2.4 in.-ib, 0.3 N m) Cross shaft adjusting screw end play mm in. Ball clearance STD mm in. Limit 0.15 mm in. Worm bearing preload at Starting kg-em in.-ib N m Total preload at Starting Add worm bearing preload kg-em in.-ib N m Tilt steering Collar No.1 outer diameter mm in mm in mm in mm in mm in. Collar No.2 outer diameter mm in mm in. Tilt steering support shim thickness 0.2mm in. 0.5mm in. 0.8mm in. 1.4 mm in. 1.8 mm in.

32 A-32 SERVICE SPECIFICATIONS - Steering Tightening Torque Steering Tightening part kg-cm ft-ib N m Steering wheel x Steering main shaft Column tube x Instrument panel Flexible coupling x Steering main shaft Flexible coupling x Steering intermediate shaft Flexible coupling x Worm shaft (2WD) (4WD) Steering main shaft x Steering intermediate shaft Column tube x Upper bracket in.-ib 5.4 Column tube x Column tube bracket Tilt steering Tilt steering pawl set bolt Tilt lever retainer Castle nut (Support x Column bracket) Upper bracket x Tile steering support in.-ib 7.8 Column bracket x Column tube Main shaft x Intermediate shaft Steering gear Worm bearing adjusting screw lock nut 1, housing End cover x Gear housing (2WD) Sector shaft adjusting screw lock nut Gear housing x Body Steering gear End cover x Gear housing housing Sector shaft adjusting screw lock nut (4WD) Gear housing x Body Power steering Pressure port union x Rear housing Front housing x Rear housing Union x Rear housing Vane pump x Bracket Pressure tube x Vane pump Pump pulley x Rotor shaft Worm adjusting screw lock nut Gear housing x Valve housing End cover x Gear housing Cross shaft adjusting screw lock nut Pressure and return line x Valve housing Steering linkage Pitman arm x Gear housing 1, (2WD) Pitman arm x Relay rod Tie rod clamp bolt Tie rod x Relay rod Tie rod x Knuckle arm Relay rod x Idler arm Knuckle arm x Steering knuckle 1, Steering damper x Body Steering damper x Tie rod Idler arm x Body Idler arm x Idler arm bracket Steering linkage Pitman arm x Gear housing 1, (4WD) Tie rod x Knuckle arm Tie rod x Steering damper Tie rod clamp bolt Steering damper x Front axle housing

33 SERVICE SPECIFICATIONS - Winch A 33 WINCH -uecifications Winch Clutch outer race bushing bore STD mm ( in.) Limit 12.15mm ( in.) Gear case bushing bore STD mm ( in.) Limit 12.15mm ( in.) Thrust bushing thickness No.1 STD 2.0mm (0.079 in.) Limit 1.7 mm (0.067 in.) No.2 STD 1.0 mm (0.039 in.) Limit 0.8mm (0.031 in.) Drum bushing bore A STD mm ( in.) Limit mm ( in.) B STD mm ( in.) Limit mm ( in.) Thrust bushing thickness STD 1.5 mm (0.059 in.) Limit 1.0 mm (0.039 in.) Thrust washer thickness STD 2.0mm (0.079 in.) Limit 1.6 mm (0.063 in.) Motor Brush Length STD 16.0 mm (0.630 in.) Limit 10.5 mm (0.413 in.) Spring installed load STD 1.6 kg (3.5Ib) Limit 1.0 kg (2.2Ib) Commutator Outer diameter STD 28.0 mm (1.102 in.) Limit 27.0 mm (1.063 in.) Undercut depth STD mm ( in.) Limit 0.2mm (0.008 in.) Circle runout Limit 0.4 mm (0.157 in.) Tightening Torque Tightening part kg-cm ft-ib N m Ring gear x Gear case Drum plate x Gear case Commutator end frame x Gear case Bracket x Gear case Bracket x Drum plate x Wire guide Filler and Drain plug

34 A-34 LUBRICANTS SERVICE SPECIFICATIONS - Lubricants Item Capacity Liters US qts Imp. qts Classification Engine oil Drain and refill wlo Oil filter change wi Oil filter change Dry fill API grade SF or SF/CC multigrade, fuel efficient and recommended viscosity oil Manual transmission oil (2WD) W46, W55, W API GL-4 or GL-5 (4WD) W SAE 75W-90 G A/T fluid ATF DEXRON n Dry fill Drain and refill Transfer oil API GL-4 or GL-5, SAE 75W-90 Differential oil API GL-5 hypoid gear oil (2WD) 1/2 ton Above -lsoc (O F) 1 ton and C & C SAE 90 (4WD) Front Below -lsoc (O F) Rear SAE SOW-90 or 80W Steering gear box oil API GL-4, SAE 90 (2WD) cc cu in. (4WD) 580 cc 35.4 cu in. Power steering fluid Pump 300 cc 18.3 cu in. Total 850 cc 51.9 cu in. ATF DEXRON or DEXRON IT Winch gear oil 200 cc 12.2 cu in. ATF DEXRON IT Ball joint grease (2WD) - Molybdenum disulphide lithium base, NLGI NO.1 or No.2 Chassis grease (4WD) Propeller shaft (Except double cardan joint) Double cardan joint Drag link ends Lithium base, NLGI NO.2 Molybdenum disulphide lithium base, - NLGI No.2 Lithium base, NLGI No.1 Wheel bearing grease - Lithium base multipurpose, NLGI No.2 Steering knuckle and front axle Molybdenum disulphide lithium base, shaft grease (4WD) - NLGI No.2 Brake fluid - SAE J1703, DOT 3.