A–1

SERVICE SPECIFICATIONS –

SERVICE SPECIFICATIONS
A–2
SERVICE SPECIFICATIONS – Maintenance (4A–FE)

MAINTENANCE (4A–FE)
Engine
Drive belt tension
w/ Borroughs drive belt tension gauge No. BT–33–73F
or Nippondenso BTG–20 (95506–00020)
Alternator
PS

A/C

Coolant capacity (w/ heater) M/T (Ex. AE92L–ACMXKK

M/T (AE92L–ACMXKK)
A/T
Engine oil capacity Drain and refill
w/ oil filter– change

Spark plug
Type

Gap
Firing order
Valve clearance (cold)

Idle speed

Chassis
Front brake
Pad thickness
Disc thickness
Disc runout
Rear brake
Lining thickness
Drum inside diameter
Front axle and suspension
Ball joint vertical play
Steering wheel freeplay
Torque specifications:
Front seat mounting bolt
Engine center member
Front suspension crossmember x Body
Rear suspension member x Body (2W/D only)
 A–3
SERVICE SPECIFICATIONS – Maintenance (4A–GE)

MAINTENANCE (4A–GE)
Engine
Drive belt tension
w/ Borroughs drive belt tension gauge No. BT–33–73F
or Nippondenso BTG–20 (95506–00420)
Alternator
PS and/or A/C

Coolant capacity (w/ heater)

Engine oil capacity Drain and refill
w/ oil filter change

Spark plug
Type

Gap
Firing order
Valve clearance (cold)

Idle speed 800 rpm

Chassis
Front brake
Pad thickness
Disc thickness
Disc runout
Rear brake
Pad thickness
Disc thickness
Disc runout

Front axle and suspension

Ball joint vertical play
Steering wheel freeplay
Torque specifications:
Front seat mounting bolt
Engine center member x Body
Front suspension crossmember x Body
Rear– suspension member x Body
A–4
SERVICE SPECIFICATIONS – Engine Mechanical (4A–FE)

ENGINE MECHANICAL (4A–FE)

Specifications
Compression at 250 rpm
pressure
Differential of pressure between each cylinder

Idler pulley tension Free length

spring at 50.2 mm (1.976 in.)
Installed tension

Cylinder head Head surface warpage

Manifold surface warpage
Cylinder head thickness
Valve seat Refacing angle
Contacting angle
Contacting width
Spark plug tube protrusion height

Valve guide Inside diameter

bushing Outside diameter

Protrusion height
Replacing temperature (cylinder head side)

Valve Valve overall length

Valve face angle

Stem diameter

Stem oil clearance

Valve head edge thickness

Valve spring Free length

Installed length
Installed load

Squareness

Valve lifter Outer diameter

Inner diameter
(Cylinder head lifter bore)
Oil clearance

Intake and Manifold surface warpage

exhaust
manifold
 A–5
SERVICE SPECIFICATIONS – Engine Mechanical (4A–FE)

Specifications (Cont’d)
Camshaft Thrust clearance

Journal oil clearance

Journal diameter

Circle runout
Cam lobe height

Camshaft gear spring end free distance

Camshaft gear backlash

Cylinder block Cylinder head surface warpage

Cylinder bore diameter

On standard sized piston

On O/S 0.50 sized piston
Cylinder bore wear
Difference of bore between cylinder
Taper and out–of–round

Piston and Piston diameter

piston ring

Piston to cylinder clearance

Piston ring end gap

Piston ring groove clearance

Piston pin installing temperature

Connecting rod Thrust clearance

Connecting rod bearing center wall thickness

A–6
SERVICE SPECIFICATIONS – Engine Mechanical (4A–FE)

Specifications (Cont’d)
Connecting rod Bearing oil clearance
(cont’d)
Rod bend
Rod twist

Crankshaft Thrust clearance

Thrust washer thickness

Main journal oil clearance

Main journal diameter

Main journal finished diameter

Main bearing center wall thickness

Crank pin diameter

Crank pin finished diameter U/S 0.25
Circle runout
Main journal taper– and out–of–round
Crank pin journal taper and out–or–round

Torque Specifications
Part tightened

Cylinder head bolt

Cylinder head x Camshaft bearing cap
Cylinder head x Spark plug
Cylinder head x Intake manifold
Cylinder head x Exhaust manifold
Cylinder block x Timing belt idler pulley
Cylinder block x Oil pump
Cylinder block x Crankshaft bearing cap
Cylinder block x Oil pan
Camshaft x Camshaft timing pulley
Crankshaft x Crankshaft pulley
Crankshaft x Flywheel
Connecting rod cap x Connecting rod
Oil pump x Oil strainer
 A–7
SERVICE SPECIFICATIONS – Engine Mechanical (4A–GE)

ENGINE MECHANICAL (4A–GE)

Specifications
Compression at 250 rpm
pressure
Difference of pressure between each cylinder

Idler pulley Free length

tension spring Installed tension at 50.2 mm (1.976 in.)

Cylinder head warpage Cylinder block side

Intake manifold side
Exhaust manifold side
Valve seat Refacing angle
Contacting angle
Contacting width

Valve guide Inside diameter

bushing Outside diameter

Replacing temperature (Cylinder head side)

Valve Valve overall length

Valve face angle

Stem diameter

Stem oil clearance

Margin thickness

Valve spring Free length

Installed load at 34.7 mm (1.366 in.)

Squareness

Valve lifter Lifter diameter

Inner diameter
(Cylinder head lifter bore)
Oil clearance

Manifold Manifold surface warpage

A–8
SERVICE SPECIFICATIONS – Engine Mechanical (4A–GE)

Specifications (Cont’d)
Camshaft Thrust clearance

Journal oil clearance

Journal diameter
Circle runout
Cam lobe height

Cylinder block Cylinder head surface warpage

Cylinder bore diameter

On standard sized piston

On O/S 0.50 sized piston
Cylinder bore wear
Difference of bore between cylinder
Taper and out–of–round

Piston and Piston diameter

piston ring

Piston oil clearance

Piston ring groove clearance

Piston ring end gap

Connecting Thrust clearance

rod
Connecting rod oil clearance

Connecting rod bearing center wall thickness

Rod bent
Rod twist
Connecting rod bolt
 A–9
SERVICE SPECIFICATIONS – Engine Mechanical (4A–GE)

Specifications (Cont’d)
Connecting rod Bushing inside diameter
(cont’d) Piston pin diameter
Piston pin oil clearance

Crankshaft Thrust clearance

Thrust washer thickness

Main journal oil clearance

Main journal diameter

Main bearing center wall thickness

Crank pin diameter

Circle runout
Main journal taper and out–of–round
Crank pin journal taper and out–of–round

Torque Specifications
Part tightened

Camshaft timing pulley x Camshaft

Idler pulley x Cylinder block
Crankshaft pulley x Crankshaft
Cylinder head x Cylinder block

Oil nozzle x Cylinder block

Cylinder head x Union
Camshaft bearing cap x Cylinder head
Intake manifold x Cylinder head
Intake manifold stay x Intake manifold
Intake manifold stay x Cylinder block
EGR pipe x Exhaust manifold
Exhaust manifold x Cylinder head
Exhaust manifold stay x Exhaust manifold
Exhaust manifold stay x Cylinder block
Main bearing cap x Cylinder block
Connecting rod cap x Connecting rod

Flywheel x Crankshaft
A–10
SERVICE SPECIFICATIONS – EFI System (4A–FE)

EFI SYSTEM (4A–FE)

Specifications
Fuel pressure Fuel pressure
regulator

Cold start Resistance

injector Fuel leakage

Injector Resistance
Injection volume
Difference between each injector
Fuel leakage

Throttle body Throttle valve fully closed angle

Throttle position Throttle opening Clearance between

sensor angle (from vertical) stop screw and lever

Start injector
time switch

Water temp.
sensor and air
temp. sensor

HINT:
1. Perform all voltage and resistance measurements with the computer 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.

Terminal STD voltage Condition

Ignition switch ON

Throttle valve open

Ignition switch ON
Throttle valve fully closed

Ignition switch ON

Ignition switch ON

Engine start
 A–11
SERVICE SPECIFICATIONS – EFI System (4A–FE)

Specifications (Cont’d)
Terminal STD voltage Condition

Ignition switch ON

Intake air temperature 20 °C (68°F)

Ignition switch ON
Coolant temperature 80 °C (176 ° F)

Cranking
Idling
A/C switch ON
Ignition switch ON
A/C switch OFF
Check connector TE 1 – E 1 not connect
Ignition switch ON
Check connector– TE 1 – E 1 connect

Terminal Condition Resistance

Throttle valve open

Throttle valve fully closed
Throttle valve fully open

Throttle valve fully closed

Intake temperature 20 °C (68°F)

Coolant temperature 80 °C (176°F)

Fuel cut rpm Fuel cut rpm

Fuel return rpm

Torque Specifications
Part tightened

Pressure regulator x Delivery pipe

Fuel inlet pipe x Delivery pipe
Cold start injector pipe x Delivery pipe
Cold start injector pipe x Cold start injector
Fuel tank band x Fuel tank
Fuel inlet pipe x Fuel tank
Fuel pump x Fuel tank
Fuel sender gauge x Fuel tank
Drain plug
A–12
SERVICE SPECIFICATIONS – EFI System (4A–GE)

EFI SYSTEM (4A–GE)

Specifications
Fuel pressure Fuel pressure
regulator
Cold start Resistance
injector Fuel leakage

Injector Resistance
Injection volume
Difference between each injector
Fuel leakage

Throttle body Throttle valve fully closed angle

Throttle position Clearance between

Between terminals Resistance
sensor stop screw and lever

Start injector Resistance

time switch

Air flow meter Resistance

Water temp. Resistance

sensor and air
temp. sensor

Oxygen sensor Heater resistance

EG R gas temp. Resistance

sensor
 A–13
SERVICE SPECIFICATIONS – EFI System (4A–GE)

Specifications (Cont’d)
HINT:
1. Perform all voltage and resistance measurements with the computer 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.

Terminal STD voltage Condition

Ignition switch ON

Ignition switch ON Throttle valve open

Ignition switch ON Throttle valve fully closed

Throttle valve fully open

Ignition switch ON

Measuring plate fully closed

Ignition switch ON
Measuring plate fully open

Idling

Intake air temperature 20 0 C (68° F)

Ignition switch ON
Coolant temperature 80 °C (176° F)

Cranking

Ignition switch ON

Idling

Check connector TE1 – E1 not connect

Ignition switch ON
Check connector– TE1 – E1 connect

A/C switch ON
Ignition switch ON
A/C switch OFF

Ignition switch ON

Engine start
A–14
SERVICE SPECIFICATIONS – EFI System (4A–GE)

Specifications (Cont’d)
Terminal Condition Resistance

Throttle valve open

Throttle valve fully closed

Throttle valve fully open

Throttle valve fully closed

Measuring plate fully closed

Measuring plate fully open

Intake air temperature 20 °C (68° F)

Coolant temperature 80 °C (176°F)

Fuel cut rpm Fuel cut rpm

w/ Vehicle speed 0 km/h, coolant Fuel return rpm
temperature
80°C (176°F) and A/C switch off

Torque Specifications
Part tightened

Pressure regulator x Delivery pipe

Fuel inlet pipe x Delivery pipe
Cold start injector pipe x Delivery pipe
Cold start injector pipe x Cold start injector
Fuel tank band x Fuel tank
Fuel inlet pipe x Fuel tank
Fuel pump x Fuel tank
Fuel sender gauge x Fuel tank
Drain plug
 A–15
SERVICE SPECIFICATIONS – Cooling System

COOLING SYSTEM
Coolant capacity (w/ heater)
4A– F E M/T(Ex. AE92–ACM X K K )
M/T(AE92L–ACMXKK)
A/T
4A–GE

Radiator Relief valve opening pressure

Thermostat Valve opening temperature

Starts to open at
Fully opens at
Valve opening travel

LUBRICATION SYSTEM
Oil pressure (normal operating temperature)

Oil pump 4A–FE

Body clearance

Tip clearance

Side clearance

4A–GE
Body clearance

Side clearance
A–16
SERVICE SPECIFICATIONS – Ignition System (4A–FE)

IGNITION SYSTEM (4A–FE)

Ignition timing T/ M i n N range

Spark plug Type

Gap

Firing order

High–tension Resistance
cord

Ignition coil Primary coil resistance

Secondary coil resistance

Distributor Signal generator resistance

IGNITION SYSTEM (4A–GE)

Ignition timing T/ M i n N range

Spark plug Type

Gap

Firing order

High–tension Resistance
cord

Ignition coil Primary coil resistance

Secondary coil resistance

Distributor Signal generator resistance

STARTING SYSTEM
Reduction Rating voltage and output power
type starter No–load characteristic at 11.5V

Brush length

Commutator
Outer diameter

Undercut depth

Circle runout
Spring installed load
 A–17
SERVICE SPECIFICATIONS – Clutch

CHARGING SYSTEM
Battery specific gravity
When fully charged at 20°C (68°F)
Delco

Alternator Rated output ampere

Rotor coil resistance
Slip ring diameter

Brush exposed length

Alternator Regulating voltage

regulator (IC)

CLUTCH
Specifications
Pedal height (from asphalt sheet)
Push rod play at pedal top
Pedal freeplay
Clutch release point (from full stroke and position)
Release fork end play
Disc rivet head depth
Disc runout
Diaphragm spring out of alignment
Diaphragm spring finger wear Depth
Width
Flywheel runout

Torque Specifications
Part tightened

Clutch line union .

Master cylinder set nut
Clutch pedal setting nut
Release cylinder set bolt
Clutch cover x Flywheel
Bleeder plug x Release cylinder
Release fork support
A–18
SERVICE SPECIFICATIONS – Manual Transaxle (C50 and C52)

MANUAL TRANSAXLE (C50 and C52)

Specifications
Input shaft
Roller bearing journal diameter
3rd gear journal diameter
4th gear journal diameter
5th gear journal diameter
Runout
Output shaft
Roller bearing journal diameter
1st gear journal diameter
2nd gear journal diameter
Runout
Gear thrust clearance

Gear oil clearance

1st, 2nd, 3rd, 4th and 5th

Shift fork to hub sleeve clearance

Synchronizer ring to gear clearance
Oil seal drive in depth
Speedometer driven gear
Input shaft snap ring thickness
No. 2 clutch hub

Input rear bearing

 A–19
SERVICE SPECIFICATIONS – Manual Transaxle (C50 and C52)

Specifications (Cont’d)
Output shaft snap ring thickness
No. 1 clutch hub

No. 3 clutch hub

Side bearing preload

(at starting)

Pinion to side gear backlash

Side gear thrust washer thickness

Side bearing adjusting shim thickness

Shift lever vertical play

A–20
SERVICE SPECIFICATIONS – Manual Transaxle (C50 and C52)

Torque Specifications
C50 and C52 Part tightened
transmissions
Transmission case x Transaxle case
Transmission case x Case cover
Transmission case protector
Rear bearing retainer
Output shaft bearing lock plate
5th driven gear lock nut
Reverse idler shaft lock bolt
Reverse shift arm bracket
Oil receiver pipe
Shift fork x Set bolt
Reverse restrict pin holder
Shift and select lever shaft lock bolt
Filler plug
Drain plug
Back–up light switch
Front bearing retainer
Speedometer driven gear lock plate
Straight screw plug (shift fork shaft)
Lock ball assembly
Control shaft cover bolt
Transaxle x Engine

Transaxle x Rear end plate

Ball joint x Lower arm

Transaxle x Starter
Engine mounting center member x Body
Engine mounting center member x Mounting
Front mounting insulator bolt
Exhaust pipe x Exhaust manifold
Exhaust pipe x Converter
Exhaust pipe clamp bolt
Bond cable x Body
Release cylinder x Transaxle

Differential Ring gear x Differential case

 A–21
SERVICE SPECIFICATIONS – Manual Transaxle (E55F5 and E57F5)

MANUAL TRANSAXLE (E55F5 and E57F5)

Specifications
TRANSMISSION ASSEMBLY
Input shaft
Roller bearing journal diameter
3rd gear journal diameter
4th gear journal diameter
Runout
Output shaft
1st gear journal diameter
2nd gear bushing diameter
Runout
Gear thrust clearance

Gear oil clearance

1st and 4th gear

2nd and 3rd gear

5th gear

Shift fork to hub sleeve clearance

Synchronizer ring to gear clearance
Oil pump assembly
Rotor body clearance

Rotor tip clearance

Side clearance

Input shaft snap ring thickness

No. 2 clutch hub
A–22
SERVICE SPECIFICATIONS – Manual Transaxle (E55F5 and E57F5)

Specifications (Cont’d)
Input shaft snap ring thickness (cont’d)
4th gear and rear bearing

DIFFERENTIAL ASSEMBLY
Differential side bearing preload (at starting)

No. 1 case bushing inner diameter

No. 2 case bushing inner diameter

Front case outer diameter

No. 1 case side

No. 2 case side

Conical spring washer height

For No. 1 case

For No. 2 case

Differential No. 1 case backlash

Front differential case backlash
Differential No. 2 case thrust clearance
Front differential case thrust clearance
Thrust washer thickness
For No. 1 case side gear
 A–23
SERVICE SPECIFICATIONS – Manual Transaxle (E55F5 and E57F5)

Specifications (Cont’d)
Thrust washer thickness (cont’d)
For front case side gear

For No. 2 case side gear

For No. 2 case and front case

Shim thickness
For differential side bearing preload
A–24
SERVICE SPECIFICATIONS – Manual Transaxle (E55F5 and E57F5)

Specifications (Cont’d)
Shim thickness (cont’d)
For differential side bearing preload (cont’d)

TRANSFER ASSEMBLY
Ring gear runout
Ring gear mounting case runout
Ring gear backlash
Driven pinion preload (at starting)
Transfer total preload (at starting)
(Add driven pinion preload)
Adjusting shim thickness
For ring gear backlash

For tooth contact

 A–25
SERVICE SPECIFICATIONS – Manual Transaxle (E55F5 and E57F5)

Torque Specifications
Part tightened
Oil pump x Cover
Ring gear x Differential case
Rear bearing retainer x Transmission case
Transmission case x Transaxle case
Oil pump assembly x Transaxle case
Shift fork x Shaft
Oil pipe x Housing
Transaxle case x Transaxle case receiver
Transmission case x Transmission case cover
Shift and select lever shaft assembly x Transmission case
Bellcrank x Transmission case
Back–up light switch x Transmission case
Drive pinion x Bearing cage See page MT–110
Ring gear x Ring gear mounting case
Driven pinion cage x Transfer case
Transfer left case x Transfer right case
Transfer case x Inspection hole cover
Differential lock sleeve x Shift fork
Transfer right case x Transfer case cover
Driven pinion cage x Extension housing
Transaxle assembly x. Transfer assembly
Differential lock indicator switch
Filler plug
Drain plug
Oil cooler pipe X Elbow
Elbow x Transaxle
Lock bolt x Transaxle case
Breezer plug x Transmission case
No. 1 and No. 2 oil receiver pipe X Transmission case
Reverse idler gear retaining bolt
Transmission case x Plug (for shift fork shaft)
(for reverse restrict pin)
Speedometer cable adopter
Oil tube x Transfer left case
Transfer left case x Plug (Large)
(Small)
Transfer case x Actuator bracket
Transaxle assembly x Engine M12 bolt
M10 bolt
Drive shaft x Rotor disc
Tie rod end x Steering knuckle
PS pump x Pump bracket
Engine mounting insulator x Bracket
Engine mounting insulator bracket x Transaxle
Engine mounting insulator bracket x Member
Starter x Transaxle
Transaxle x Stiffener plate 10 mm bolt
8 mm bolt
A–26 Automatic Transaxle (A131L)
SERVICE SPECIFICATIONS –

Torque Specifications (Cont’d)

Part tightened
Exhaust manifold x Exhaust front pipe
Exhaust front pipe x Exhaust center pipe
Lower arm x Ball joint
Engine mounting insulator LH x Engine mounting insulator
LH bracket
Engine mounting insulator– LH bracket x Transaxle
Engine mounting insulator RH x Engine Nut
Bolt
Transfer vacuum actuator bracket x Stiffener plate
10 mm bolt
Engine mounting insulator LH x Transaxle
Engine mounting insulator RH x RH bracket
Protector x Transaxle

AUTOMATIC TRANSAXLE (A131L)

Automatic Transmission
Specifications
Governor pressure
Counter drive gear
1,000

1,800

3,500

Line pressure
Engine idling

At stall

Engine stall revolution

Time lag

Engine idle speed (Cooling fan and A/C OFF)

Speedometer driven gear oil seal drive in depth

Throttle cable adjustment (Throttle valve fully opened)

Input shaft thrust play

 A–27
SERVICE SPECIFICATIONS – Automatic Transaxle (A131L)

Specifications (Cont’d)
Drive plate runout
Torque converter runout
Torque converter correct distance
Shift point km/h D range (Throttle valve fully open) *Throttle valve is closed. L range
Differential
(mph)
gear ratio

* : OPT for– U.S.A.

Valve body Coil outer No.

Free length Color
spring mm diameter coils
(in.) Upper valve body
Throttle modulator valve
Accumulator control valve
Low coast modulator valve
Down shift plug
2nd coast modulator valve
Throttle valve
Lock–up relay valve

Lower valve body (AISI N A.W)

Primary regulator valve
1–2 shift valve
Detent regulator valve
2–3 shift valve
Lock–up signal valve
Secondary regulator valve
Pressure relief valve
Cooler– by–pass valve

Lower– valve body (TOYOTA)

Primary regulator valve
1–2 shift valve
Detent regulator valve
2–3 shift valve
Lock–up signal valve
Secondary regulator valve
Pressure relief valve
Cooler by–pass valve

Accumulator B2 (Center)
piston spring
mm (in.)
C1 (Transaxle rear cover side)

C2 (Torque converter side)

A–28
SERVICE SPECIFICATIONS – Automatic Transaxle (A131L)

Specifications (Cont’d)
Oil pump Side clearance

Body clearance

Tip clearance Driven gear

Clutch piston Forward clutch (C1)

stroke Direct clutch (C2)

Brake piston Second coast brake (B1)

stroke

Bushing mm Bushing Finished bore Bore limit

(in.)
Front
Stator support
Rear
Oil pump body
Direct clutch drum
Front planetary ring gear flange
Input sun gear (Front and Rear)

Front planetary pinion gear thrust clearance

Rear planetary pinion gear thrust clearance

Torque Specifications
Part tightened

Engine mounting
Transaxle case x Engine
Drive plate x Crankshaft
Torque converter x Drive plate
Oil pump x Transaxle case
Oil pump body x Stator shaft
Second coast brake band guide
Upper valve body x Lower valve body
Valve body
Accumulator cover
Oil strainer
Oil pan
Oil pan drain plug
Cooler pipe union nut
Testing plug
Parking lock pawl bracket
Transaxle rear cover x Transaxle case
Neutral start switch x Transaxle case (bolt)
Neutral start switch (nut)
Ball joint x Lower arm
 A–29
SERVICE SPECIFICATIONS – Automatic Transaxle (A131L)

Torque Specifications (Cont’d)

Part tightened

Lower– crossmember x Body

Center member x Body
Center member x Transaxle mounting bracket
Exhaust pipe x Exhaust manifold

Differential
Specifications
Side bearing preload (at Starting)

Drive pinion preload (at Starting)

Total preload (at Starting)

Pinion to side gear backlash

Side gear thrust washer thickness

Side bearing adjusting shim thickness

A–30
SERVICE SPECIFICATIONS – Automatic Transaxle (A240L )

Torque Specifications
Part tightened

Ring gear– x Differential case

Side bearing cap
Side bearing retainer
Drive pinion nut
Differential carrier cover
Filler plug
Drain plug

AUTOMATIC TRANSAXLE (A240L)

Automatic Transmission
Specifications
Governor pressure
Differential drive pinion rpm (Vehicle speed reference)
800 (28 km/h, 17 mph)
1,600 (57 km/h, 35 mph)
2,400 (85 km/h, 53 mph)

Line pressure
Engine idling

At stall

Engine stall revolution

Time lag

Engine idle speed (Cooling fan and A/C OFF)

Speedometer driven gear oil seal drive in depth
Throttle cable adjustment (Throttle valve fully opened)

Input shaft thrust play

Drive plate runout
Torque converter runout
Torque converter correct distance

Shift point km/h D range (Throttle valve fully open) * Throttle valve is closed L range
Differential
(mph)
gear ratio
 A–31
SERVICE SPECIFICATIONS – Automatic Transaxle (A240L)

Specifications (Cont’d)
Valve body Coil outer No.
Free length Color
spring mm diameter coils
(in.) Upper valve body
Primary regulator valve
Lock–up relay valve
2nd coast modulator valve
Down shift plug
Throttle valve
Throttle modulator valve
Accumulator control valve

Lower valve body

3–4 shift valve
1–2 shift valve
Secondary regulator valve
2–3 shift valve
Low modulator valve
Lock–up signal valve
Detent regulator valve
3–4 switch valve
Cooler by–pass valve
Pressure relief valve

Accumulator
piston spring mm
(in.)

Oil pump Side clearance

Body clearance

Tip clearance

Clutch piston Forward clutch (C1)

stroke Direct clutch (C2)
Underdrive clutch (C3)

Brake piston Second coast brake (B1)

stroke
A–32
SERVICE SPECIFICATIONS – Automatic Transaxle (A240L)

Specifications (Cont’d)
Bushing mm Bushing Finished bore Bore limit
(in.) Front
Stator– support
Rear
Oil pump body
Direct clutch drum
Front planetary ring gear flange
Input sun gear (Front and Rear)

Under drive Front

clutch drum Rear
Planetary sun gear
Flange Direct clutch
thickness
Underdrive clutch

Forward clutch

Intermediate shaft protrusion length (Reference)

Second coast piston rod length

Counter– shaft End play

Height
w/ spring tension
gauge
Starting torque
w/ torque
gauge
Front planetary pinion gear thrust clearance

Rear planetary pinion gear thrust clearance

Under–drive planetary pinion gear thrust clearance

Torque Specifications
Part tightened

Engine mounting
Transaxle housing x Engine

Drive plate x Crank shaft

Torque converter x Drive plate
Oil pump x Transaxle case
Oil pump body x Stator shaft
Second coast brake band guide
Upper valve body x Lower valve body
Valve body
Accumulator cover
 A–33
SERVICE SPECIFICATIONS – Automatic Transaxle (A240L)

Torque Specifications (Cont’d)

Part tightened

Oil strainer
Oil pan
Oil pan drain plug
Cooler pipe union nut x Union elbow
Union elbow x Transaxle case
Testing plug
Parking lock pawl bracket
Transaxle rear cover x Transaxle case
Neutral start switch x Transaxle case
Neutral start switch
Ball joint x Lower arm
Lower crossmember x Body
Center member x Body
Center member x Transaxle mounting bracket
Exhaust pipe x Exhaust manifold

Differential
Specifications
Side bearing preload (at Starting) New bearing
Reused bearing

Pinion to side gear backlash

Side gear thrust washer thickness

Side bearing adjusting shim thickness

A–34
SERVICE SPECIFICATIONS – Automatic Transaxle (A241H)

Torque Specifications
Part tightened

Ring gear– x Differential case

Transaxle housing x Transmission case

AUTOMATIC TRANSAXLE (A241H)

Automatic Transmission
Specifications
Governor pressure
Drive pinion rpm (Vehicle speed reference)

Line pressure
Engine idling

At stall

Engine stall revolution

Time lag

Engine idle speed (Cooling fan and A/C OFF)

Speedometer driven gear oil seal drive in depth
Throttle cable adjustment (Throttle valve fully opened)

Input shaft thrust play

Drive plate runout
Torque converter runout
Torque converter correct distance

Shift point km/h D range (Throttle valve fully open) * Throttle valve is closed L range
(mph)

Valve body Coil outer No.

Free length Color
spring mm diameter coils
(in.) Upper valve body
Primary regulator valve
Lock–up relay valve
2nd coast modulator– valve
Down shift plug
Throttle valve
Throttle modulator valve
Accumulator– control valve
No. 2 pressure regulator valve
 A–35
SERVICE SPECIFICATIONS – Automatic Transaxle (A241H)

Specifications (Cont’d)
Valve body spring Coil outer No. Color
Free length
(cont’d) diameter coils
mm (in.) Lower valve body
Secondary regulator
1–2 shift valve
Low modulator valve
2–3 shift valve
Cooler by–pass valve
Pressure relief valve
3–4 shift valve
Lock–up signal valve
Detent regulator valve
3–4 switch valve

AccumuIator
piston spring
mm (in.)

Oil pump Side clearance

Body clearance

Tip clearance Driven gear

Clutch piston Forward clutch (C1)

stroke Direct clutch (C2)
Underdrive clutch (C3)

Brake piston Second coast brake (B1)

stroke

Bushing Bushing
mm (in.) Front
Stator support
Rear
Oil pump body
Direct clutch drum
Front planetary ring gear flange
Input sun gear

Under drive Front

clutch drum Rear
Planetary sun gear
A–36
SERVICE SPECIFICATIONS – Automatic Transaxle (A241H)

Specifications (Cont’d)
Flange Direct clutch
thickness
Underdrive clutch

Forward clutch

Intermediate shaft protrusion length (Reference)

Second coast piston rod length

Counter shaft End play

Height

w/ spring tension
gauge
Starting torque
w/ torque
gauge

Front planetary pinion gear thrust clearance

Rear planetary pinion gear thrust clearance

Underdrive planetary pinion gear thrust

clearance

Torque Specifications
Part tightened

Transaxle housing x Engine

Drive plate x Crankshaft

Torque converter x Drive plate
Oil pump x Transaxle case
Oil pump body x Stator shaft
No. 2 pressure regulator valve body x Upper valve body
Upper valve body x Lower valve body
Valve body
Detent spring
Oil tube bracket
Oil pan
Oil pan drain plug
Union elbow x Transaxle case
Testing plug
Par–king lock pawl stopper plate
Transaxle rear cover x Transaxle case
Transaxle case x Transaxle housing
Neutral start switch x Transaxle case
Neutral start switch
Counter shaft lock nut
Driven gear lock nut
 A–37
SERVICE SPECIFICATIONS – Automatic Transaxle (A241H)

Differential and Transfer

Specifications
Differential side bearing preload (at starting)

Transfer driven pinion preload (at starting)

w/ Transfer (Add driven pinion preload)

Drive pinion bearing cage preload (at starting)

Backlash
Differential side gear
Center differential
Transfer ring gear
Differential end play
Center differential case thrust clearance
Oil seal depth
Transfer left case
Transfer right case

Extension housing
Differential side thrust washer
A–38
SERVICE SPECIFICATIONS – Automatic Transaxle (A241H)

Specifications (Cont’d)
Conical spring washer

Center differential side gear thrust washer

Transfer left case side plate washer

 A–39
SERVICE SPECIFICATIONS – Automatic Transaxle (A241H)

Specifications (Cont’d)
Transfer ring gear adjusting shim

Torque Specifications
Part tightened

Transfer x Transaxle (nut)

Ring gear mounting left case x Right case
Left case x Driven pinion bearing cage
Left case x Control valve sleeve cover
Left case x Case retainer
Left case x Inspection hole cover
Right case x Level gauge guide plate
Extension housing x Driven pinion bearing cage
Mode select lever and rod
Driven pinion lock nut
Left case x Ring gear
Left case x Right case

PROPELLER SHAFT
Specifications
Bearing axial play
Front propeller shaft runout
Intermediate shaft runout
Rear propeller shaft runout
Inter–mediate shaft flange runout

Torque Specifications
Part tightened

Propeller shaft x Differential

Intermediate shaft x Propeller shaft
Center support bearing x Body
Intermediate shaft x Center bearing x Joint flange

Cross groove joint set bolt

A–40
SERVICE SPECIFICATIONS – Suspension and Axle

SUSPENSION AND AXLE

Specifications
Cold tire inflation Tire size Front Rear
pressure
kg/cm2 (psi, kPa)

2WD

4WD

Chassis ground Tire size

clearance mm
(in.)

2WD

4WD All models

Front wheel Inspection STD Adjustment STD

alignment
Toe–in
Left–right error

4A–F engine
2WD
Camber 4A–GE engine

4WD

Left–right error

Coupe
4A–F
2WD engine Ex. coupe

Caster 4A–GE engine

4W/D

Left–right error

4A–F engine
Steering axis 2WD
4A–GE engine
inclination
4WD

Left–right error
 A–41
SERVICE SPECIFICATIONS – Suspension and Axle

Specifications (Cont’d)
Front wheel Outside wheel
Maximum
alignment at 20°
Engine Grade
(cont’d) Inside Outside Inside
wheel wheel wheel
Wheel angle LE, DX
4A–F (w/o PS)
Others

2W D 4A–F (w/ PS)

4A–G E (w/o PS)
All
4 A–G E (w/ PS)

4WD All

Rear wheel Inspection STD Adjustment STD

alignment Toe–in mm (in.)
(2WD)
4A–F engine

Camber
4A–GE engine

Left–right error

Wheel later–al runout

Front axle and Hub bearing axial direction play (4WD) Limit
suspension Ball joint rotation condition
Ball joint vertical play

SAGINAW
TYPE
2WD
Drive shaft TOYOTA
standard length TYPE

4WD

Rear axle and Rear axle shaft bearing inner retainer installing
suspension temperature
(4WD) Rear axle shaft runout
Rear axle shaft flange runout

Differential Drive pinion bearing preload at

(4WD) Starting

Total preload

Drive pinion to ring gear backlash

Pinion gear to side gear backlash
Ring gear runout
Companion flange runout

Ring gear installing temperature

Oil seal drive depth
A–42
SERVICE SPECIFICATIONS – Suspension and Axle

Specifications (Cont’d)
Differential Side gear thrust washer thickness
(4WD)
(cont’d )

Drive pinion adjusting plate washer thickness

Torque Specifications
Part tightened

[Front Axle and Suspension]

Tie rod end lock nut
Shock absorber x Steering knuckle
Tie rod end x Steering knuckle
Ball joint x Lower arm
Disc brake caliper x Steering knuckle
Hub bearing lock nut
Ball joint x Steering knuckle
Suspension support x Body
Piston rod x Suspension support
Front disc brake hose union bolt
Suspension crossmember x Body
(Front bolts of left and right side)
(Rear bolts of left and right side)
(Bolts and nuts of center part)
Stabilizer bar x Lower arm (2WD 4A–F engine & 4WD)
(2WD 4A–GE engine)
Lower arm bushing nut
Lower arm front bolt
Lower arm rear bracket x Body
(Lower arm side)
(Stabilizer side)
(Small bolt and nut)
 A–43
SERVICE SPECIFICATIONS – Brake System

Torque Specifications (Cont’d)

Part tightened

[Rear Axle and Suspension]

(2WD)
Axle bearing lock nut
Axle carrier x Shock absorber
Axle hub x Axle carrier
Strut rod x Axle carrier
No. 1 and No. 2 suspension arm x Axle carrier
Piston rod x Suspension support
No. 1 suspension arm x Body
No. 2 suspension arm x Body
Strut rod x Body
Stabilizer bar x Stabilizer bar link
Shock absorber x Stabilizer bar link
Stabilizer bar bracket x Body
Fuel tank band x Body
Hub nut
(4WD)
Rear axle shaft bearing retainer x Backing plate
Propeller shaft x Companion flange
Ring gear x Differential case
Side bearing cap x Differential carrier
Side bearing adjusting lock nut
Differential carrier x Axle housing
Rear shock absorber x Body
Rear– shock absorber x Rear axle housing
Lateral control rod x Body
Upper control arm x Rear axle housing
Upper control arm x Body
Lower control arm x Rear axle housing
Lower control arm x Body
Stabilizer bar bracket x Rear axle housing
Stabilizer bar link x Stabilizer bar
Hub nut

BRAKE SYSTEM
Specifications
Brake pedal Pedal height (from asphalt sheet)
Pedal freeplay
Pedal reserve distance at 50 kg (110.2 l b, 490 N )
Rear drum brake
Rear disc brake
4WD
A–44
SERVICE SPECIFICATIONS – Brake System

Specifications (Cont’d)
Brake booster Booster push rod to piston clearance w/ SST

Front brake Pad thickness

Disc thickness 4A–GE

4A–FE

Disc runout

Rear brake Lining thickness

(Drum)
Drum inner diameter

Shoe to parking brake shoe lever clearance

Parking brake shoe lever shim thickness

Drum to shoe clearance

Rear brake Pad thickness

(Disc)
Disc thickness

Disc runout

Parking brake Lever travel

Torque Specifications
Part tightened

Master cylinder x Piston stopper bolt

Master cylinder x Reservoir
Master cylinder x Brake booster
Brake booster x Pedal bracket
Brake booster clevis lock nut
Front brake cylinder installation bolt
Front disc brake torque plate x Steering knuckle
 A–45
SERVICE SPECIFICATIONS – Steering

Torque Specifications (Cont’d)

Part tightened

Front disc brake cylinder x Union bolt

Brake tube union nut
Bleeder plug
Rear– drum brake wheel cylinder installation bolt
Rear disc brake cylinder torque plate x Rear axle carrier
Rear disc brake cylinder installation bolt
Rear disc brake cylinder x Union bolt
Brake pedal setting nut
Parking brake lever x Body

STEERING
Specifications
Steering column Steering wheel freeplay
Collar outer diameter

Manual gear Steering rack runout

housing Pinion bearing preload
Total preload

Power steering Drive belt tension

4A–FE engine

4A–GE engine

Maximum rise of oil level

Oil pressure
Steering effort
Rotor shaft to bushing oil clearance

Vane plate
Height
Thickness
Length
Vane plate to rotor groove clearance
Vane plate length Rotor and ca

Flow control spring length

A–46
SERVICE SPECIFICATIONS – Steering

Specifications (Cont’d)
Power steering Pump rotating torque
(cont’d) Steering rack runout
Rotor– shaft bushing oil clearance (TOYOTA type

Rack housing bushing drive in depth

Total preload at Turning

Torque Specifications
Steering Part tightened
column
Tilt pawl set nut
Tilt lever retainer set nut
(Tilt lever side)
(Steering bolt side)
Lower column tube x Steering support
Compression spring bushing bolt
Steering wheel nut
Column hole cover x Body
Breakaway bracket x Body
Main shaft x Intermediate shaft
Column tube x Body

Manual gear Column hole cover x Body

housing Gear housing bracket x Body
Tie rod end x Steering knuckle
Universal joint bolt
Engine rear mount bracket insulator
Lower crossmember x Body
(Front lower arm –bolts of left and right side)
(Rear bolts of left and right side)
(Bolts of center part)
(Nuts of center part)
Ball joint x Lower arm
Stabilizer bar x Lower arm
Lower– arm rear bracket x Body
(Lower arm side)
(Stabilizer side)
(Small bolt and nut)
Center crossmember x Body
(Front bolts)
(Center bolts and nuts)
(Rear nut)
Pinion bearing adjusting screw lock nut
Rack guide spring cap lock nut
Rack x Rack end
Tie rod end lock nut
 A–47
SERVICE SPECIFICATIONS – Steering

Torque Specifications (Cont’d)

Power steering Part tightened

Pressure tube x Pump body (4A–GE)

Pressure tube union bolt (4A–FE)
Power steering pump mounting bolt
Adjusting bracket x Engine (4A–FE)
Union bolt (4A–FE)
Pump bracket x Pump body (4A–GE)
Pump bracket x Engine (4A–GE)
Idler pulley bracket x Pump body (4A–GE)
Suction port union x Housing (4A–GE)
Drive pulley nut (4A–FE)
Drive pulley nut (4A–GE)
Pressure port union x Front housing
Reservoir tank x Housing (4A–FE)
Reservoir tank bracket x Housing (4A–FE)
Air control valve
Pressure and return line x Housing (TOYOTA type)
Pressure and return line x Housing (KOYO type)
Gear housing bracket x Body
Column hole cover x Body
Tie rod end x Steering knuckle
Universal joint bolt
Pressure line x Bracket
Engine rear mount bracket
Front exhaust pipe

Propeller shaft
Lower crossmember x Body
(Front lower arm bolts of left and right side)
(Rear bolts of left and right side)
(Bolts of center– part)
(Nuts of center part)
Ball joint x Lower arm
Stabilizer bar x Lower arm
Lower arm rear bracket x Body
(Lower arm side)
(Stabilizer side)
(Small bolt and nut)
Center crossmember x Body
(Front bolts)
(Center bolts and nuts)
(Rear nut)
(KOYO type)
Rack x Rack end
Tie rod end lock nut
Control valve housing x Rack housing
Control valve shaft x Bearing
Rack housing cap
Rack guide spring cap lock nut
A–48
SERVICE SPECIFICATIONS – Steering

Torque Specifications (Cont’d)

Power–steering Part tightened
(cont’d )
Turn pressure tube x Housing
(TOYOTA type)
Rack x Rack end
Tie rod end lock nut
Control valve shaft x Bearing
Rack housing cap
Rack guide spring cap lock nut
Turn pressure tube x Housing
Air control valve x Housing

BODY
Specifications
Sun roof Difference between sliding roof panel and
roof panel

Torque Specifications
Part tightened

Rear bumper set bolt

SEAT
Front Seat
Seat back x Seat adjuster
Seat cushion x Seat adjuster
Seat adjuster x Body
Rear seat (Sedan/Fixed Type)
Seat back x Body
Rear seat (Sedan/Separate Type)
Seat back x Body
Seat back side hinge x Seat back
Seat backside hinge x Body
Seat back center hinge x Seat back
Seat back center hinge x Body
Rear seat (Coupe/Fixed Type)
Seat back x Body
Rear seat (Coupe/Separate Type)
Seat back side hinge x Seat back
Seat backside hinge x Body
Seat back center hinge x Seat back
Seat back center hinge x Body
Rear seat (FWD Wagon)
Seat cushion x Body
Seat back hinge x Body
Seat back side hinge x Seat back
Seat backside hinge x Body
Seat back center hinge x Seat back
Seat back center hinge x Body
 A–49
SERVICE SPECIFICATIONS – Lubricant

Torque Specifications (Cont’d)

Part tightened

Rear seat (AII–Track/4WD Wagon)

Seat back side hinge x Seat back
Seat backside hinge x Body
Seat back center hinge x Seat back
Seat back center hinge x Body
SEAT BELT
Front Seat Belt (Canada)
Shoulder belt anchor x Body
Shoulder belt lower side x Body
ELR upper side X Body
Inner belt x Body
Belt guide x Body
Front seat belt (USA)
Shoulder buckle x Door glass run
Clevis x Body
Bracket x Front seat (Ex. Coupe)
Anchor– bracket x Lower arm (Coupe)
Inner guide x Lower arm (Coupe)
Inner backle x Bracket (Ex. Coupe)
Lap inner belt x Anchor bracket (Coupe)
Plate x Body
Shoulder inner guide x Front seat (Ex. Coupe)
Shoulder retractor x Body

Side retractor x Body

Rear Seat Belt
ELR x Body
Outer belt shoulder anchor x Body

Outer belt lower anchor x Body

Inner belt x Body

CRS tether– anchor x Body

LUBRICANT
Capacity
Item Classification
Liters US qts Imp. qts

Engine oil API service SG, multigrade fuel–efficient and

(4A–FE) Dry fill recommended viscosity oil
Drain and refill
w/ Oil filter change w/o Oil filter change
(4A–GE) Dry fill
Drain and refill
w/ Oil filter change w/o Oil filter– change
A–50
SERVICE SPECIFICATIONS – Lubricant

LUBRICANT (Cont’d)
Capacity
Item Classification
Liters US qts Imp. qts

Manual transaxle oil

C50, C52 (w/ Differential oil) API G L–4 or G L–5, SAE 75W–90 or 80W–90
E55F5, E57F5 Transaxle oil E50 (08885–80206) or equivalent
(w/ Differential oil and transfer)
Recommended oil
Oil grade : API GL–5
Viscosity : Above –18° C (0° F )
SAE 75W–90, 80W–90 o r 90
Below –18°C (0° F )
SAE 75W–90,80W–90 or 80W

Automatic transmission fluid ATF DEXRON ll

A131L Dry fill
Drain and refill
A240L Dry fill
Drain and refill
A241H Dry fill TOYOTA ATF type T (Part No. 08886–
Drain and refill 00405) or equivalent

Differential oil (A131L A/T only) ATF DEXRON 19

Transfer oil (A241H A/T only) Transaxle oil E50 (08885–80206) or equivalent
Dry fill
Recommended oil
Drain and refill
Oil grade : API GL–5
Viscosity : Above –18° C (0° F )
SAE 75W–90, 80W–90 o r 90
Below –18°C (0° F )
SAE 75W–90,80W–90 or 80W

Rear differential oil API grade GL–5

Hypoid gear oil
Viscosity: Above –18°C (0°F) SAE90
Below –18°C (0°F)
SAE 80W–90 or 80W

Power steering fluid Pump ATF DEXRON  II

Total

Steering gear housing grease Molybdenum disulphide lithium base,

N LG I No. 2

Brake fluid SAE J1703 or FM VSS No. 116 DOT 3