Class. Class Hexagon head bolt Bolt head No. Hexagon flange bolt 4T 5T 6T 7T. w/ washer hexagon bolt. Hexagon flange bolt 10T 11T

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1 STANDARD BOLT STANDARD BOLT HOW TO DETERMINE BOLT STRENGTH SS1 SS00F01 Mark Class Mark Class Hexagon head bolt Bolt head No T 5T 6T 7T Hexagon flange bolt w/ washer hexagon bolt 4 Protruding lines 9T T 9T 10T 11T Hexagon flange bolt w/ washer hexagon bolt 5 Protruding lines 10T No mark 4T Hexagon flange bolt w/ washer hexagon bolt 6 Protruding lines 11T Hexagon flange bolt Stud bolt No mark w/ washer hexagon bolt No mark 4T 4T Hexagon head bolt 2 Protruding lines 5T Grooved Hexagon flange bolt w/ washer hexagon bolt 2 Protruding lines 6T 6T Hexagon head bolt 3 Protruding lines 7T Welded bolt Hexagon head bolt 4 Protruding lines 8T 4T V

2 SS2 STANDARD BOLT SPECIFIED TORQUE FOR STANDARD BOLTS SS00G01 Class Diameter mm Pitch mm Specified torque Hexagon head bolt Hexagon flange bolt N m kgf cm ft lbf N m kgf cm ft lbf in. lbf in. lbf in. lbf in. lbf in. lbf in. lbf V

3 MAINTENANCE SS3 MAINTENANCE SERVICE DATA SS03I01 Front axle and suspension Ball joint vertical play 0 mm (0 in.) 115

4 SS4 MAINTENANCE TORQUE SPECIFICATION SS03J01 Part tightened N m kgf cm ft lbf Front seat mount bolts Front suspension member x Body 181 1, Rear suspension member x Body

5 SS5 ENGINE MECHANICAL ENGINE MECHANICAL SERVICE DATA SS03K01 Compression pressure Valve clearance at 250 rpm STD Minimum Difference of pressure between each cylinder at cold Intake Exhaust Adjusting shim for repair part Mark Mark Mark Mark Mark Mark Mark Mark Mark Mark Mark Mark Mark Mark Mark Mark Mark ,500 kpa (15.3 kgf/cm 2, 218 psi) 1,000 kpa (10.2 kgf/cm 2, 145 psi) 100 kpa (1.0 kgf/cm 2, 15 psi) or less 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.) mm ( in.) mm ( in.) Ignition timing w/ Terminals TE1 and E1 connected of DLC idle Idle speed 700 ± 50 rpm Timing belt tensioner Protrusion from housing side mm ( in.) Cylinder head Warpage Valve seat Refacing angle Contacting angle Contacting width Valve guide bushing bore diameter STD O/S pointed head cylinder head bolt diameter at tension portion STD Minimum 0.10 mm (0.039 in.) 30, 45, mm ( in.) mm ( in.) mm ( in.) mm ( in.) 8.75 mm ( in.) Valve guide Inside diameter mm ( in.) bushing Outside diameter for repair part STD mm ( in.) O/S mm ( in.) Valve Valve overall length STD Intake Exhaust Minimum Intake Exhaust Valve face angle Stem diameter Intake Exhaust Stem oil clearance STD Intake Exhaust Intake Exhaust Margin thickness STD mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) 0.08 mm ( in.) 0.10 mm ( in.) 1.0 mm (0.039 in.) 0.5 mm (0.020 in.) 117

6 SS6 ENGINE MECHANICAL Valve spring Deviation Free length Installed tension at 33.8 mm (1.331 in.) 2.0 mm (0.079 in.) mm ( in.) N ( kgf, lbf) Valve lifter Lifter diameter mm ( in.) Lifter bore diameter mm ( in.) Oil clearance STD mm ( in.) 0.07 mm ( in.) Camshaft Thrust clearance STD Journal oil clearance STD Intake Exhaust Intake Exhaust Journal diameter Circle runout Cam lobe height STD Intake Exhaust Minimum Intake Exhaust Camshaft gear backlash STD Camshaft gear spring end free distance mm ( in.) 0.12 mm ( in.) mm ( in.) mm ( in.) 0.10 mm ( in.) 0.09 mm ( in.) mm ( in.) 0.06 mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) 0.30 mm ( in.) mm ( in.) Air intake chamber Warpage 0.10 mm ( in.) Intake Warpage manifold Air intake chamber side 0.15 mm ( in.) Cylinder head side 0.08 mm ( in.) Exhaust manifold Warpage 0.50 mm ( in.) Cylinder block Cylinder head surface warpage Cylinder bore diameter 12 pointed head main bearing cap bolt diameter at tension portion STD Minimum 0.07 mm ( in.) mm ( in.) mm ( in.) mm ( in.) 7.20 mm ( in.) Piston and Piston diameter mm ( in.) piston ring Piston oil clearance STD mm ( ) 0.13 mm ( in.) Piston ring groove clearance No mm ( in.) No mm ( in.) Piston ring end gap STD No mm ( in.) No mm ( in.) Oil mm ( in.) No mm ( in.) No mm ( in.) Oil 1.00 mm ( in.) 118

7 ENGINE MECHANICAL SS7 Connecting rod Thrust clearance STD Connecting rod thickness Connecting rod bearing center wall thickness Reference Mark 1 Mark 2 Mark 3 Mark 4 Connecting rod oil clearance STD Rod outofalignment per 100 mm (3.94 in.) Rod twist per 100 mm (3.94 in.) Bushing inside diameter Piston pin diameter Bushing oil clearance STD Connecting rod bolt diameter at tension portion STD Minimum mm ( in.) 0.35 mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) 0.08 mm ( in.) 0.05 mm ( in.) 0.15 mm ( in.) mm ( in.) mm ( in.) mm ( in) 0.05 mm ( in.) mm ( in.) 7.0 mm (0.276 in.) Crankshaft Thrust clearance STD Thrust washer thickness Main journal oil clearance STD No.1 and No.4 No.2 and No.3 No.1 and No.4 No.2 and No.3 Main journal diameter Main bearing center wall thickness Reference Mark 1 Mark 2 Mark 3 Mark 4 Mark 5 Mark 6 Mark 7 Crank pin diameter Circle runout Main journal taper and outofround Crank pin taper and outofround mm ( in.) 0.30 mm ( in.) mm ( in.) mm ( in.) mm ( in.) 0.05 mm ( in.) 0.06 mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) 0.06 mm ( in.) 0.02 mm ( in.) 0.02 mm ( in.) 119

8 SS8 ENGINE MECHANICAL TORQUE SPECIFICATION SS03L06 Part tightened N m kgf cm ft lbf Timing belt plate x Oil pump in. lbf No.1 idler pulley x Oil pump No.2 idler pulley x No.2 idler pulley bracket Camshaft timing pulley x Camshaft for SST , Timing belt tensioner x Oil pump RH engine mounting bracket x Cylinder block No.2 timing belt cover x No.3 timing belt cover in. lbf No.1 timing belt cover x Oil pump in. lbf Crankshaft pulley x Crankshaft 215 2, No.2 generator bracket x Engine RH mounting bracket Cylinder head x Cylinder block 12 pointed head 1st 2nd Recessed head 54 Turn Turn Turn Camshaft bearing cap x Cylinder head Cylinder head cover x Cylinder head in. lbf Exhaust manifold x Cylinder head Exhaust manifold stay x Exhaust manifold Exhaust manifold stay x Transmission housing No.1 EGR pipe x RH exhaust manifold No.1 EGR pipe x EGR cooler PS pump bracket x RH cylinder head Oil dipstick guide x LH cylinder head in. lbf Water inlet pipe x LH cylinder head Cylinder head rear plate x LH cylinder head in. lbf No.3 timing belt cover x Cylinder head in. lbf Water outlet x Intake manifold Fuel inlet hose x Fuel filter Intake manifold x Cylinder head Air intake chamber x Intake manifold No.2 EGR pipe x Air intake chamber No.2 EGR pipe x EGR cooler No.1 engine hanger x Air intake chamber No.1 engine hanger x RH cylinder head Air intake chamber stay x Air intake chamber Air intake chamber stay x RH cylinder head Drive plate x Crankshaft Transaxle x Engine 17 mm head No.1 oil pan x Transaxle Drive plate x Torque convertor clutch Flywheel housing under cover x Transaxle in. lbf Rear engine mounting insulator x Cylinder block Front engine mounting insulator x Cylinder block Engine moving control rod x RH engine mounting bracket

9 ENGINE MECHANICAL SS9 Engine moving control rod x RH fender apron RH engine mounting stay x Water outlet RH engine mounting stay x Engine moving control rod RH engine mounting stay x No.2 RH engine mounting bracket Front engine mounting insulator x Front frame Engine mounting absorber x Front frame Engine mounting absorber x Transaxle Rear engine mounting insulator x Front frame LH engine mounting insulator x Transaxle PS pump x PS pump bracket A/C compressor x Housing bracket A/C compressor x No.1 oil pan Generator adjusting bar x Drive belt adjusting bar bracket Fuel inlet hose x Fuel filter Main bearing cap x Cylinder block 12 pointed head 1st 2nd 6 pointed head 22 Turn Turn Turn Connecting rod cap x Connecting rod 1st 2nd 24.5 Turn Turn Turn 90 Rear oil seal retainer x Cylinder block in. lbf EGR cooler x Cylinder block in. lbf Engine coolant drain union x Cylinder block Water seal plate x Cylinder block Oil filter union x Cylinder block Water inlet housing x Cylinder block in. lbf Knock sensor x Cylinder block No.2 idler pulley bracket x Cylinder block A/C compressor housing bracket x Cylinder block Generator bracket x Cylinder block Front exhaust pipe support bracket x No.1 oil pan Front exhaust pipe x Exhaust manifold Front exhaust pipe x Center exhaust pipe Center exhaust pipe x Tailpipe Front exhaust pipe bracket x Sub frame Front exhaust pipe support bracket x Front exhaust pipe stay

10 SS10 EMISSION CONTROL SERVICE DATA EMISSION CONTROL SS03M01 EGR valve position sensor Resistance (VC E2) Power source voltage (VC E2) Power output voltage (EGLS E2) at vacuum (17.3 kpa, 130 mmhg, 5.1 in.hg) at no vacuum kω V V V 122

11 EMISSION CONTROL SS11 TORQUE SPECIFICATION SS03N01 Part tightened N m kgf cm ft lbf EGR valve position sensor x EGR valve in. lbf EGR pipe x EGR valve EGR pipe x EGR cooler EGR valve x Air intake chamber EGR gas temperature sensor x EGR valve Front exhaust pipe x Exhaust manifold Front exhaust pipe x Center exhaust pipe Front exhaust pipe bracket x Sub frame Front exhaust pipe support bracket x Front exhaust pipe stay

12 SS12 SEQUENTIAL MULTIPORT FUEL INJECTION SERVICE DATA SFI SS03O01 Fuel pressure regulator Fuel pressure at no vacuum kpa ( kgf/cm 2, psi) Fuel pump Resistance at 20 C (68 F) Ω Injector Resistance Injection volume Difference between each cylinder Fuel leakage Ω cm 3 ( cu in.) per 15 sec. 13 cm 3 (0.8 cu in.) or less 1 drop or less per minute MAF meter Resistance (THA E2) at 20 C (4 F) at 20 C (68 F) at 60 C (140 F) kω kω kω Throttle body Throttle opener setting speed 900 1,950 rpm Throttle position sensor Resistance Throttle valve fully closed VTA E2 Throttle valve fully open VTA E2 VC E kω kω kω IAC valve Resistance (+B RSO or RSC) at cold at hot Ω Ω VSV for EGR Resistance at 20 C (68 F) Ω VSV for EVAP Resistance at 20 C (68 F) Ω VSV for ACIS Resistance at 20 C (68 F) Ω VSV for Vapor Pressure Sensor Resistance at 20 C (68 F) Ω Vapor Pressure Sensor Power source voltage V ECT sensor Resistance at 20 C (4 F) at 0 C (32 F) at 20 C (68 F) at 40 C (104 F) at 60 C (140 F) at 80 C (176 F) kω 4 7 kω 2 3 kω kω kω kω EGR gas Resistance at 50 C (122 F) kω temperature at 100 C (212 F) kω sensor at 150 C (302 F) 2 4 kω Air fuel ratio (A/F) sensor Heated oxygen sensor Heater coil resistance at 20 C (68 F) Ω Heater coil resistance at 20 C (68 F) Ω Fuel cut rpm Fuel return rpm 1,200 rpm 124

13 SFI SS13 TORQUE SPECIFICATION SS03P01 Part tightened N m kgf cm ft lbf Fuel line (Union bolt type) Fuel line (Flare nut type) using SST Fuel pump assembly x Fuel tank in. lbf Fuel filter x Fuel pump bracket in. lbf Fuel pressure regulator x Fuel pump bracket in. lbf Delivery pipe x Intake manifold No.1 fuel pipe x Intake manifold Fuel tank band x Body Throttle body x Air intake chamber Intake air control valve x Air intake chamber ECT sensor x Water outlet Knock sensor x Cylinder block Airfuel ratio (A/F) sensor (Bank 1, 2 sensor 1) x Exhaust manifold Heated oxygen sensor (Bank 1, 2 sensor 1) x Exhaust manifold Heated oxygen sensor (Bank 1 sensor 2) x Exhaust pipe

14 SS14 COOLING COOLING SERVICE DATA SS03Q01 Thermostat Valve opening pressure Valve lift at 95 C (203 F) C ( F) 10.0 mm (0.394 in.) or more Radiator cap Relief valve opening pressure STD Minimum kpa ( kgf/cm 2, psi) 69 kpa (0.7 kgf/cm 2, 10.0 psi) Radiator Plate height mm ( in.) Cooling fan Rotating amperage at 20 C (68 F) No.1 No A A 126

15 COOLING SS15 TORQUE SPECIFICATION SS03R01 Part tightened N m kgf cm ft lbf RH engine drain plug x EGR cooler in. lbf LH engine drain plug x Union on cylinder block Water pump x Cylinder block in. lbf Water inlet x Water inlet housing in. lbf Water inlet pipe x LH cylinder head Radiator support x Body No.1 cooling fan shroud x Radiator in. lbf No.2 cooling fan shroud x Radiator in. lbf Radiator oil cooler x Radiator lower tank in. lbf Radiator inlet pipe x Radiator lower tank

16 SS16 LUBRICATION SERVICE DATA LUBRICATION SS03S01 Oil pressure at idle speed at 3,000 rpm 29 kpa (0.3 kgf/cm 2, 43 psi) or more kpa ( kgf/cm 2, psi) Oil pump Side clearance STD Body clearance STD Tip clearance STD mm ( in.) 0.15 mm ( in.) mm ( in.) 0.30 mm ( in.) mm ( in.) 0.35 mm ( in.) 128

17 LUBRICATION SS17 TORQUE SPECIFICATION SS03T01 Part tightened N m kgf cm ft lbf Oil pressure switch x Cylinder block No.2 oil pan x Drain plug Oil pump x Relief valve plug Oil pump x Cylinder block 10 mm head 12 mm head in. lbf 14 Crankshaft position sensor x Oil pump in. lbf Oil pan baffle plate x No.1 oil pan in. lbf No.1 oil pan x Cylinder block No.1 oil pan x Oil pump 10 mm head 12 mm head in. lbf 14 No.1 oil pan x Rear oil seal retainer in. lbf No.1 oil pan x Transaxle Oil strainer x Main bearing cap in. lbf Oil strainer x Oil pump in. lbf No.2 oil pan x No.1 oil pan in. lbf Oil level sensor x No.1 oil pan in. lbf Flywheel housing under cover x Transaxle in. lbf A/C compressor housing bracket x Cylinder block PS pump x PS pump bracket PS pump drive belt adjusting strut x PS pump PS pump drive belt adjusting strut x Oil pump Exhaust pipe bracket x No.1 oil pan

18 SS18 IGNITION IGNITION SERVICE DATA SS03U06 Firing order Spark plug Recommended spark plug DENSO NGK Correct electrode gap for new plug electrode gap for used plug Ignition coil Primary coil resistance at cold at hot Secondary coil resistance at cold at hot PK20TR11 BKR6EKPB mm (0.043 in.) 1.3 mm (0.051 in.) Ω Ω kω kω Camshaft position sensor Resistance at cold at hot 835 1,400 Ω 1,060 1,645 Ω Crankshaft position sensor Resistance at cold at hot 1,630 2,740 Ω 2,065 3,225 Ω 130

19 IGNITION SS19 TORQUE SPECIFICATION SS03V01 Part tightened N m kgf cm ft lbf Spark plug x Cylinder head Ignition coil x Cylinder head in. lbf Camshaft position sensor x Cylinder head in. lbf Crankshaft position sensor x Oil pump in. lbf 131

20 SS20 STARTING SERVICE DATA STARTING SS03W01 Starter Rated voltage and output power Noload characteristics Brush length Spring installed load Commutator Diameter Undercut depth Circle runout Magnetic switch Contact plate for wear Current rpm STD Minimum STD Minimum STD Minimum STD Minimum 12 V 1.4 kw 90 A or less at 11.5 V 3,000 rpm or more 15.5 mm (0.610 in.) 10.0 mm (0.394 in.) N ( kgf, lbf) 11.8 N (1.2 kgf, 2.6 lbf) 30.0 mm (1.181 in.) 29.0 mm (1.142 in.) 0.6 mm (0.024 in.) 0.2 mm (0.008 in.) 0.05 mm ( in.) 0.9 mm (0.035 in.) 132

21 STARTING SS21 TORQUE SPECIFICATION SS03X01 Part tightened N m kgf cm ft lbf Starter mounting bolt End cover x Field frame in. lbf Starter housing x Magnetic switch in. lbf Field frame x Armature assembly in. lbf Lead wire x Terminal C of starter in. lbf Terminal nut x Terminal C of starter Terminal nut x Terminal 30 of starter Magnetic switch end cover x Magnetic switch in. lbf 133

22 SS22 CHARGING SERVICE DATA CHARGING SS03Y03 Battery Voltage at 20 C (68 F) V Drive belt Generator Voltage regulator Tension New belt Used belt Rated output Rotor coil resistance Slip ring diameter Brush exposed length Regulating voltage at 20 C (68 F) STD Limit STD Limit 175 ± 5 lbf 115 ± 20 lbf 12 V 80 A Ω mm ( in.) 12.8 mm (0.504 in.) 10.5 mm (0.413 in.) 1.5 mm (0.059 in.) V 134

23 CHARGING SS23 TORQUE SPECIFICATION SS03Z01 Part tightened N m kgf cm ft lbf Bearing retainer x Drive end frame in. lbf Rectifier end frame x Drive end frame in. lbf Cord clip x Rectifier end frame in. lbf Generator pulley x Rotor , Rectifier holder x Coil lead on rectifier end frame in. lbf Voltage regulator and brush holder x Rectifier end frame in. lbf Plate terminal x Rectifier holder Nut Screw in. lbf 35 in. lbf Rear end cover x Rectifier holder in. lbf Terminal insulator x Rectifier holder in. lbf Generator x Generator bracket Generator x Adjusting bar

24 SS24 AUTOMATIC TRANSAXLE SERVICE DATA AUTOMATIC TRANSAXLE SS05X02 Line pressure (wheel locked) Engine idling D position R position at stall (Throttle valve fully opened) D position R position Engine stall revolution kpa ( kgf/cm 2, psi) kpa ( kgf/cm 2, psi) 1,138 1,236 kpa ( kgf/cm 2, psi) 1,716 1,854 kpa ( kgf/cm 2, psi) 2,600 ± 150 rpm Time lag Engine idle speed (A/C OFF) N D position N R position N position Less than 1.2 seconds Less than 1.5 seconds 700 ± 50 rpm Throttle cable adjustment (Throttle valve fully opened) Drive plate runout Torque converter clutch runout Torque converter clutch installation distance Max. Max. Between boot and face and inner cable stopper 0 1 mm ( in.) 0.3 mm ( in.) 0.20 mm ( in.) More than 13.7 mm (0.539 in.) Lockup point (Throttle valve opening 5%) 3rd gear (O/D main switch OFF) Lockup ON Lockup OFF O/D gear Lockup ON Lockup OFF Shift schedule D position (Throttle valve fully opened) O/D O/D (Throttle valve fully closed) 3 O/D O/D 3 2 position (Throttle valve fully opened) L position (Throttle valve fully opened) km/h (37 40 mph) km/h (33 35 mph) km/h (37 40 mph) km/h (33 35 mph) km/h (37 41 mph) km/h (70 75 mph) km/h ( mph) km/h ( mph) km/h (65 70 mph) km/h (31 34 mph) km/h (22 24 mph) km/h (12 15 mph) km/h (37 41 mph) km/h (76 81 mph) km/h (31 34 mph) km/h (66 71 mph) km/h (34 37 mph) 136

25 AUTOMATIC TRANSAXLE SS25 TORQUE SPECIFICATION SS05Y02 Part tightened N m kgf cm ft lbf Front engine front mounting insulator x Front frame assembly Rear engine mounting insulator x Front frame assembly LH transaxle mounting insulator x Transaxle Engine mounting absorber x Front frame assembly Transaxle x Engine 17 mm bolt Transaxle x Engine 12 mm bolt Torque converter clutch x Drive plate Valve body x Transaxle case Oil strainer x Valve body Oil pan x Transaxle case in. lbf Oil pan drain plug Park/Neutral position switch x Transaxle case (bolt) in. lbf Park/Neutral position switch (nut) in. lbf B 3 apply pipe retainer Manual valve body x Transaxle case Detent spring x Manual valve body Oil pipe bracket Steering gear housing x Front suspension member 181 1, Stabilizer bar bracket Vehicle speed sensor x Transaxle case Direct clutch speed sensor x Transaxle case in. lbf Transfer lubrication apply pipe retainer Exhaust manifold bracket x Transaxle case Front frame x Body 19 mm 181 1, Front frame x Body 14 mm Front frame x Body Nut Exhaust front pipe x Exhaust center pipe Exhaust manifold x Exhaust front pipe Exhaust front pipe support stay x Exhaust front pipe support bracket Exhaust pipe support x Front frame Starter x Torque converter clutch housing Throttle cable adjusting nut Drive plate x Crankshaft Shift control cable x Transaxle control shaft lever Shift solenoid valve No.1, No.2, SL, SLN x Valve body in. lbf Front wheel nut 103 1, Exhaust front pipe support bracket x Body Steering return pipe x Front frame

26 SS26 SUSPENSION AND AXLE SUSPENSION AND AXLE SERVICE DATA SS05P05 Cold tire inflation Pressure Front wheel alignment Rear wheel alignment Front axle Front drive shaft 180 kpa (1.8 kgf/cm 2 or bar, 26 psi) Tire size P205/65R15 92H Front* 1 Rear* kpa (1.8 kgf/cm 2 or bar, 26 psi) Front* kpa (2.2 kgf/cm 2 or bar, 32 psi) Rear* kpa (2.2 kgf/cm 2 or bar, 32 psi) Vehicle height Front* mm (8.39 in.) Rear* mm (10.20 in.) Camber Caster Steering axis inclination Toein (total) Wheel angle Camber Toein (total) Axle bearing backlash Axle hub deviation Drive shaft standard length Leftright error Leftright error Leftright error Tie rod end length difference Inside wheel Outside wheel Leftright error No.2 lower suspension arm length difference LH RH 0 37 ± 45 (0.62 ± 0.75 ) 45 (0.75 ) or less 2 18 ± 45 (2.30 ± 0.75 ) 45 (0.75 ) or less ± 45 (13.07 ± 0.75 ) 45 (0.75 ) or less 0 ± 12 (0 ± 0.2, 0 ± 2 mm, 0 ± 0.08 in.) 1.5 mm (0.059 in.) or less ± ± 45 (0.80 ± 0.75 ) 45 (0.75 ) or less 0 24 ± 12 (0.4 ± 0.2, 4 ± 2 mm, 0.16 ± 0.08 in.) 1.0 mm (0.04 in.) or less 0.05 mm ( in.) or less 0.05 mm ( in.) or less ± 2.0 mm ( ± in.) ± 2.0 mm ( ± in.) Front Lower ball joint turning torque N m (10 35 kgf cm, in. lbf) suspension Stabilizer bar link turning torque N m ( kgf cm, in. lbf) Rear axle Axle bearing backlash Axle hub deviation 0.05 mm ( in.) or less 0.07 mm ( in.) or less Rear No.2 lower suspension arm length mm ( in.) suspension Stabilizer bar link turning torque N m ( kgf cm, in. lbf) * 1 : For all load including full rated loads * 2 : For reduced loads (1 to 4 passengers) * 3 : Measure from the ground to the center of the front side lower suspension arm mounting bolt. * 4 : Measure from the ground to the center of the front side strut rod mounting bolt. 138

27 SUSPENSION AND AXLE SS27 TORQUE SPECIFICATION SS05Q04 Part tightened N m kgf cm ft lbf FRONT Hub nut 103 1, Tie rod end lock nut Steering knuckle x Shock absorber 211 2, Steering knuckle x Brake caliper 107 1, Steering knuckle x Tie rod end Axle hub x Drive shaft 294 3, Lower ball joint x Lower suspension arm 127 1, Lower ball joint x Steering knuckle 123 1, Steering knuckle x Disc brake dust cover in. lbf Drive shaft center bearing lock bolt Inboard joint shaft x Outboard joint shaft Shock absorber cap x Suspension support Suspension support x Body Suspension support x Piston rod 49 (36) 500 (365) 36 (26) ABS speed sensor set bolt in. lbf Flexible hose x Shock absorber ABS speed sensor wire harness x Shock absorber Lower suspension arm set bolt 206 2, Stabilizer bar bracket x Suspension member Stabilizer bar link set nut ( ): For use with SST 139

28 SS28 SUSPENSION AND AXLE Part tightened N m kgf cm ft lbf REAR Hub bolt 103 1, No.2 lower suspension arm lock nut Brake caliper x Rear axle carrier Axle hub bearing set bolt Shock absorber x Axle carrier New nut Reused nut (apply engine oil the threads) ,600 2, Flexible hose x Shock absorber ABS speed sensor set bolt in. lbf ABS speed sensor wire harness x Shock absorber in. lbf Rear seatback set bolt Rear seat belt set bolt Suspension support x Body Suspension support x Piston rod 49 (36) 500 (365) 36 (26) Parking brake cable set bolt Lower suspension arm x Suspension member 181 1, Lower suspension arm x Rear axle carrier 181 1, Strut rod x Body 113 1, Strut rod x Rear axle carrier 113 1, Suspension member x Body Suspension member lower stopper subassembly x Body Stabilizer bar bracket x Suspension member Stabilizer bar link set nut ( ): For use with SST 140

29 BRAKE SS29 BRAKE SERVICE DATA SS06214 Brake pedal height (from asphalt sheet) mm ( in.) Brake pedal freeplay 1 6 mm ( in.) Brake pedal reserve distance at 490 N (50 kgf, lbf) Brake booster push rod to piston clearance (w/ SST) More than 70 mm (2.76 in.) 0 mm (0 in.) Front brake pad thickness STD 11.0 mm (0.433 in.) Front brake pad thickness Minimum 1.0 mm (0.039 in.) Front brake disc thickness STD 28.0 mm (1.102 in.) Front brake disc thickness Minimum 26.0 mm (1.024 in.) Front brake disc runout 0.05 mm ( in.) Rear brake pad thickness STD 10.0 mm (0.394 in.) Rear brake pad thickness Minimum 1.0 mm (0.039 in.) Rear brake disc thickness STD 10.0 mm (0.394 in.) Rear brake disc thickness Minimum 9.0 mm (0.354 in.) Rear brake disc runout 0.15 mm ( in.) Rear brake disc inside diameter STD 170 mm (6.69 in.) Rear brake disc inside diameter 171 mm (6.73 in.) Parking brake lining thickness STD 2.0 mm (0.079 in.) Parking brake lining thickness Minimum 1.0 mm (0.039 in.) Parking brake pedal travel at 294 N (30 kgf, 66 lbf) Parking brake clearance between rear shoe and lever Parking brake adjusting shim thickness for rear disc brake 3 6 clicks Less than 0.35 mm ( in.) 0.3 mm (0.012 in.) 0.6 mm (0.024 in.) 0.9 mm (0.035 in.) 141

30 SS30 BRAKE TORQUE SPECIFICATION SS06301 Part tightened N m kgf cm ft lbf Master cylinder x Piston stopper bolt Master cylinder x Reservoir in. lbf Master cylinder x Brake booster Brake line union nut 10 mm nut mm nut Brake booster clevis lock nut Brake booster x Pedal bracket Front brake caliper installation bolt Bleeder plug in. lbf Front disc brake torque plate x Steering knuckle 107 1, Front disc brake caliper x Flexible hose Flexible hose x Shock absorber Rear disc brake caliper installation bolt Rear disc brake cariper main pin installation bolt Rear disc brake caliper x Flexible hose Rear disc brake torque plate x Rear axle carrier Parking brake pedal assembly x Body ABS (& TRAC) actuator x Actuator bracket in. lbf ABS (& TRAC) actuator bracket x Body Front speed sensor installation bolt in. lbf Front speed sensor harness clamp bolt in. lbf Rear speed sensor installation bolt in. lbf Rear speed sensor harness clamp bolt in. lbf 142

31 STEERING SS31 STEERING SERVICE DATA SS05R01 ONVEHICLE INSPECTION Steering wheel freeplay 30 mm (1.18 in.) Drive belt tension New belt lbf Drive belt tension Used belt lbf Fluid level rise 5 mm (0.20 in.) Fluid pressure at idle speed with valve closed Minimum 7,845 kpa (80 kgf/cm 2, 1,138 psi) Steering effort at idle speed 5.9 N m (60 kgf cm, 52 in. lbf) PS VANE PUMP Vane pump rotating torque 0.3 N m (2.8 kgf cm, 2.4 in. lbf) Oil clearance between pump shaft and bushing STD mm ( in.) Oil clearance between pump shaft and bushing 0.07 mm ( in.) Vane plate height Minimum 8.6 mm (0.339 in.) Vane plate thickness Minimum mm ( in.) Vane plate length Minimum mm ( in.) Clearance between the rotor groove and plate mm ( in.) Vane plate length Pump rotor and cam ring mark NONE mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) Spring free length Minimum 32.3 mm (1.272 in.) PS GEAR Steering rack runout 0.30 mm ( in.) Total preload (Control valve rotating torque) N m (8 14 kgf cm, in. lbf) 143

32 SS32 STEERING TORQUE SPECIFICATION SS05S01 Part tightened N m kgf cm ft lbf STEERING COLUMN Steering wheel pad set screw (Torx screw) in. lbf Steering wheel set nut Intermediate shaft assembly x Control valve shaft Steering column assembly x Intermediate shaft assembly Steering column assembly set nut Turn signal bracket x Column tube in. lbf Lower column tube attachment x Column tube PS VANE PUMP Pressure feed tube x Pressure feed tube 20 (25) 203 (250) 15 (18) Clamp plate set nut in. lbf Pump assembly set bolt A bolt 29 (43) 293 (440) 21 (32) Pump assembly set bolt B bolt Oil pressure switch x Union bolt Union bolt x Pressure feed tube Vane pump pulley set nut Front bracket x Rear bracket Suction port union set bolt Pressure port union Rear housing set bolt PS GEAR Pressure feed clamp plate set nut Pressure feed and return tubes x Control valve housing 32 (25) 326 (250) 24 (18) Stabilizer bar set bolt PS gear assembly set bolt and nut 181 1, Turn pressure tube union nut 10 (13) 102 (130) 7 (9) Tie rod end lock nut Rack x Rack end 60 (83) 615 (850) 45 (62) Rack guide spring cap lock nut 50 (69) 513 (700) 37 (51) Rack housing cap Seltlocking nut Control valve housing set bolt ( ): For use without SST 144

33 SUPPLEMENTAL RESTRAINT SYSTEM TORQUE SPECIFICATION SUPPLEMENTAL RESTRAINT SYSTEM SS33 SS06140 Part tightened N m kgf cm ft lbf Steering wheel Steering wheel pad in. lbf Front passenger airbag assembly x Instrument panel Airbag sensor assembly

34 SS34 BODY ELECTRICAL SERVICE DATA BODY ELECTRICAL SS05U10 INTEGRATION RELAY (Relay Circuit) (Junction Block Side) 1 Ground (Constant) Battery positive voltage 7 Ground (Ignition switch LOCK or ACC) No voltage 7 Ground (Ignition switch ON) Battery positive voltage 9 Ground (Ignition switch LOCK or ACC) No voltage 9 Ground (Ignition switch ON) Battery positive voltage 11 Ground (Ignition switch LOCK) No voltage 11 Ground (Ignition switch ACC or ON) Battery positive voltage (Wire Harness Side) A1 Ground (Constant) B1 Ground (Light control switch OFF) B1 Ground (Light control switch TAIL or HEAD) B4 Ground (Light control switch OFF or TAIL) B4 Ground (Light control switch HEAD) B2 Ground (Constant) B3 Ground (Constant) Battery positive voltage No voltage Battery positive voltage No voltage Battery positive voltage Battery positive voltage Battery positive voltage DAYTIME RUNNING LIGHT RELAY (MAIN) (Wire Harness Side) 1 Ground (Ignition switch position LOCK or ACC) No voltage 1 Ground (Ignition switch position ON or START) Battery positive voltage 5 Ground (Engine Running) No voltage 5 Ground (Engine Stop) Battery positive voltage 7 Ground (Constant) Battery positive voltage 9 Ground (Constant) Battery positive voltage AUTOMATIC LIGHT CONTROL SENSOR (Connector disconnected) 1 Ground (Ignition switch position LOCK or ACC) No voltage 1 Ground (Ignition switch position ON) Battery positive voltage 2 Ground (Constant) Battery positive voltage (Connector connected) 1 Ground (Ignition switch position ON) 10 V or more 1 Ground (Ignition switch position OFF) 1 V or less 3 Ground (Door courtesy switch ON) 1 V or less 3 Ground (Door courtesy switch OFF) 9 V or more 5 Ground (Vehicle s surroundings are dark) 1.8 V or less 5 Ground (Dimmer switch position Flash) 0.3 V or less 6 Ground (Vehicle s surroundings are dark) 1.5 V or less 8 Ground (Vehicle s is under the direct sun light) (Sensor is not covered) 8 Ground (Vehicle s surroundings are dim) (Sensor is covered and taillights are ON) 8 Ground (Vehicle s surroundings are dark) (Sensor is covered and headlights are ON) 3.7 V or more V 0.42 V 146

35 BODY ELECTRICAL SS35 TURN SIGNAL FLASHER Flashes/ Minute LIGHT FAILURE RELAY (Wire Harness Side) 3 Ground (Light control switch OFF) No voltage 3 Ground (Light control switch TAIL or HEAD) Battery positive voltage 4 Ground (Ignition switch LOCK or ACC) No voltage 4 Ground (Ignition switch ON) Battery positive voltage 7 Ground (Stop light switch OFF) No voltage 7 Ground (Stop light switch ON) Battery positive voltage 8 Ground (Ignition switch LOCK or ACC) No voltage 8 Ground (Ignition switch ON) Battery positive voltage SPEEDOMETER (ONVEHICLE) USA: Standard indication (mph) Allowable range (mph) CANADA: Standard indication (km/h) Allowable range (km/h) TACHOMETER (ONVEHICLE)/ DC 13.5 V 25 C at (77 F) Standard indication Allowable range , ,100 2,000 1,850 2,150 3,000 2,800 3,200 4,000 3,800 4,200 5,000 4,800 5,200 6,000 5,750 6,250 7,000 6,700 7,300 FUEL RECEIVER GAUGE A B Approx Ω A C Approx Ω B C Approx Ω 147

36 SS36 BODY ELECTRICAL FUEL SENDER GAUGE Float position mm (in.) Resistance (Ω) F: Approx (3.587) Approx /2: Approx (1.346) Approx E: Approx (1.213) Approx ENGINE COOLANT TEMPERATURE RECEIVER GAUGE (Resistance) A B A C B C Approx Ω Approx Ω Approx Ω ENGINE COOLANT TEMPERATURE SENDER GAUGE (Resistance) Temperature C ( F) Resistance (Ω) 50 (122.0) (248.0) SLIDING ROOF CONTROL RELAY AND SWITCH (Wire Harness Side) 4 Ground (Ignition switch LOCK or ACC) * No voltage 4 Ground (Ignition switch ON) Battery positive voltage *: Exceptions: For 60 seconds after the ignition switch ON OFF (ACC) or until driver or passenger door is opened after the ignition switch ON OFF (ACC). 148

37 BODY SS37 BODY TORQUE SPECIFICATION SS05T05 Part tightened N m kgf cm ft lbf FRONT BUMPER Reinforcement x Body REAR BUMPER Reinforcement x Body HOOD Hood x Hood hinge HOOD SUPPORT Hood support x Hood Hood support x Body HOOD LOCK CONTROL Hood lock x Body (A bolt) in. lbf Hood lock x Body (B bolt) FRONT DOOR Upper stop x Door panel Window regulator x Door panel in. lbf Window guide lower plate x Window regulator in. lbf Door glass guide x Door panel in. lbf Door lock x Door panel in. lbf Outside handle x Door panel in. lbf Door hinge x Body Door hinge x Door REAR DOOR Upper stop x Door panel Rear window guide x Door panel in. lbf Front window guide x Door panel in. lbf Window regulator x Door panel in. lbf Window guide lower plate x Window regulator in. lbf Door lock x Door panel in. lbf Outside handle x Door panel in. lbf Door hinge x Body Door hinge x Door FUEL LID Fuel lid lock assembly x Body in. lbf Fuel lid opening lid lock retainer x Fuel filler opening lid in. lbf OUTSIDE REAR VIEW MIRROR Outside rear view mirror x Door panel in. lbf LUGGAGE COMPARTMENT DOOR AND HINGE Luggage compartment door x Luggage compartment door hinge in. lbf Door lock striker x Body in. lbf Door lock x Door panel in. lbf Door lock cylinder x Door panel in. lbf 149

38 SS38 BODY Part tightened N m kgf cm ft lbf FRONT WIPER AND WASHER Wiper link assembly x Body in. lbf Wiper arm and blade x Wiper link assembly INSTRUMENT PANEL Front passenger airbag assembly x Reinforcement Steering wheel set nut FRONT SEAT Seat adjuster x Body REAR SEAT Seatback pad with frame x Body SEAT BELT Front Seat Belt Shoulder anchor x Adjustable anchor Floor anchor x Body Retractor x Body (Upper bolt) in. lbf Retractor x Body (Lower bolt) Inner belt x Seat Rear Seat Belt Floor anchor x Body Retractor x Body Inner belt x Seat Inner with center belt

39 AIR CONDITIONING SS39 AIR CONDITIONING SERVICE DATA SS05V01 Refrigerant charge volume 800 ± 50 g (28.22 ± 1.76 oz.) Drive belt tension New belt 165 ± 26 lbf Used belt 110 ± 11 lbf Idleup speed Magnetic clutch not engaged 700 ± 50 rpm Magnetic clutch engaged 700 ± 50 rpm Magnetic clutch clearance 0.5 ± 0.15 mm (0.020 ± in.) 151

40 SS40 AIR CONDITIONING TORQUE SPECIFICATION SS05W10 Part tightened N m kgf cm ft lbf Compressor x Discharge hose Compressor x Suction hose Condenser x Disaharge hose Condenser x Liquid tube Receiver x Liquid tube in. lbf A/C unit x Liquid tube and suction tube Expansion valve x Evaporator in. lbf Compressor x Engine Compressor x Compressor bracket Drive belt adjusting bar bracket x Compressor Drive belt adjusting bar bracket x Adjusting bar Pivot bolt Adjusting lock bolt Pressure switch x Liquied tube Pressure plate x Compressor Suction line (Piping joint) Suction line (Block joint) Liquid line (Block joint)