ae 2-2. Tightening Torque Schedule . . Service Data 2. SERVICE DATAww . Tightening Torque Schedule In threaded fastening parts holding down a ‘component in place, the holding force is preserv- ed primarily in the male and female threads in contact. Screw threads are capable of withstand- ing this force up to a certain limit. Here occurs ‘the need to tighten them without exceeding the limit, and this need can be met by using torque wrenches. Fastening parts, for which the limit is specified because their fastening or holding function is critical, is listed below, Use torque wrenches and Fig. 2-1 adhere to the torque specifications when tightening them at the time of periodical inspec- tion or overhauling or serv Saat aria Tightening torque Nm kom lb-ft Cylinder heed bolt 55-60 55-60 | 400-430 Spark plug 20-30 20-30 | 145-215 Inlet & exhaust manifold nut 18-23 18-23 | 130-165 Camshaft timing pully bott 80-60 5.0-6.0 | 365-430 Valve adjusting nut 18-20 18-20 | 11.0-140 | Timing belt cover bolt 3-4 0.3-0.4 2.8 Crankshaft pully bott 50-60 50-60 | 365-43.0 Connecting rod bearing cap nut 28-32 28-32 | 20.5-23.0 Engine | Crankshaft bearing cap bole 43-48 43-48 | 316-348 Flywheel bolt 40-45 40-45 | 200-325 | Oil pressure unit 12-18 12-15 9.0- 10.5 Oil filter Ass'y ‘| 10-15 10-15 75-105 Oil filter stand 20-26 20-25 145 - 18.0 Oil pan bolt 4.5 04-05 30- 38 Oil drain plug 20-25 20-25 14.5 - 18.0 Cylinder head cover bolt 4.5 04-05 | 30-35 Engine suspension frame bolt 30: 55 3.0-6.5 22.0 - 40,0 Engine mounting framesidenutwan] 40-60 40-60 | 29.0-430 Engine mounting nut (L&R) 40-60 40-60 | 290-430 Engine rear mounting nut 40-60 40-60 | 290-430System Fastening parts Rocker arm shaft screw 7.0- 85 Engine | Camshaft thrust plate screw 7.0- 85 Oil pump gear plate screw 7.0- 85 Gearshift control rod rear nut 58-75 Gearshift control rod front nut 88-75 Gearshifting | Control lever guide plate bolt 58. 7.8 control Control lever housing bolt 18.0 - 29.0 Control lever housing nut 10.5 - 14.6 Extension rod nut 18.0 - 29.0 Oil drain plug and level plug 22.0- 36.0 Transmission | Rear mounting nut 16.5 - 20.0 Differential cose bolt $8.0- 72.0 Leaf spring U bolt nut 21.8 - 33.0 Leaf spring front nut 32.5 -51.0 Leaf spring shackle pin nut 21.5 40.0 Front strut supportnut | | 13.0-20.0 | Front strut lock nut 28.5 - 43.5 Front strut bracket lock nut 50.5 - 65.5 Suspension [Stabilizer bar castle nut 28.6 655 Stabilizer bar mount bolt 21.5-40.0 Wheel nut 50-70 50-70 | 36.0-61.0 Drive shaft castle nut | 480-270 | 15.0-27.0 | 108.0- 195.5 Lower arm bolt 50-70 6.0-7.0 | 360-510 Lower ball joint bolt 50-70 60-7.0 | 36.0-51.0 Rear axle castle nut 0-120 | 80-120 | 57.5-87.0System Fastening parts Tightening torque Nom kgm lb-ft Steering shaft nut 25 - 40 25-40 18.0- 28.5 ‘Steering shaft joint bolt 20-30 2.0-3.0 14.0 - 22.0 Steering column bolt W-17 Wt 47 7.5 -125 Steering Steering gear case bolt 20-30 2.0-3.0 14.0 - 22.0 Steering pinion securing nut 55 - 80 5.5 -8.0 40,0 - 57.5 ‘Tie rod end lock nut 35-55 35-55 25.5 - 39.5 Tie rod end castle nut 40-70 4.0-7.0 28.5 - 61.0 Rear brake backing plate bolt 18-28 18-28 13.0 - 20,0 Brake master cylinder nut 25-40 25-40 18.0 - 28.5 Brake tube union nut 15-18 1.5-1.8 11.0 - 13.0 Brake flexible hose nut 20-40 2.0-4.0 14.5 - 28.5 Brake pipe 2-way joint bolt 6-10 0.6- 1.0 45- 7.0 Proportioning valve bolt 6-10 0.6- 1.0 45- 7.0 Brake Brake bleeder plug 9-13 09-13 65- 9.5 Wheel cylinder mounting nut 7-1 07-11 5.0- 8.0 Front brake caliper pin bolt 22-92 2.2-3,2 15.5 - 23.0 Front brake disc bolt 40-60 4.0-6.0 28.5 - 43.0 Front brake carrier bolt 70 400 7.0 40.0 50.5 - 72.0 Brake flexiblo hose bolt 20-25 2.0-2.5 14.0-18.0 For other bolts and nuts not listed above, refer to this chart: Tightening Torque Thread i ‘or ca) ao) =| om Conventional bolt “4” Marked bolt “7" Marked bolt Nem kgm lb-ft Nem kg-m Ib-ft 4 1- 2 O1- 02] O7- 1.5 1.5- 3.0} 0.15- 0.30 10-22 5 2-4 O2- 04 14-29 3.- 6 03 - 06 21- 46 6 4- 7 0.4- 0.7 28-65 8 - 12 O8 - 1,2 55- 9.0 8 10- 16 1.0- 1.6 7.0- 120 | 18 - 28 18 - 28 13,0- 20.5 10 22- 35 2.2- 35] 155- 265 | 40 - 60 40 - 6.0 28,5- 43.5 12 35- 55 3.5- 5.5 | 25.0- 40.0 | 70 - 100 7.0 - 10.0 50.5- 72.5 14 50- 80 5.0- 8.0 | 36.0- 58.0 |110 -160 /|11,0 - 16.0 79,6 - 116.0 16 80-130 8.0-13.0 | 67.5- 945 (170 -250 |17.0 -25.0 | 122.5- 181.0 18 130 - 190 13.0- 19.0 | 94.0- 137.5 |200 -280 |20.0 - 28.0 | 144.5 - 203.02-2. Service Data ENGINE Them ‘Standard Service Limit 135 Kalen (182.0 psl) 400 r/min 10.0 kg/ent (142.2 psi] 400 r/min| Compression pressure Difference between 1.0 ka/em (14.2 psi) 400 r/min| evlinders Valve clearance [Cold 0.13=0.18mm (0.008 ~ 0.007 in.) (olet, Exhaust) [Hot 023-0.28mm _ (0.009 ~ 0.011 in.) Tanition Timing 7° B.T.D.C. below 900 rmin (rem) Flatness of gasketed surface (0.05 mm (0.002 Qimm (0.004 fitting length 40 mm (1.87 in.) E | Flatness of manifoldfiniee = = | sont [Outlet —— O.imm (0.004 z ‘Seating [inter = 1.Emm (0.0812 ~0.0500 in.) & | Valve seat widt exhaust =1.5mm (0.0512 ~0.0590 in) [Seating enale 45° ‘Camsheft/Journal clearance | 0,060~0,091 mm (0,0020~0.0036in,) | 018mm (0.0089 in.) ‘Camshaft thrust clearance (0,080 ~ 0.160 mm (0.0020 ~ 0.0059 030mm (0.0118 in.) Inlet 36.152mm (1.4239 in) 36.100 mm (1.4212 in.) Camhoight Exhaust —[88.152mm (1.4233 36.100 mm (1.4212 in.) (Bese circle +A) Feat pump con] 33.300 mm (1.3110 33.000 mim (1.2982 in.) Camshaft deflection —- 0.10 mm — (0.0039 in.) $ | valve tem damote 6.965 ~ 6.080 mm (0.2742 ~ 0.2788 in.) a Exhaust | 6.955~ 6.970 mm (0.2738 ~0.2744 in) EB [ vawo guise uo. [set 7.000~ 7,016 mm (0.2755 ~ 0.2761 in.) : Exhaust | 7.000~ 7.016 mm (0.2765 ~0.2761 ind ee © [Vane guide tovane|iniet 0.020 0.080 mm (6.0008 ~0.0018in) | G07 mm 10.0027 in] & | stemelearonce [Exhaust | 0.030~ 0,060 mm (0,0012~0.0023in.) | 0.08mm — (0.0035 in.) £ | Thickness of vaive [Iniet 080=1.20mm (0.0315 ~0.0472in) | C&mm (0.0236 in.) S |_head periphery Exhaust [080~ 1.20 mm —(0.03%5~0.0472 in.) | G.7mm (0.0276 in.) § [Contact width of [Inlet 1.371.5mm (0.0512 ~ 0.0890 in.) —— S |_valve end volve seat [Exnaust | 13~1L.Smm (0.0812 ~0.0500in.) ————— Valve spring net 47.7 om (1.8779 in.) 46.5 mm (1.8307 in} free length Exhaust | 47.7 mo (1.8779 in.) 46.5 mm _ (1.8307 in.) ioe 26 ~ 30 kg (67.9 ~66.1 Ib) for 24g (52.9 1b) for fiting vane sariy fitting length 40 mm (1.87 in.) length 40 ram (1.87 in.) ae Exhaust | 26~30 kg (57.8~66.1 Ib) for 24g (52.9 Ib) for fitting Fength 40 mm (1.67 in.)item Siandard Series Limit Rocker shaft 0. 14.968 ~ 14,980 mm (0.589~0.690 in) Be | Rockerarm 10. 14.885 ~ 16,008 mm (0.590 0.581 in.) £5 | sana Inter (0.005 ~0.040 mm (0,0002~ 0.0016 in.) [0.07 mm (0.0027 in.) [| aera Exhauit0005~0.0407mm (0.0002 ~0.0016in.) [07 mm (0.0027 in.) © 8 | Rocker shaft deflection (0.06 mm (0.0028 in.) Flatness of gasketed surface 0.05 mm (0.0020 in.) 5 | Ovlinder bore (8.7.0.) [68.505 ~ 68.520 mm (2,6070~ 2.0876 in © | bittrancs in bore between eylindsrs 0.05 mm _ (0.0020 in.) S {Wear limit on bore 0.05 mn (0.0020 in.) Gylinder-topiston clearance [0.048 ~0,058 mm (0.0018 ~0.0022 in. } [standerd [68.450 ~ 68.476 mm2.6849 ~ 2.6969 in.) [Oversize:0.25 Piston diameter ram(0,0098in,| 68,700 ~ 68.725 mm(2.7047~2.7087 in.) 5 Pre rpg {68-960 ~ 68.975 mm (2,7146 ~2,7165 in] 2 Hropring _[1.82~1.54mm _(0.0596~ 0.0606 in Piston ringgroove bad ring _[.61~ 1.69. _(0.0564~ 0.0602 in) [Oil ring [2.81~ 2.83 mm (0.1106 ~ 0.1114 in.) Piston pin diameter 5.995 ~ 16,000mm(0.6207 ~ 0.6209 in.) Piston pin elearance in con. rod J.003~ 0,016 mm (0,0001~ 0.0008 in.) | 0.08 mm (0.0020 in.) Top ring |1.47~ 149mm (0.0878~ 0.0886 in.) Piston ring thickness{2nd ring __|1.47~ 1.49 mm _ (0.0578 ~ 0.0586 in.) . Olling [045mm (0.0177 in) EF ingclearnesin [Too ring (09~0.07 mm (00012 0.0027 1m) _[as12 mm (0.0047 in) & [peo Band ring 02 0.06mm —(0,0008~ 0.00731) _|0.10mm _(0.00891n.) a (Top ring 10.15~0.35mm {0.0069~ 0.0137 in.) [0.7mm — {0.0275 in.} Piston ringend g9p [and ring [0.10 ~0.30mm (0.0038~0.0118 in.) [0.7mm (0.0275 in} ‘Oil ring (0.30~0.90mm {0.0118~ 0.0384 in.) [1.8mm {0.0708 in.} ‘Grankshatt detection (mide) [0.06 mm (0.0023 in.) ge [Crank pin diamoter 17.985~ 38.000mm (1.4954 ~ 1.4960 in.) -B [Crank pin clearance in con. rod [0,020~ 0,040 mm (0.0008~ 0.0016 in.) _|0.08mm (0.0081 in.) | cag ad nara se fo =e Gi soon aia © Ferank journal diameter |49.985 ~ 50.000 mm (1.9679 ~ 1.9686 in.)} Bearing to journal cosrence ,020~ 0,040 mm (0.0068 00016 in.) _|0.08mm (0.0032 in.)them Standard Service Limit Grankahafe trust play 013 =O28mm (00051 0.6110im) | 035mm (0,0728in) $ | Connecting rod big end thruct Part aaapaniss 0.10 ~0,20mm — (0,0039~ 0.0078 in.) 0,30 mm (0.0118 in.) é Twist ‘O.t0mm (0.0039 in.) Connecting rod Bow 10.08 mm (0.0020 In) CLUTCH & TRANSMISSION Tem Siandard Service Limit ede play 5-25 mm (06-1. 4 | Facing wear (Rived head depression} [1.2 mm (0.050) 0mm (0.02in.) & | Facinginpu shaft seration backlesh 05mm (0.02in.) ‘Cuteh release arm play [a= 4 mm (0.08~ 0,16 in) Glearance betweun gears and rings [0.8~ 1.2mm (0.03 ~ 0.08 in) 05mm (0.02in.) Low gear Tamm(atind | 8.1mm (0.2In.) Key slot width of synebronizer ring | gecond third 7 Second third 9.mm (0.38 ind 2.9mm (0.99in) 2 | Fork shaft locating spring 5 |& Goar shift arm spring _|Ptee lensth] 19.5 mm (0.767 in.) 17.0 mm (0.669 in. & ow & second goar bactash lo10~ 0.1mm — (0.0039~0.0088in.) | OSmm (O0118in) Third 8 top gear backlesh lo.1~0.20mm — (0.0059~0.0078in.) | 03mm (0.0118in.) Reverse gearroverse idle gear z an ae a backlash 0.15~0.30mm —(0,0059~ 0,0118 in.) O4 (0.0187 in.) LUBRICATION item Standard Service Limit Outer gear periphery clearance iz ee a In pump case 0.05 ~0.10mm — (0.0020 ~0.0039 in.) | 0.16 mm (0.0059 in.) Outer er tooth carne ome asioen Gary ans '§ | Inner gear tooth clearance in a, i 2 | ptote 0.177 ~0.328 mm (0.0070 ~0.0129 in.) 3 [oir pump side clearance (anass) [0.036 ~0.085 mm (0.0014 ~ 0,003 in.) | 0.16 mm (0,00691n,) il rotiet valve | Pree lensth Biclulu {4.77 in) sering 10.7 mm (0.42 in) (13.601 85) sz mm (O42 ind | 206k 5.200 kg (11.684 15) ‘Set pressure of oil pressure switch 0.2~0.4 kgicm? —(2.84~ 6.68 psi)COOLING SYSTEM hem Standard Sarvice Limit Fan belt tension as deflection under 10 kg (22 Ib} push applied to middle 10~ 16mm — (04~ 06 ind point between pulleys ‘Thermostat start-to-open [ ‘i apart g2"c (79°F) “Thermostat full-open tempersture a5 (20°F) Valve lift 8mm (0.31 in DIFFERENTIAL Iam Standara Service Limit Side gear backlash 1.05 ~ 0.10 mm (0,002 ~ 0.004 in.) Final gear backlash 0.08 ~ 0.12 mm (0.003 ~ 0.005 in.) SUSPENSION tom ‘Standard Service Limit Front coil spring rato 1.48 kg/mm (83 Ib/in.) Rear leat spring rate 2.17 kgitm (122 Ib/in.} *2.6 kg/mm (145.6 lin.) Front coil spring free langthy 352 mm (13.9 ind Rear leaf spring free height | 135.5 mm (5:33 in.) © 127.6 mm (5.02 in.) 156 mm (6.1 in.) Front strut stroke 195 mm (6.3 in.) Foor shock absorber stroke 160. mm (6.3 in.) "175mm (6.9 in.) * For rear leaf spring of three-leaf type © For the right side leaf spring of aloft hand stearing vehiete,STEERING SYSTEM item Standard Service Limit Gear ratio (gear ease) 175 Steering angle, inside 38° Steering angle, outside 32° Minimum turning 44m (144) Front 190 kPa {1.9 kg/em?, 27 psi) Tre intating presure 790 kPa (1.0 kefom?, 27 pat *220 kPa {2.2 kg/em?, 31 psi) Torin 2~4mm (0.079 ~0.187 In) Camber angle 1° 20" Trail 13mm (0.51 ind King pin inclination 12° 50" Caster angle 3°15" * For vehicle with rear leaf spring of throe-leat type BRAKE tom Standard Serve Limit Brake drum Inside diameter 180mm (7.087 in) 182mm (7.168in1 Brake drum “outofround’” Omm (ind) 5mm (0.02 in.) eee Zomm —— (027in} Somm (042%) hen ada depron at 30 kg (66 lb) 80 mmm (1.97 in.Jminiemum Brake dis thickness Timm (0433 in) 95mm (0.974 in.) Brake aise detection 0.18 mm (0.006 in.) Palko 156mm (0910in) 65mm (0256in)ELECTRICAL Item Standard Service Limit Ignition timing 7° B.T.D.C, below 900 r/min (rpm) Ignition order 1-3-2 & | Breaker point gap 0.4-0.5mm (0.016 - 0.019 in) g Cam dwell angle 62° § | Condenser capacitance 0.25 microfarad ‘E | Ignition coil, Primary winding | About 3 ohm (inclusive of the 1.8:0hm ~ | resistance resistor) Ignition coil; Secondary winding | About 8 kiloohms resistance Voltage 12 Volts ._ [Output 0.6 kw | Rating 30 seconds E | Brush length 19 mm (0.75 in.) 2mm (0.47 in.) i Number of pinion teeth 9 ‘Commutator diameter 32.5 mm (1.28 in.) Mica undercut 0.5-0.8mm _(0.02-0.03 in.) __ [0.2mm (0.007 in.) Nominal operating voltage 12 Volts ‘Maximum alternator output 0A Effective pulley diameter 65 mm (2.58 in.) Maximum permissibie alternator | 49 600 e/min (rpm) speed 5 Working temperature range 40 - 80°C (-104 - 176°F) : Rotor, Ringtoring circu eee Z| Brush length 13.5 mm (0.53 in.) 6.0 mm (0.20 in.) Standard output voltage 13.8- 14.8 Volts, 20 A minimum and current Regulated Vottage 13,.8- 14.8 Volts Voltage-relay cut in Voltage 4,2 ~5.2 Volts Field circuit resistance Several ohms 2-10