SERVICE SPECIFICATIONS

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1 TO INDEX SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS STANDARD BOLT HOW TO DETERMINE BOLT STRENGTH SPECIFIED TORQUE FOR STANDARD BOLTS HOW TO DETERMINE NUT STRENGTH LUBRICANTS AND COOLANTS SPECIFIED LUBRICANTS AND CAPACITY REFERENCE VALUES FOR PERIODIC MAINTENANCE ENGINE APPARATUS FOR PREVENTING RELEASE OF HARMFUL GASES SUCH AS FUMES AND ODOROUS GASES SUSPENSION DRIVING APPARATUS BRAKE APPARATUS STEERING MECHANISM OPERATION SETTING WHEN DISCONNECTING AND RECON- NECTING NEGATIVE BATTERY TERMINAL SERVICE OPERATION SETTINGS WHEN INSTALLING, REMOVING AND REPLACING PARTS SERVICE

2 1 SERVICE SPECIFICATIONS - STANDARD BOLT STANDARD BOLT SERVICE SPECIFICATIONS HOW TO DETERMINE BOLT STRENGTH Bolt Types Hexagonal Bolt Normal Recess Bolt Deep Recess Bolt Stud Bolt Welded Bolt Class No Mark No Mark No Mark w/ Washer w/ Washer D025089J01

3 SERVICE SPECIFICATIONS - STANDARD BOLT 2 SPECIFIED TORQUE FOR STANDARD BOLTS 1. SPECIFIED TORQUE The torque values listed below are the specifications for tightening unlubricated zinc-plated bolts. Class Diameter (mm) Pitch (mm) Specified Torque (Hexagon Head Bolt) (N*m [kgf*cm]) Hexagon Flange Bolt (N*m [kgf*cm]) 4T {55} 6{60} {130} 14{145} {260} 29{290} {480} 53{540} {760} 84{850} {1150} 127{1300} 5T {65} 7.5{75} {160} 17.5{175} {330} 36{360} {600} 65{670} {930} 100{1050} {1400} 157{1600} 6T {80} 9{90} {195} 21{210} {400} 44{440} {730} 80{810} {1100} 125{1250} {1750} 191{1950} 7T {110} 12{120} {260} 28{290} {530} 58{590} {970} 105{1050} {1500} 165{1700} {2300} 255{2600} 8T {125} 14{145} {300} 33{330} {620} 68{690} {1100} 120{1250} {1750} 195{2000} {2700} 299{3050} 9T {340} 37{380} {710} 78{790} {1300} 140{1450} 10T {390} 42{430} {800} 88{890} {1450} 155{1600} 11T {430} 47{480} {890} 97{990}

4 3 SERVICE SPECIFICATIONS - STANDARD BOLT Class Diameter (mm) Pitch (mm) Specified Torque (Hexagon Head Bolt) (N*m [kgf*cm]) Hexagon Flange Bolt (N*m [kgf*cm]) {1600} 175{1800}

5 SERVICE SPECIFICATIONS - STANDARD BOLT 4 HOW TO DETERMINE NUT STRENGTH Standard Hexagonal Bolt Nut Types Old Standard Hexagon Nut Cold Forged Nut Cutting Processed Nut Class No Mark No Mark (w/ Washer ) No Mark (w/ Washer) No Mark No Mark More than one mark on the back of the nut D025090J01 When replacing a nut, use a nut with a nut strength classification that is equal or higher than the strength classification number of the opposing bolt. (Example: Bolt = 4 T, Nut = 4 N or more)

6 5 SERVICE SPECIFICATIONS - LUBRICANTS AND COOLANTS LUBRICANTS AND COOLANTS SERVICE SPECIFICATIONS SPECIFIED LUBRICANTS AND CAPAC- ITY 1. ENGINE OIL Engine oil viscosity chart C TEMP. F Engin oil (4 stroke) 5W-20* 0W-20* 10W-30,10W-40,10W-50 20W-40,20W-50 5W-30 * Standard recommended oil 30 D Engine Model Oil Only Replacement Filling Volume (L) Oil and Oil Filter Filling Volume When Replacing (L) 3SZ-VE K3-VE The filling volume when replacing the oil or the oil filer is the amount of oil that is drained from the drain plug. NOTICE: Based on the table, use an oil with a viscosity that is best suited to the air temperature. Close the drain plug after confirming that the old oil has been sufficiently drained. With an oil level gauge, always perform a final check of the amount of oil. (After warming up the engine, with the engine stopped and after it has been allowed to idle for 5 minutes, check that the amount of oil is at the F level of the gauge.) 2. LUBRICANTS AND COOLANTS OTHER THAN ENGINE OIL Item (Type) Capacity (L) (Reference) Specified Lubricant Coolant (3SZ-VE) M/T: 4.6 Ethylene glycol based anti-freeze solution A/T: 4.4 Coolant (K3-VE) M/T: 4.3 A/T: 4.2 Automatic transmission fluid (Transmission) 4.6 DEXRON-III Transfer oil (Four wheel drive vehicles with automatic transmission) 1.6 Manual Transmission Gear Oil (API GL-3 or GL-4, SAE 75W-90, 75W-85 or 75W-80) Manual transmission oil (FR vehicle) 1.2 Manual transmission oil (4WD) 2.2 (Including transfer) Front differential oil 0.45 Rear differential oil (excluding vehicles equipped with limited slip differential) Rear differential oil (Vehicles equipped with limited slip differential) Differential Gear Oil (API GL-5, SAE 80W-90) Limited Slip Differential Gear Oil (API GL-5, SAE 80W-90) Power steering fluid 0.7 DEXRON-III Brake fluid - FMV116 DOT3 or DOT4 Clutch fluid - A/C compressor oil - ND-OIL8

7 SERVICE SPECIFICATIONS - REFERENCE VALUES FOR PERIODIC MAINTENANCE REFERENCE VALUES FOR PERIODIC MAINTENANCE SERVICE SPECIFICATIONS ENGINE 6 1. ENGINE-RELATED Item 3SZ-VE K3-VE W/P pulley and P/S pump belt deflection (thrust force 100 N [10.2 kgf]) (mm): when installing new parts (when cold) 9-11 W/P pulley and P/S pump belt deflection (thrust force 100 N [10.2 kgf]) (mm): for maintenance (when cold) W/P pulley and P/S pump belt tension (N [kgf]): when installing new parts (when cold) {90 5} {65 5} W/P pulley and P/S pump belt tension (N [kgf]): for maintenance (when cold) {45 10} Battery fluid specific gravity (fluid temperature 20 C [68 F]): specified values Battery fluid specific gravity (fluid temperature 20 C [68 F]): difference between cells Below 0.04 Ignition timing (BTDC)/(r/min): EFI-T short circuit (*1) 4-8/ Ignition timing (BTDC)/(r/min): EFI-T open circuit (*1) 0-15/ Ignition timing (using the DS-II): TC terminal ON BTDC 4-8CA Ignition timing (using the DS-II): TC terminal OFF BTDC 0-15CA Idle speed (N and P range) (r/min) IN valve clearance (when cold) (mm) EX valve clearance (when cold) (mm) Tightening torque [N*m{kgf*cm} ] Check is unnecessary due to tightening of plasticity area Intake manifold tightening torque (N*m [kgf*cm]) 19{194} Exhaust manifold tightening torque [N*m{kgf*cm}] 35{357} Compression pressure (330 r/min) (MPa [kgf/cm 2 ]): standard value 1.47{15.0} Compression pressure (330 r/min) (MPa [kgf/cm 2 ]): limit 1.08{11.0} Compression pressure (330 r/min) (MPa [kgf/cm 2 ]): difference between cylinders 0.15 (1.5) or below Spark plug gap (mm): specified values (*2) Spark plug gap (mm): maximum 1.1 Radiator cap valve opening pressure (kpa[kgf/cm 2 ]): specified values { } Radiator cap valve opening pressure (kpa[kgf/cm 2 ]): maximum 78.5{0.8} (*1): Between terminals EFI-T and E of the DLC (*2): No adjustments required because the iridium plug is used.

8 7 SERVICE SPECIFICATIONS - REFERENCE VALUES FOR PERIODIC MAINTENANCE APPARATUS FOR PREVENTING RELEASE OF HARMFUL GASES SUCH AS FUMES AND ODOROUS GASES 1. EXHAUST GAS PREVENTION-RELATED APPARATUSES Item 3SZ-VE K3-VE Idle CO Concentration (%) Below 0.2 Idle HC Concentration (ppm) Below 200 SUSPENSION 1. FRONT SUSPENSION-RELATED Item J200LG J210LG J211LG J200RG J210RG Front side slip (per 1 m) (mm) 0 5 Front toe-in (mm) 0 2 Front camber (degree) 0 30' 45' Front caster (degree) 4 47' 1 Front steering axis inclination (degree) 12 25' 1 Tire turning angle (vehicles with tire size of 215/65 R16) Tire turning angle (vehicles with tire size of 235/60 R16) Inside 40 32' 2 Outside 34 05' 2 Inside 39 06' ' 2 Outside 33 06' ' 2 DRIVING APPARATUS 1. DRIVING APPARATUS Item J200LG J210LG J211LG J200RG J210RG Looseness of front axle hub (mm) Below 0.05 Looseness of rear axle hub (mm) Below 0.8 Wheel nut tightening torque (N*m[kgf*cm]) 103{1050} Remaining tire groves (mm) 1.6 or more 2. AIR PREURE (a) Same for both general and high speeds Tire Size Front wheels (kpa [kgf/cm 2 ]) Rear wheels (kpa [kgf/cm 2 ]) 215 / 65R16 98S 200{2.0} 235 / 60R16 100H 210{2.1}

9 SERVICE SPECIFICATIONS - REFERENCE VALUES FOR PERIODIC MAINTENANCE BRAKE APPARATUS 8 1. BRAKE-RELATED Item J200LG J210LG J211LG J200RG J210RG Brake pedal free play (without vacuum) (mm) Brake pedal reserve distance (mm) Parking brake pedal release rate (Operating force of 196 N [20 kgf] ) (number of notches) Parking brake engagement: braking force Thickness of rear drum brake shoe lining (mm): maximum Inner diameter of rear brake drum (mm): maximum Thickness of front disc brake pad (mm): maximum Thickness of front disc rotor (mm): maximum Brake engagement (braking force) (*): total of back wheels Brake engagement (braking force) (*): asymmetry in each wheel Brake engagement (braking force) (*): sum total 122 or more (The engine is idling after warmed up, and pedaling force is 294 N [30 kgf]) (*): For vehicles where all front wheels are locked and therefore difficult to measure, presume in such a situation that this conforms with the sum total. STEERING MECHANISM 1. CHAIS-RELATED 4-7 Above 20% of vehicle weight upon inspection 1.0 (Reference: 5.5 for a new product) (Reference: for a new product) 1.0 (Reference: 10.0 for a new product) 15.0 (solid disc) (Reference: 16.0 for a new product) 21.0 (ventilated disc) (Reference: 22.0 for a new product) Over 10% of the axle load Under 8% of the axle load Above 50% of vehicle weight upon inspection

10 9 SERVICE SPECIFICATIONS - REFERENCE VALUES FOR PERIODIC MAINTENANCE Item J200LG J210LG J211LG J200RG J210RG Steering wheel free play (Outer circumference of wheel) (mm) 0-30

11 SERVICE SPECIFICATIONS - OPERATION SETTING WHEN DISCONNECTING AND RECONNECTING NEGATIVE BATTERY TERMINAL 10 OPERATION SERVICE SPECIFICATIONS SETTING WHEN DISCONNECTING AND RECONNECTING NEGATIVE BATTERY TERMINAL SERVICE Work item Initialization of power window system Work procedure 1. Disconnect the negative (-) terminal of the battery or the connector to the power window master switch. 2. After 5 seconds or more has elapsed, connect the negative (-) terminal of the battery or the connector to the power window master switch. 3. Fully open the window of the driver seat door. 4. Make the window of the driver seat door go up and continue to keep the switch in the UP direction for at least 2 seconds even after the window is fully closed. Non-compliant Behavior, Non-working Functions Automatic opening and closing function of the door window Jam protection function Remote operation of each seat with the driver seat switch Remarks Settings are required for the driver seat master switch

12 11 SERVICE SPECIFICATIONS - OPERATION SETTINGS WHEN INSTALLING, REMOVING AND REPLACING PARTS OPERATION SETTINGS WHEN INSTALLING, REMOVING SERVICE SPECIFICATIONS AND REPLACING PARTS SERVICE 1. Replacement Work Replacement Part Automatic transmission assembly Valve body assembly Engine assembly Transmission wire Required Work 1. Automatic transmission learned value initialization Non-compliant Behavior, Nonworking Functions Transmission harsh engagement Remarks Yaw rate sensor 1. Acquire yaw rate sensor and G sensor and master cylinder pressure sensor zero point Slip indicator light comes on Buzzer sounds VSC control prohibition or erroneous operation Actuator assembly (equipped in skid control ECU) 1. Acquire yaw rate sensor and G sensor and master cylinder pressure sensor zero point Slip indicator light comes on Buzzer sounds VSC control prohibition or erroneous operation Master cylinder pressure sensor 1. Acquire yaw rate sensor and G sensor and master cylinder pressure sensor zero point Slip indicator light comes on Buzzer sounds VSC control prohibition or erroneous operation Immobiliser code computer (ID code box) 1. Identification code registration (see the manual for registration method) Wireless functions Engine start Power window master switch assembly Power window regulator motor assembly (driver seat) Front door window regulator (driver seat) 1. Initialization of power window system Automatic opening and closing function of the door window Jam protection function Remote operation of each seat with the driver seat switch Settings are required for the driver seat master switch 2. AUTOMATIC TRANSMIION LEARNED VALUE INITIALIZATION NOTICE: Wait at least 1 minute after connecting the battery terminal before performing the initialization of the automatic transmission learned values. Learned values will not be initialized (erased) by simply disconnecting the negative (-) terminal of the battery. (a) After confirming that the shift position is in the P range, connect the DS-II to the DLC and turn the ignition switch ON and the DS-II power ON. NOTICE: Do not start the engine. (b) Conduct AT learned value initialization (1) To initialize learned values, follow the DS-II screen display, select MAIN MENU [OPERATION SUPPORT] OPERA- TION SUPPORT CLAIFICATION [A/T] [AT LEARNED

13 SERVICE SPECIFICATIONS - OPERATION SETTINGS WHEN INSTALLING, REMOVING AND REPLACING PARTS 12 VALUE INITIALIZATION] and run [AT LEARNED VALUE INITIALIZATION]. Initialization will complete in about 1 minute. 3. ACQUIRE YAW RATE SENSOR AND G SENSOR AND MASTER CYLINDER PREURE SENSOR ZERO POINT NOTICE: Always measure the zero point on a level surface (incline of less than 1%). Do not open or close the doors or shake the vehicle during the operation. Also, do not start the engine to avoid idling vibration. (a) ACTIVATE SENSOR ZERO POINT ACQUISITION MODE (1) Stop the vehicle on a level surface. (2) Turn the ignition switch to the ON position, and press the TRC OFF switch to activate the sensor zero point acquisition mode. The slip indicator turns on and a buzzer will sound at the same time. (b) Acquire zero point for yaw rate sensor and master cylinder pressure sensor. (1) Leave the vehicle stationary and release the brake pedal for 1 second or more. When the zero point of the master cylinder pressure sensor is successfully acquired, only the buzzer will turn off. (2) When the zero point of each sensor is acquired, the zero point acquisition mode ends and the slip indicator turns off. If wheel speed is detected, the acquire zero point mode will be canceled and the slip indicator light will go out. If the TRC OFF switch is handled during the acquire zero point mode the slip indicator light will go out and the acquire zero point mode will be cancelled. (Turning off the ignition switch will cancel the acquire zero point mode as well.) Pressing the TRC OFF switch again will restart the acquire zero point mode. However, the zero point acquisition mode will not be performed for the items which have been completed. If malfunction items are detected, the acquire zero point mode is terminated due to handling of the TRC OFF switch, and the applicable items cannot be reexamined without restarting the acquire zero point mode. TO INDEX TO NEXT SECTION

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