arose) Lon r:\ DA weWAN TANUAL 2TG (D) 20 ~ 25 02-2TG (D) 20 ~ 25 42-2TD 20 ~ 25FOREWORD This manual covers the service procedures of the TOYOTA TOWING TRACTOR 2TD/2TG20, 25 Series. Please use this manual for providing quick, correct servicing of the corresponding towing tractor models. This manual deals with the above models as of March 1998. Please understand that disagreement can take place between the descriptions in the manual and actual vehicles due to change in design and specifications. Any change or modifications thereafter will be informed by Toyota Industrial Vehicles’ Parts & Service News. For the service procedures of the mounted engine, read the repair manuals listed below as reference together with this manual. (Reference) Repair manuals related to this manual are as follows: TOYOTA INDUSTRIAL VEHICLE 1DZ-II ENGINE (No. CE618-2) REPAIR MANUAL TOYOTA INDUSTRIAL VEHICLE 4Y ENGINE (No. CE602-2) REPAIR MANUAL TOYOTA INDUSTRIAL VEHICLE 2Z ENGINE (No. CE625-4) REPAIR MANUAL TOYOTA Material Handling Company [Din of TOYOTA NOUSTRIES CORPORATIONSECTION INDEX GENERAL ENGINE Mt AUTOMATIC TRANSMISSION (Up to '95. 5) [EAI AUTOMATIC TRANSMISSION (From ‘95. 6) [EI CLUTCH EZ MANUAL TRANSMISSION PROPELLER SHAFT iz DIFFERENTIAL _ a REAR AXLE EE FRONT AXLE _ STEERING BODY FRAME z= fio BRAKE 7 p12 APPENDIXGENERAL Page VEHICLE EXTERIOR VIEWS .. 02 MODEL LINEUP .... 03 FRAME SERIAL NUMBER .... ABBREVIATIONS .. OPERATIONAL TIPS ... . 04 STANDARD BOLT & NUT TIGHTENING TORQUE ........ 0-5 PRECOAT BOLTS .. . 0-7 HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE .. . 07 WIRE ROPE SUSPENSION ANGLE LIST ... . 0-8 SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE ... - 0-8 MEMBER WEIGHTS ... . 0-9 PERIODIC REPLACEMENT PARTS & LUBRICANTS ...... 0-10 RECOMMENDED LUBRICANT TYPES & CAPACITIES ... 0-11 LUBRICATION CHART .. PERIODIC MAINTENANCE .. . 0-130-2 VEHICLE EXTERIOR VIEWS.0-3 MODEL LINEUP oamian Installed Tn Tan — 2 — 2000kg [022720 | __10z “Torque converter t (4400 Ibs) 21G20 ay Qlutch t 02-2TG20 4y Torque converter t Te 27025 1DZ Clutch t 2500kg |_022TD25 | 10z ‘Torque converter t (5500 Ibs) 21G25 ay Quutch t 2500 kg_ 42-21025 az t t FRAME SERIAL NUMBER Pea cma amiss as a — a Te a hntalhenad 27G25-10011 sree aS 21625 | “27625-11001 Center on top of frame LH ‘BZengre ‘2102 1998.8 ~: a S 27025-3100104 ABBREVIATIONS Abbreviations used in this manual are as follows ‘Abbreviation ‘Abbreviation Cone) Meaning coal Meaning ‘ABDC ‘After button dead center PS Horsepower ASSY Assembly Ps. Power steering ATDC After top dead center RH Right hand ATM Automatic transmission SAE Society of automotive engineers BTC Before top dead center (USA) uy Less sst Special service tool LH Left hand stD Standard luc Long life coolant SUB-ASSY Sub-assombly MT. Manual transmission T= Tightening torque onV ‘Overhead valve oot Number of teeth (00) opr Option u/s Undersize o/s Oversize wi with OPERATIONAL TIPS. 1. Safe operation (1) Make sure that correct size wire is used for hoisting a heavy material (2) After jacking up. always support with rigid racks or stands. 2. Preparation of SSTs and measuring tools (1) Prepare STs and measuring tools before starting operation. 3. Clearing and arrangement (1) Always keep the workshop neat and orderly for easy operation. (2) Disassembly of hydraulic equipment shall always be done in a clean place using clean tools. 4, Genuine Toyota parts Genuine Toyota parts should be used even in the replacement of packings. gaskets and O-rings. 5. Repairs on electrical system Before doing any repairs on the electical system, disconnect the cables from the battery terminals. Be sure to disconnect the negative © cable first 6. Tightening torque for installation Be sure to observe the tightening torque given in this manual. If not specified. tighten to the torque listed in standard bolt & nut tightening torque. 7. Defect status grasp Do not start disassembly and replacement as soon as a defect is found. but first grasp whether the defect requires disassembly and replacement. In the case of torque converter for example, do not attempt torque converter disassembly upon a failure in starting the vehicle, but first check such factors as the oil, pressure and rotation status causing the failure.0-5 STANDARD BOLT & NUT TIGHTENING TORQUE Standard bolt and tightening torques are not indicated. Judge the standard tightening torque as shown below. 1. _ Find out the type of the bolt from the list below and then find the bolt tightening torque from the table. 2. The nut tightening torque can be judged from the mating bolt type. BOLT STRENGTH TYPE IDENTIFICATION METHOD 1. Identification by bolt shape 2. Identification by part No. Shape and class Hexagon head bok] Bolt head No. - Part No. Hexagon 91611-40625 head bolt Length (mm) O No mark ar Diameter (mmm) Class Hexagon — ror, | Emme | a Hexagon Two protruding | gy head bolt lines Hexagon Two protruding | gy : flange bolt lines Stud bolt Hexagon Three recat | GI eae tne | 7 Part No. 92132-40614 Hexagon Four readte | GS) Frtcinosoes | er Length Diameter (mm) Class mare! AS | a No mark a Stud bolt Grooved06 TIGHTENING TORQUE TABLE 145 670 1050 1600 1950 120 82 lee x88 8885 ajsaag 3/28 i E ie 28 8 glee a 288 5B glpeaes i gE RRR ewe SR haw PS ewe hh ewle¥$ Sew i S8ieeleshies Seeleki8enehises 5 zé egze esse esseslererze esse 8 3 &07 ‘Seal lock agent PRECOAT BOLTS {Bolts with seal lock agent coating on threads) 1. Do not use the precoat bolt as it is in either of the following cases. (a) After itis removed. (b) When the precoat bolt is moved (loose tightened) by tightness check, etc. Note: For torque check, use the lower limit of the allowable tightening torque range. If the bolt moves, retighten it according to the steps below. 2. Method for reuse of precoat bolts (1) Wash the bolt and threaded hole. (The threaded hole must be washed even for replacement of the bolt.) (2). Porfectly dry the washed parts by air blowing. (3) Coat the specified seal lock agent to the threaded portion of the bolt. HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE 1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces with clean cloth to remove foreign matters and dirt. Also check no dent or other damage on the contact surfaces before installation. 2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and tight- en the fitting. 3. The maximum tightening torque must not exceed twice the standard tightening torque. Nominal diameter Standard tightening torque _N-m (kgf-cm) [ft-Ibf] of scrow Standard Tightening range TAG -20UNF | 25 (250) (18.11 24-26 (240-270) [17.4~19.5} 6 (0.24) 9/16 - 18UNF | 49 (500) (36.2) ‘47-52 (480-530) (34.7-38.3) 9 (0.35) 3/4 = TEUNF_| 59 (600) 143.4) ‘56-62 (570-630) [41.2~45.6] 12(0.47) 778 - V4UNF_| 59 (600) (43.4) ‘56-62 (570-630) (41.2-45.6] 12 (0.47) 778 - Y4UNF | 78 (800) (57.9) ‘74-82 (760-840) (55.0-60.8) 15 (0.59) LANG -12UNF_| 178 (1200) (86.8) 112-123 (1140-1250) (82.5-90.4] 19 (0.75) 1.5/6 - 2UNF_[ 137 (1400) {101.3} 130-144 (1330-1470) [96.2-106.4] 25 (0.98) PFS 25 (250) (18.1) 24-26 (240-270) [17.4-19.51] 6 (0.24) PF/B 49 (500) [36.2] ‘47-52 (480-530) [34.7-38.3} 9 (0.35) PEV2 ‘59 (600) 143.4] 56-62 (570~630) (41.2~45.6] 12 (0.47) PFA 118 (1200) (86.8) 112-123 (1140-1250) [82.5-90.4] 19 (0.76) PFI 137 (1400) (101.31, 130-144 (1330-1470) [96.2-106.4] 25 (0.98)08 WIRE ROPE SUSPENSION ANGLE LIST [Suspension] tongion | Compres-| Suspension [Suspension Compres- | Suspension ‘angie | Tension | "sion | method | angie | Tso | sion ‘method o | 1.00time | otime | = 90° | 1.41 time | 1.00 time o Pa 30° | 1.04time | 0.27time | 3 120° | 2.00time | 1.73 time Ps & = cor | 1.16time | 0.58 time <” SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE Unit: _N (ton) {tb} Rope | Cuting | Sinlezone ‘Two-rope suspension Four-rope suspension diameter] toad o o | 3° | 6 | 9 | o | 30° | 6 | 90° mm | 21380 | ~30a0 | “6080 |“SB80| 5200 | ~4310_| T2160 | 11770-| T0400 | 8630 (ozam| 2:18 | (3 | (0.62) | (oo) | 053) | 04a | 124 | (1.2) | (1.06) | (0.88) 407) |_t683.61_| t13671 | 11323) | 11169) |_1970)_| (2734) | 12646) | (23371 | 11940) . ‘31480 |~ 4410 | 8830 | 8530 | 7650 | 6280 | 17650 | 17060 | 15300 | 12550, (oszim| 220 | (0.45) | (0.9) | (0.87) | (0.78) | (0.64) | (1.8) | (1.78) | (1.86) | (1.28) 17678) |_1982.31 | (1985) | 119181 | 117201 | 114111 | 139691 | 139371 | 13440) | 12322) Jo am | 49230] 6960 | 14020 | 13440-[ T1770 | 9810 [27460 | 26480 | 23540 | 19610 fost | (602 | corn | 4s | e137) | 2) | (0) | a | 27 | a | (20) 4 in) | 110691 | 11565.61 | 131531 | 130211 | 26461 | 122051 | 161741 | 159541 | 15292) | 14410) 25 mml 76980 | 10980 [21570 | 21280 | 18630 | T4710 | 43150 -| 41190 | 37270 | 29420 iasmm| Gee | cir2) | 22) | a | as) | as) | wa | a2 | Ge | ao -8 in) | 1173871 | 2469.5) | 14851) | 14631) | 14190) | 13308) | 197021 | 192611 | 183791 | 166151 Jamm | 98400 | 13730 | 27460 [26480 | 23540 | 18630 | 54920 | 62960 | 47070 | 37270 tosem| 283 | (0 | 2a | an | aa | a9 | 6 | 64) | ae | eer 56 in) | :216751| 130871 | 16174) | 15954) | 15292) | 14190) | (42348) | 1119071 | 110584) | (8379)MEMBER WEIGHTS ay 134 kg (294.8 1) 11314 NI Engine ASSY 102 176 kg (387.2 16) (1726 NI 2 240 kg (529.2 Ib) (2364 NI ‘Automatic transmission ASSY 129 kg (283.8 10 (1265 NI ‘Manual transmission ASSY 70 kg (154 i) 1686.5 NI Differential carior ASSY 2TD/2TG20, 25 (60 kg (132 Wo) (588.4 NI Rear axle ASSY 2TD/2TG20, 25 {326 kg (717 8) 13197 NI Front weight 36 kg (79.2 ib) [353 NI 2TD/2TG 20 series {990 kg (2178 i) 19709 NI Rear upper weight, ZTD/2TG 25 series 1448 kg (3180 Ib) 114170 NI 2TDATG 20 series 460 kg (1012 Ib) 14511 NI Rear lower weight 2TDIATG 25 sories {630 kg (1386 ib) (6178 NI0-10 PERIODIC REPLACEMENT PARTS & LUBRICANTS. Replacement timing — hem B weeks 3 months 6 months 12 months 250 hours, 800 hours 1000 hours 2000 hours Engine oi Engine oil fter nso) ‘Coolant (Replace LUC every 2 years) Fuel filter ‘Automatic transmission oil elelele ‘Manual ranemission oll Differential oil Power steering oll Steering gear box oil Brake Fluid (Clutch fluid ‘Spark plug Trailing am shaft grease Wheel bearing grease Cyclone air cleaner element PCV valve Brake booster rubber parts Whee! cylinder cup and seals Brake and clutch hoses Clutch and brake fluid reservoir hose eon va ‘Stop switch end ee Power steering hose re Power steering rubber parts ? Mv ea) Fue! hose oon vo ‘Automatic transmission rubber hose entreeon RECOMMENDED LUBRICANT TYPES & CAPACITIES Doscapton | Gesstionton 7) a Sse se | Steaww cetionsoecw 1108 00 crane eau cusp ee Die eae woe vient 4%, | OSES Choin cata 794 go0US saeionoD = (2.11 US gal) Tanai x ameter ‘transmission ae en (Up to '95. 5) 2.64. US gan cerns pee tee — stot teoa Tinease | aaa (From ‘95. 6) (2.9 US gal) API 3.18 ne ee Ce imo ta Sette” | cts oiteerss |, 9, | nptcerorsacaswion | 8 saibmaaoo | 758 tomes | obo : canes | aae roversingat [AF | OM Down wa zee Tae a Suoeg graced cewr0 sein ieee Caches ok Sees. 0OTS Cinch noaas_| Peper ona 2 I x 06t Gee eso nk SAE 709,003 ee sane Toe cov race Fuel tank is a s = gal) Lighe of omen (18.48 US gal) Canoe We Gree Tas | Peper amour ‘* LLC 30-50% mixture tfor winter {2.56 US gal) , a coo oat coca aaa ue Coolant with rustinhibitor (for ez (2.2 US gall spring, summer and autumn) ait z (2.40 US gal) Sosa ws ae (reservoir trank) t aoa (0.16 US gad)0-12 LUBRICATION CHART 1. Tealng am bearing 11. Storing gearbox © MP grease 2. Steering knuckle king gin 12. Titsteering locking mechanism — @) Engine ci 3. Front wheel boating Bout day inspection @ Hipoyd goer of 4. Brake & clutch 10-hour week inspection © Brake hid 5. Rear wheel bearing MN, 250-hour (6 woeks) inspoction GM Dexron@it 6. Diferentilend subtransmission IV. 100¢hour (month) inspection Automate vehicle) 7. Power steering reservow tank ——V._2000-hourfaneually inspection Gear of (Clutch vehicle) 8. Engine crankshaft (© Inspection snd oil addition 9. Torque converter case ‘© Replacement 0. Universal joint ‘uubncation Chart0-13 PERIODIC MAINTENANCE INSPECTION METHOD | Inspection. Repair or replacement if required M: Measurement. Repair or adjustment if requried T: Retightening C: Cleaning L: Lubrication Inspection period: Inspec: Inspection items tion | Every6 | Every3 | Every 6 | Every 12 method | weeks | months | months | months «250 | (800) | (1000) | (2000) ‘Steering whee! 1. Play and looseness 1 2. Function ' Gear box 1. Oil leak 2. Looseness of mounting 3. Relief valve fiter clogging 4. Steering gear box ot! change: Rod. links and arm 1. Ball joint dust boot cracks and damage 1 2. Looseness and damage 1 ° ° 3._Linkage wear and mounting condition Il oo |oo 00 joo 000 joo 0° 000 |oooo Joo Knuckle 1. King pin looseness 1 ° ° ° 2._ Cracks and deformation ' ‘Steering shaft 1. Wheel alignment 2. Left and right turning angle Steering system z= Power steering Bett looseness and damage Fluid leak and capacity LLooseness of mounting Power steering hose replacement Power stooring fluid change Replacement of internal rubber parts -----= 000 000 © 0000-14 Inspection items Inspec: ton method Every 6 wooks (250) Inspection period Every 3 months (500) Every 6 months (1000) Every 12 months, (2000) Brake pedal 1. Play and floor clearance 2__ Braking effectiveness oo ° ° 0° Parking brake 1. Margin in pulling distance 2._ Braking effectiveness Rood and cable 1._Looseness and damage Hose and piping 1. Leakage. damage and installation condition 2. Brake hose replacement 3. Brake fluid reservoir replacement 4. Vacuum pump oil hose replacement ° jo joo o Jo joo Reservoir tank 1. Amount of fluid © |o 00 Jo Joo © Joo0o Jo Joo joo Master cylinder, wheel cylinder and disk brake caliper 1. Operation, wear and damage 2. Master cylinder and wheel cylinder rubber parts replacement (cups. dust seals, including disc brake caliper parts) 3. Brake fluid change 4._Stop switch (hydraulic) replacement Braking system ° ° Power-assist ‘Air cleaner clogging Operation. ‘Vacuum hose replacement Rubber parts replacement ‘Compressor hose replacement Air pressure gauge hose replacement foXo} 00 Brake drum and brake shoe Clearance between drum and lining 2. Wear of shoe sliding portion and lining 3. Drum wear and damage 4._Loose drum mounting --z= © Jooocoo0d |o Backing plate 1. Deformation, cracks and damage 2. Loose mounting ©0 }o000 |oooc00 |oo0.15 Inspection period Inspec Inspection items tion | Everv6 | Every 3 | Ever 6 | Every 12 method | weeks | months | months | months 250) | ¢500)_| (1000) | (2000) Front axle 1._ Cracks, damage and deformation ° Rear axle 1._Cracks, damage and deformation Wheels 1. Tite inflation pressure Tire cuts, damage and uneven wearing Loose rim and hub nuts Tite groove depth Metal chips. pebbles and other foreign matter trapped in tie grooves Loose wheel nuts and wheel bolts Rim, side bearing and disc wheel damage ‘Abnormal sound and looseness of front wheel bearing 9. Abnormal sound and looseness of rear wheel | 1 bearing 10, Front wheet bearing grease replacement 111, Rear wheel bearing grease replacement ing vat M ' Dri --4 © 000 900000 © 000 00000 ©0 0 000 C0000 ‘Chassis springs 1. Damage ' 2._Uneven deflection between left and right i Installation and joints 1. Loosening and damage of installation 1 2. Looseness of joints 1 3._Leat displacement ' ‘Suspension arms 1._Looseness of joints and arm damage ' Shock absorber 1. Oil leak and damage 1 2._Loaseness of installation Il Suspension system eo Jo Jooo Joo Joo 0 000 co0CO Jo0-16 Inspection items Inspec ton method Inspection period Every 3 months (500) Every 6 months (4000) Every 12 ‘months (2000) ‘Clutch 1. Pedal play and floor clearance at disengagement Operation Fluid level Clutch fluid change ° ° ° ° ° ° ° fansmission and automatic transmission Oil leakage and level (transmission) Fluid leakage and level (automatic transmission) Loose operating mechanism ‘Automatic transmission - Stall test and oil pressure measurement Transmission - il change ‘Automatic transmission - Oil change ‘Automatic transmission ~ Rubber hose replacement °° °° 00 CO CO ©00 00 00 Jooo Power transmission system Propeller shaft and drive shaft Loose joint LLooseness at spline connections Looseness of universal joint Looseness of center bearing ‘Shake of propeller shaft Twisting and cracks of axle shaft Differential 1. Oil leakage and level 2. Differential oi! change 3. Loose bolts Ignition system 1. Spark plug condition 2. Ignition timing 3. Breaker point condition 4. Operation of advance mechanism 5. Plug cord internal discontinuity 6._ Spark plug discontinuity 000 Electrical system Battery 1. Battery fluid level 2. Battery fluid specific gravity 3._Continuation condition of terminal °° 000 |000000 Jooo0 Joo0000 Electrical wining 1. Damage of wiring harness 2. Fuses 00Inspection items Inspec tion method Inspection period Every 6 weeks (250) Every 3 months (600) Every 6 ‘months (1000) Every 12 ‘months (2000) Engine Main body 1. Proper starting and abnormal noise 2. Rotating condition at idling and during acceleration Exhaust condition Air cleaner element Compression pressure Valve clearance Cyclone air cleaner element replacement Tightening condition of cylinder head and manifolds 4-Z--- 00 CO 0000 CO © 0000 00 Governor 1, Maximum static speed without load ° Lubrication system Oil leakage Oil contamination and level ii iter clogging Oil change Oil iter change © 0° 00 00 Jo ‘uel system Fuel leakage Carburetor linkage operation. Thwoitle valve and choke valve operation Ful fiter element clogging Injection pressure and spray pattern Injection timing and volume Fuel feed pump operation Fuel filter replacement Fuel hose replacement 10. Sedimenter water dain ~---g2---- ° 2 oo oo jo Cooling system Woter temperature Fan belt looseness and damage Water leakage Radiator cap operation Rubber hase deterioration Looseness at fan mounting Coolant change Coolant change (vehicies with LLC) re--Z-Z- 00 0CO e00 000 000 000 jo 00 0 0000000 Joo 0000000 |o0000 |o (4000)0-18 Inspection period Inspec Inspection items tion | Every6 | Every3 | Every 6 | Every 12 method | weeks | months | months | months (250) | (500) | (1000) |_ (2000) Blow-by gas recovery system 1. Metering valve condition 1 ° ° ° 2._ Piping damage i ° 3 ° 0° Fuel evaporative emission contol system 1. Piping damage 1 2. Charcoal canister clogging and damage 1 3__Check valve operation 1 System Tor SHOR, Emission control system for carbon monoxide, etc. 1. Loose mounting and damage of emission con. 1 trol system (catalytic converter, etc ) 2. Secondary air supply unit ' 3._Piping damage and installation condition 1 foul ogor.hainntul gas. ete. Emasion Con Heat damage prevention system 1. Loose mounting and installation condition of | 1 insulating plate © Joo 0 Jooo Lighting system and tum signal lamps 1. Operaiton ° ° ° Homs 1. Operation i ° ° ° Back buzzer 1._ Operation 1 ° ° ° Wiper, washer, defroster and locks 1._Operation Rear- view mirrors and reflectors 1. Reflecting condition 1 2._ Contamination and damage I 0° 0° 0° Instruments 1. Operation l ° ° ° Exhaust pipe and mutter 1. Looseness and damage at mounting ' 2__Muttler operation i Fuel system for high-pressure gas Gas leakage at piping and joint Piping and joint damage Tar in vaporizer Looseness and damage at gas container Air tightness to the cabin with seats Frame and body 1. Door lack operation 1 2. Looseness and damage Il Safety device, ete ‘Seat 1. Seat belt condition Towing device 1. Looseness at draw bar mounting 1 2. Wear of drawbar pin and bracket 1 ‘3._Damage and wear at drawbar pin link portion 1 Others 1. Lubricating condition of chassis components 1 2. Steering linkage and universal joint lubrication | _1 ° ° (oXorey 0°00 000 co00o ©0000 0000 00 Jooo |o Joo Jooooo joo jo joo Jo Jo jo jo 0°ENGINE Page ENGINE SECTIONAL VIEWS . ENGINE PERFORMANCE CURVES .. SPECIFICATIONS . ENGINE ASSY REMOVAL & INSTALLATION .. ENGINE SPEED INSPECTION & ADJUSTMENT . AIR GOVERNOR ADJUSTMENT . ACCELERATOR PEDAL . COMPONENTS... er ACCELERATOR PEDAL ADJUSTMENT. AIR CLEANER (UP TO ‘98. 2) GENERAL ‘SPECIFICATIONS COMPONENTS INSPECTION .. AIR CLEANER (FROM ‘98. 3) GENERAL .. ‘SPECIFICATIONS COMPONENTS INSPECTION 112 ENGINE SECTIONAL VIEWS. ie ~ DZ Engine Sectional View TAR7.822 Engine Sectional View15 ENGINE PERFORMANCE CURVES 17.0/1600 17 16 15 14 13 6 55/2400 5 ie x 2 100 fe 185/1400 te ‘ eee 10 14 18 22 26 Engine speed (rpm) ree Shaft torque (ke-m) ‘Fuel consumption (g/psh) DZ Engine Performance Curves60, 5 3 4 g 5 3 2 (es) 6 16.5/1800 54/2400 195/2300 10 14 18 22 Engine rpm (rpm) 18 N6 14 12 ‘Shaft torque (ke-m) 10 +m) 60 40 20 00 ‘uel consumption (g/psh) md (g/psh) x10 ‘Y Engine Performance CuresShaft output (PS) (os) 50 22/1600 (~ 2003.8) 20.4/1600 (2003.9 =} 23 22 21 20 19 {66/2200 (~ 2003.8) '57/2200 (2003.9 ~) (o/pshy 180 170 160 st is0 1 Engine rpm (rpm) x10? Shaft torque (kg-m) Fuel consumption (g/peh) 2Z Engine Performance Curves18 SPECIFICATIONS — z z = Ses Cycle 4 ee imap Injection order al 1-3-4-2 oes Rasen —— =a anion Saino —— we a Ts ———- a a Compression pressure kgfom*/rpm IkPafrpm] 29/260 [2844/260) 33/260 (3230/260) woclo mee ms : ns iscimamei | oneonaes| ‘co acai = wa ‘dina speed ‘pm 0 750% Oil ring 1 Cylinder liner type Dry type Intake valve opening & closing timing Open BTDC 16° = eae | Se aes ose |e = = a ar I a on ae a a = aoe eee voncmeny [Sag] 20030 66/2200 87/2200 #2: 2003.8 : 22.0/1600 [216/160] 2003.9 ~ : 20.4/1600 [200/1600)Engine mode! ay. Type Gasoline ovale 4 No of eylinaers and arrangement Incline 4 cylinders. longitudinal arrangement Staring method _ Seit-starting Combustion chamber type 7 Wedge type Valve mechanism OHV, Chain drive Bore * Stroke mm (in) 91.0 = 86.0 (3.58 « 3.39) Total displacement - cc (cu-in) 2237 (136) aaa Compression ratio _ 86 Compression pressure kg/cm? (psi)/rom [kPa/spm) 12.5 (178)/250 [1225 8/260) Rated horsepower 7 PS/rpm 1/2400 Maximum topaue ka-m (felb)/rom [Nisam 165 (119)/1800 [161 6/1800) Minimum fuel consumption at full load ‘a/os-h (pm) 200 (2000) Engine dimensions (length * width * height) rm (in) | _ 676 812 707 (266 « 202 = 278) Service weight = kg (Vo) (N} 134 (295) [1314] ‘Number of piston rings 2 compression rings and ol ing - Open 12° BTDC Intake valve timing Close. 40" ABDC Open 5a" BBOC Exhaust valve timing nae Same Intake 0 (Seif adiusting) Valve clearance Exhaust 0 (Selt adjusting) Idle speed ‘pm 660 + & ‘No-load maximum governed speed ‘om 2800 + 60 PCV system type Closed type1-10 ENGINE ASSY REMOVAL & INSTALLATION ‘The state of the engine ASSY removed from the vehicle is as follows, Automatic transmission vehicle (Up to ‘95. 5) = Automatic transmission vehicle (From ‘95. 6) .. Clutch vehicle .. Engine ASSY w/automatic transmission Individual engine ASSY .. Engine ASSY wimanual transmission licates the removal step No.) Engine ASSY Removal & Installation Tarmasa REMOVAL Drain cooling water Remove the engine hood Disconnect the battery terminal and remove the battery. [Point 1] Disconnect electrical witing, fuel piping and power steering piping Disconnect the accelerator wire and automatic transmission throttle cable (in ATM vehicle only) on the engine side Disconnect the exhaust pipe Remove the front grille Remove the radiator ASSY and torque converter cooler. [Point 2] Remove the engine mounting bracket set nuts Disconnect the shift lever link rod. Be8c8 B8ee8aco) Beea a @ ® @ a Disconnect the speedometer cable and each switch wiring Disconnect the propeller side on the transmission side. Remove the toe board ‘# Remove the torque converte drive plate set bolts. [ATM vehicle] [Point 3] « Disconnect the clutch release cylinder piping. [MTM vehicle] ‘@ Remove the clutch cover and clutch disc [MTM vehicle] ‘Support the rear part ofthe transmission with a pantagraph jack [Point 4] Disconnect the torque converter cooler hose {Point 5] « Slightly hoist the engine ASSY w/automatic transmission. [ATM vehicle] [Point 6] ‘ Slightly hoist the engine ASSY w/manual transmission. [MTM vehicle] ‘¢ Remove the automatic transmission rear set bolts. [Point 7] ‘¢ Remove the manual transmission rear mounting bracket set bolts ‘@ Remove the engine ASSY w/automatic transmission. [Point 8] ‘¢ Remove the engine ASSY w/manual transmission 1 Separate the engine ASSY from the automatic transmission. [Point 9} ‘@ Separate the engine ASSY w/clutch housing from the manual transmission. Remove the flywheel and drive plate housing. [ATM vehicle] Remove the flywheel and clutch housing, [MTM vehicle] INSTALLATION: ‘The installation procedure is the reverse of the removal procedure. Caution: me Always operate as follows after engine installation, ‘@ Inspect and adjust the engine speeds. (See page 1-12, 1-13) '@ Bleed air from the power steering system. (See page 9-11) Drive the vehicle to check the feeling of the automatic transmission.1:12 OPERATION POINTS Point 1 Removal Disconnect the negative © battery terminal first. installation Connect tne negative © battery terminal later Point 2 Removai/ installation: Carefully operate the prevent the radiator and torque converter fins from damage. Point 3 (ATM vehicle) Remove/installetion Use the crank pulley set bolt when rotating the converter Installation Tighten the set bolts to the specified torque after installing all set bolts temporarily. T= 15 ~ 20kg-m (10.8 ~ 145 ft-ib) (14.71 ~ 19.61 Nm] Point 4 Removal/installation Supply the rear part of the transmission with a antagraph jack Do not raise the jack exces- sively Disconnecting the Batery © Termin Taraake notes of the cooler hose cor nstallatio Connect the cooler hos s according to the memos taken at the time of disc: nection Point 6 Removal/installation ‘SST 09090-76001-71 (SST 09080-04010) Point 7 [ATM Veh le] Removal/installation © Four set boits (two upner and two bolts) ate used on one side Loosen the mounting set ruts for easier op Installation Align the mounting holes by operating the antagraoh jack Point 8 Removal/installation Adjust the length of the chain of SST 09030. (04010 and pay sufficient attention to the sur- rounding area operation. Rear Set Bots (ATM Vehicle) ~ Romoving te Engine ASSY w/ATM ssT rar.21114 Operation procedure (From ‘95. 6) (No. indicates the removal step No.) 3] [2] [4 Drain cooling water. Remove the engine hood. Disconnect the battery terminals and remove the battery. [Point 1] Disconnect the electrical wiring, air cleaner hose, fuel piping and power steering piping. Disconnect the accelerator wire and automatic transmission throttle cable (ony in ATM vehicle) from the engine side. Disconnect the exhaust manifold Disconnect the engine hood opener wire and remove the piate. Remove the radiator ASSY. [Point 2] Remove the torque converter drive Oplate set bolts. [Point 3] Remove the engine mounting bracket set nuts. Support the transmission atts front bottom with a pantograph jack. [Point 4} 8 aoe aeB_ Temporary hoist the engine ASSY. [Poi {13 Remove the drive plate housing set bolts {@ Remove the engine ASSY. INSTALLATION ‘The installation procedure is the reverse of the removal procedure Coution: Always perform the following jobs after installing the engine: ‘© Engine rpm inspection and adjustment (See page 1-18) © Bleed air from the power steering system. (See page 10-11) © Drive the vehicle to check the ATM feeling.1.16 OPERATION POINTS Point 1 Removal Disconnect the battery negative terminal first. Instattation: Connect the negative terminal ater. Point 2 Removai/instaltation: Carefully operate so as not to damage the radiator and torque converter cooler fins. Point 3 (ATM vehicle) Removai/installation: Use the crank pulley set bolt for rotating the converter. Installation: Tighten the set bolts to the specified torque after temporarily installing all of them. T= 15 ~ 2.0kg-m (10.8 ~ 14.5 ftb) (14.71 ~ 19.61 Nm} Point 4 Removal/installation: Support the transmission at its front bottom with a pantograph jack. Do not raise the jack excessively. Removing the Raditor varias Removing the Drive Plate Set Bots man t Supporting the Transmission tthe Bottom TarSTs1417 Point 5 Removal/installation SST 09090-76001-71 (SST 09090-04020)1:18 ENGINE SPEED INSPECTION & ADJUSTMENT (1DZ-2Z Engine) IDLING SPEED INSPECTION AND AD- JUSTMENT 1. Warm up the engine Coolant temperature: 80°C or above Engine oil temperature: 60°C or above the tachometer. 3. Inspect the idling speed (1) Check the accelerator wire return status. and confirm contact between the injection pump idle adjusting scrow and adjusting (2) Idling speed Standard: 650 + 5 rpm (102) 750 + 50 rpm (22) (From ‘98. 3) 4. Adjust the idling speed (1) Loosen the lock nut and turn the adjusting screw for adjustment Standard: 650 + §§ rpm (10z) 750 + 50 rpm (22) (From ‘98. 3) (2) Tighten the lock nut, and inspect the idling speed again. MAXIMUM SPEED INSPECTION AND ADJUSTMENT 1 Warm up the engine 2. Set the tachometer. 3. inspect the no toad static maximum speed. (1) With the engine in stopped state, depress the accelerator pedal fully and cneck that the adjusting lever is in contact with the maximum set screw (2) Start the engine and measure the engine speed when the accelerator pedal is de. pressed fully. Standard: 2600 + 50 rpm (1DZ-22) 4, Adjust the no-load static maximum speed (1) Unseal the set screw, end tum the set screw for adjustment ‘Standard: 2600 + 50 rpm (1DZ-22) (2) After adjustment, seal the set screw. ‘Adjusting the No-load Static Maximum Speed(4Y Engine) IDLING SPEED INSPECTION AND AD- JUSTMENT 1. Warn up the engine. Coolant temperature: 80°C or above Engine oil temperature: 60°C or above 2. Set the tachometer and vacuum gauge (1) Disconnect the connector for inspection from the tchometer mesauing cord, and connect the cord 1 the black wie side (2) Disconnect the intake maniold plug, and set the vacuum gauge 4. taling speed inspection and adjustment (1) Stat the engine. Alterately adjust the throttle adjusting screw © and idle adjust- ng screw @ to obtain stabilized maximum degree of vacuum at the specified idling speed (2) Ifthe idle up actuator rodis in contact with the adjusting sciew to make lowering of the idling speed dificult loosen the idle ue adjusting screw Standard idling speed: 650 + 8 rpm Vacuum: 400 mmHg or above ‘Adjusting te ling Speed Kasia 2s1:20 AIR GOVERNOR ADJUSTMENT A ® ‘Lock bolt D oO 7 == ss @—= | = OC 8 F using © oO Spring @ 6 Eine note stig ng 3 7 Tova ae re ADJUSTING PROCEDURE FOR EACH PART Lock bott © Counterclockwise turn... Unlocks busing @. Clockwise turn Locks bushing @. Bushing @ Counterclockois tum... Decreases the no-load stati maximum speed Clockwise tun Increases the no-load state maximum speed Caution: Fix screw @ always with a screwdriver when turning bushing @. Adjusting screw ® Courterclockwise turn... Decreases the relief down at power steering Return 1/10 tum clockwise from the state where the relief down is the smallest to conect the torsion of spring @ ‘Clockwise turn Decreases hunting at the no-load and loaded static maximum speed. ‘Turn the adjusting screw gradually clockwise Return it by 1/4 tura counterclockwise from the position where hunting is eliminated Turn it again clockwise by 1/10 tun to correct the torsion of spring @NO-LOAD STATIC MAXIMUM SPEED INSPECTION & ADJUSTMENT 1. Waim up the engine. Coolant temperature: 80°C of above Engine oil temperature: 60°C or above 2. Set the tachometer. 3. Adjust the no-load static maximum speed (1) Remove the sealing (2) Loosen the bushing lock bolt. (3) Measure the engine speed when the accel erator pedal is fully depressed (the throttle valve is fully opened) Above the specified maximum speed Turn the bushing counterclockwise ® Below the specified maximum speed Turn the bushing clockwise - @ No-load static maximum speed: 2800 + 50 rpm 4, Adjusting hunting (1) If hunting is generated at the no-load and Joaded static maximum speed as a result of adjustment in steps 3 and 4 adjust it by turning the bushing end adjusting screw Adjusting screw ....... Hunting adjustment Bushing ...... Maximum speed adjustment Caution: If hunting disappears in a few cycles, it is regarded as.no hunting, Repeat steps 3 to § above for setting to the standard adjustment value (2) After adjustment, seal the screw. Hunting adjustment Kasse1-22 ACCELERATOR PEDAL COMPONENTS Woq seddorg (ous6u3 Av) Assy-ans Aauna reyoeig reped (ouou3 za) ‘Acoslrator Pedal Components1-23 ACCELERATOR PEDAL ADJUSTMENT ‘Stopper bolt ‘Adjusting the Accelerator Pedal ‘TArSZ28 251 Pedal height adjustment Adjust the height of the pedal tip end (with pad) from the front floor to 149 mm (8.87 in) by turning the stopper bolt. ‘Accelerator pedal height (with pad) 149 mm (6.87 in) Accelerator wire adjustment Adjust the accelerator wire bracket mounting position to make the distance between the accelerator wire clamp and clevis 0 ~ 0.5 mm (0.0197 in) at the idling position,1:24 AIR CLEANER (UP TO '98. 2) GENERAL Warning lamp sensor ‘ir Cleaner (Single) SPECIFICATIONS Single (standard) Double (option) Outer: 18500 (2868) Fitering a in 14200 2201) mangas Gull’ Inner: 535 (62.9) Fiter mediom Fiter paper © COMPONENTS NOs 48 | RS Lu SoS et ac Maa ag ™~ oo 1703-295 1703 ‘Air Cleaner Components1:25 INSPECTION Air Cleaner Element inspection and Cleaning 1. Open the engine hood and remove the air ‘leaner cap. 2. Remove the element 3. Remove the dust cap and clean the dirt ‘accumulated in the air cleaner cap, 4, Element cleaning (1) For cleaning in ordinary status, blow compressed air (690 kpa (7 kg/cm [100 psi} or less) form the inside of the element along the pleats. If the element is heavily contaminated, washing is possible. (2) Element washing method Dissolve a neutral detergent in tepid water {about 40°C). Immerse the element for about 30 minutes in the washing liquid, and then rinse it thoroughly with clean water. {The water pressure must be 275 Kpa (2.8 kg/em’) [40 psil or less.) Caution: Carefully protect the filtering paper from damage during washing. After washing, dry it by standing or with a dryer (cold air. Caution: Do not use compressed air or hot air for drying. Element Cleaning the Element ‘Washing the Element1-26 Clogging Warning Inspection 1. Warning lamp inspection (1) Check that the air cleaner warning lamp comes on when the ignition switch is tumed on, and goes off when the engine starts, AIR CLEANER Inspecting the Warning Lamp 2. Individual inspection (1) Use Mighty Vac and inspect vacuum switch for conduction upon application of a negative pressure. Switchon pressure | Switchotf pressure Gasoline -260 ~-360 mm Aq | -210 ~ -340 mm Ag 19.1 ~-26.5 mm Ha | -15.4 ~ -25 mm Hg Dieser [810 ~-790mm Aq | -570 ~-780 mm Ag 44.9 ~ -68.1 mm Hq | ~41.9 ~ -57.4 mm Hg Inspecting the Individual Vacuum Switch 3. Vacuum switch wiring (1) A nonpolar sensor is adopted as the air | SS Vacuum Switch WiringAIR CLEANER (FROM ‘98. 3) GENERAL Evacuator valve ‘Air Cleaner (Single) ‘SPECIFICATIONS ‘Single (STO) Double (OPN Type Cyclone type. = Size Finch = Intake type Fresh air introduction type. = ° Gn Outer: 18600 (2883) Fitering area com? Gin) 14600 (2263) meEsODaTI Others With evacuator valve = COMPONENTS 1703 ‘Air Cleaner Components1:28 INSPECTION Air Cleaner Element Inspection and Cleaning 1. Open the engine hood 2. Remove the element. (1) Element Caution: In case of the double element type (OPT), do not remove the inner element for other than replacement. 3. Clean the element. () For ordinary cleaning, blow with compressed air {690 kPa (7 kg/cm’) {100 psi} or less} vertically along the pleats from the inside of the element. if heavily contaminated, washing is possible, (2) Element washing method Dissolve neutral detergent in tepid water (approx. 40°C (104°F)) and immerse the element in it for about 30 minutes. Then, rinse the element well with clear water. {Water pressure: 275 kPa (2.8 kg/cm’) 140 psil or less} Alter washing, naturally dry the element or dry the element with a dryer (cold ait. Caution: ‘@ Donot damage the element during washing. ‘© Never use compressed air or hot air for drying. 4. Clean the evacuator valve (dust discharge valve) (1) Hold the tip end of the evacuator valve and discharge dust and dirt from the inside of the valve. 5. Inspect the element. (1) After cleaning, place an electric bulb in the element to inspect any damage in the element. If any pinhole, tear or damage is found, replace it with a new element, 6. Element replacement Replace the element after it is washed six times ‘or generally at intervals of 12 months. ‘Ramove the Elmont {lasning the Eloment ‘spect he Element1:29 Clogging Warning Inspection 1. Warning lamp inspection (1) Check that the air cleaner warning lamp comes on when the ignition switch is turned on, and goes off when the engine starts. 2. Individual inspection (1) Use Mighty Vac and inspect vacuum switch for conduction upon application of a negative pressure. 270 ~ 330 mm Ag 199 ~ 233mm Hg 706 ~ 820 mm Ag 51.7 ~ 60.3 mm Hg Inspecting the Warning Lamp Inspecting the individual Vacuum SwitchAUTOMATIC TRANSMISSION (UP TO ‘95. 5) SECTIONAL VIEW ... SPECIFICATIONS COMPONENTS .. INSPECTION & ADJUSTMENT 214 ELECTRICAL CONTROL . 2-26 AUTOMATIC TRANSMISSION (ATM) REMOVAL & INSTALLATION (ENGINE ASSY w/ATM REMOVAL & INSTALLATION) . w+ 2-27 AUTOMATIC TRANSMISSION REMOVAL & INSTALLATION (INDIVIDUAL ATM REMOVAL & INSTALLATION) .. 2-29 TORQUE CONVERTER ASSY 2-30 DISASSEMBLY ... 2-30 INSPECTION . 2-32 REASSEMBLY .. 2-34 AUTOMATIC TRANSMISSION ASSY DISASSEMBLY . 2-38 MANUAL VALVE LEVER & SHAFT 2-50 OIL PUMP 2-53 TRANSMISSION INPUT SHAFT & OVERDRIVE CASE .. 2-57 FRONT CLUTCH ASSY 2-59 REAR CLUTCH ASSY . 2-67 CENTER SUPPORT ASSY . 2-72 PLANETARY GEAR ASSY & OUTPUT SHAFT 2-78 FIRST & REVERSE BRAKE . 2-86 GOVERNOR VALVE ASSY - 291 VALVE BODY ASSY .... . 2-96 FRONT UPPER VALVE BODY ASSY . - 2-104 REAR UPPER VALVE BODY ASSY . 2-112 LOWER VALVE BODY ASSY .. - 2-123 TRANSMISSION ASSY REASSEMBLY . 2134 24122 SECTIONAL VIEW IP ey “Automatic TransmissionSPECIFICATIONS 02-2TD(G)20, 02-2TD23, 02-2TD(G)25 3celement, 1-stage, 2-phase type. hydraulically con- speed oo 02-2TD15, 02-2TD18 7 meen ac ‘Speed ch ti Forward 2nd = C(US gal) | 10 (2.64)24 COMPONENTS, 20 2 AD AF Ao 458 458 Torque converter No. 1 case SUB-ASSY Speedometer sieeve SUS-ASSY ‘Transmission case SUB-ASSY Ol level gauge SUB-ASSY il pan il pan packing Drain plug Speedometer kiven gear Noutral start switch il seat Gasket Magnet BL Lock plate OH Cover DO Oilseat DR Clip EC Spacer EL Clamp. KC Oil filler woe SUB-ASSY KO. Transmission rear housing KE Gasket PB Manual valve lover SUB-ASSY PK Manual valve lever shaft PL Transmission control shaft lever “Automatic Transmission Housiung Components25 o " 12 4 20 2 23 24 25 26 28 30 31 45 Torque convertor ASSY Oil pump ASSY Stator ASSY Pump impeller ASSY Diive plate ring gear ASSY Turbine runner SUB-ASSY Oil pump drive gear i pump driven gear Pump impeller SUB-ASSY Stator SUB-ASSY Drive cover SUB-ASSY il pump case SUB-ASSY Extension SUB-ASSY ‘Stator hub 458 Thrust washer No. 1 ac x 1 pump case cover packing Roller Spring Spring cap Thrust plate Turbine front washer Drive plate spacor Center ring support 0 seat ‘Spacer Front oil pump cover Check ball Compression spring ‘Thrust bearing race “Thrust bearing race ‘Thrust bearing Torque Converter Components TAM01 Governor body ASSY 40. Governor body 440A Governor body gasket 41 *Bovernor body support AA Governor oll strainer ‘AB Governor No. 1 valve “Governor Components Ac AD Ae aK Governor No. 2 valve Compression spring Spacer Governor weight Ring Governor valve No. 2 shaft21 Clutch No. 2 drum SUB-ASSY 24 Clutch No. 1 shaft SUB-ASSY 408 Front clutch dise 408 Roar clutch aise 41A Front clutch plate 418 Rear clutch plate CL Thrust bearing CT Overdrive case SUB-ASSY CU. Thrust bearing race CV Thrust bearing race CW Front clutch piston SUB-ASSY CX Rear clutch piston SUB-ASSY cy oz 08 pe Do ve oF oc on ot bs Compression spring Return spring seat ‘Thrust bearing “Thrust bearing race Front elutch hub Thrust bearing race ‘Compression spring “Thrust bearing race ‘Thrust bearing Rar clutch hub Return spring seat Clutch cushion plate oK oN op eM EN ep £0. eR ES eu ev Rear clutch flange Thrust bearing race Input shaft oil seal ring ‘Clutch drum oi sea ring Center support O-ring retainer ‘Transmission input shaft SUB-ASSY Input shatt sleeve ‘Transmission input shat flange it seal ring ‘Thrust bearing race ‘Thrust bearing race Theust bearing TarMeD.1929 40C Clutch aise (for brake) EA. Oil seal ring ANC Brake pi cP pa or ov ow oy EB Rear planetary sun gear Washer EC. Canter support ring retainer 2nd brake piston retuen spring SUB-ASSY Brake No.1 piston Brake No. flange Front planetary sun gear sub-assy ‘Comer support SUB-ASSY “Torqueconverter Clutch2:10 13 4 18 45 51 AK ps or ou Front planetary goer ASSY Rear planetary gear ASSY 1 -way clutch ASSY Out put No.t Shatt Speedometer drive gear Spacer Intermediate shaft Planetary carrier thrust No.1 washer Planetary carrier thrust No.2 washer ov vy oz eB ec ce F Front planetary carter ving gear Rear planetary ring gear Rear planetary ring gear flange Thrust needle roller bearing Thrust needle roller bearing Thrust bearing race Output shaft flange “Thwust bearing race Torqueconverter Gearx HG HH a" HK HL HM HN Hz ka KB. KO KE KF Kt Plug Lockup relay valve ‘Compression spring Lockup reiay control valve Lockup relay valve No. 1 sleeve Lockup relay valve No. 2 sleeve Lockup relay valve body plate Lockup relay valve body gasket Primary regulator valve Compression spring Washer Primary regulator valve plunger Primary regulator valve sleeve Manual valve Ball wo u Lo. Me MG mi NI MK ms NE NF Mt Nu NY Valve body cover plate Lower modulator valve ‘Compression spring ‘Low coast shift valve 1-2 relay valve ‘Compression spring 1-2 shift valve ‘Compression spring ‘Second lock valve Vatve body No. 2 cover 3-2 kickdown orice contol valve ‘Compression spring ‘Accumulator control No. 1 valve Compression spring ‘Apply tube “Transmission Components (3) Tare212 wf AL e ates” AG Plug MA Spring cy Plug MB Throttle vaive HD Lockup signal valve MC Compression spring HF Compression spring MN Intermediate coast shift valve HP Spring seat MO Secondary regulator valve HU Secondary down seat plug SUB-ASSY MP Compression spring HV Compression spring MV Third coast valve HW Primary down seat valve SUB-ASSY MW Overdrive clutch exhaust valve HX Compression spring MX. Compression spring KV 2.3 shift timing valve plug NA. Secondary thotte valve LE 2-3 shift timing valve plug steeve NB Compression spring LF Intermediate modulator valve NC 2-3 shift timing valve LG Compression spring ND Compression spring LU Lower modulator valve NM Manual down timing valve LJ Compression spring NP 3.4 shitt valve LM_ Thvottle valve No. 1 sleeve NQ_ Compression spring LS 2.3.hitt vate NT 3-4 coast shitt valve LT Compression spring NU Throttle valve cam ASSY LW Cutback valve PN. Apply tube 12 Throttle valve No. 2 sleave PU. Imormediate coast shift sleeve “Transmission Components (8) TAPES.2.13 1 16 7 18 ay DR ey cz He Ho HR Hs Transmission cover & valve ASSY Lower valve body ASSY Rear upper valve body ASSY Front upper valve body ASSY Spring Control valve body plato (Overdrive brake accumulator piston Front elutch aceumulator cover Front clutch accumulator plate Apply tube Oil strainer SUB-ASSY Gasket aT HY KO KP. xo KR KS. Kr NK NY Throttle oil strainer ‘Manual detent spring SUB-ASSY 18-2 accumulator piston ‘Compression spring C-1 accumulator piston CCoripression spring C-2 accumulator piston ‘Compression spring Ball Detent spring cover ‘Transmission table apply tube TaFMee244 INSPECTION & ADJUSTMENT AUTOMATIC TRANSMISSION FLUID LEVEL CHECK 1 Engine inspection Note Refer to each engine repair manual for the ‘engine inspection method. 1DZ Engine Repair Manual No. CE618 4Y Engine Repair Manual No. CE602 (1) Inspec the dig speed Standard 102: 650 *80 pm +50 rpm. 4¥; 850 £50 rp (2) Inspect the injection timing (102) and ignition tming (4Y) SST 09275-76002-71 (SST 09275-64010) SST 09240-32880-71 Standard a 1DZ:_ 0° (stationary) BTDC Inspecting the tection Timing (102) wane 4Y: BTDC 7"/rpm Fluid level check Caution: © Park the vehicle on a flat ground. — © Check the level at the fluid temperature EE (70° ~ 80°) in normal traveling state (1) Appty the parking brake. (2) Move the shift lever fully from the N range to the L range with the engine in idling state, end return the lever to the N range. (3) Check that the fluid level is in the HOT are na pug io comm range on the level at the N range in idling state Caution: ‘© When level check at a low oil temperature (20 ~ 30°C) is necessary for oil replacement or other Purpose, adjust to the COOL range on the gauge and check under HOT conditions later. © If the level is different between the front and rear sides of the level gauge, use the lower one for measurement. Carefully prevent excessive oil as it may cause various troubles. © If the oil ievel is insufficient, check oil leakage. Fluid used: GM Dexron®ll_ volume: About 10 £ (2.64 US gal) ‘The amount of oil to be replaced every 6 months (7,000 hours) is 2.0 t0 2.5 2 (0,83 to 0.66 US gab.THROTTLE CABLE INSPECTION & ADJUSTMENT 1 2 Throttle cable inspection and adjustment (1) Depress the accelerator pedal fully and push the throttle lever to check full opening. H not fully opened, adjust the accelerator wire Throttle cable inspection and adjustment (1) Check that the throttle cable is securely installed to the throttle lever without any bend, (2) Measure distance between the edge of the cable adjustment mark and the cable end face when the throttle valve is fully closed ‘Standard: 0.5 ~ 1.5 mm (0.0197 ~ 0.059 in) If the standard is not satisfied, use the adjusting nut for adjustment. xx When a boot is provided, remove the boot and adjust the distance between the cable lend face and cable adjustment mark to 0.5 ~ 1.8 mm (0.0197 ~ 0.089 in) (3) Inspect the cable stroke when adjusting the injection timing and/or injection pump. (1DZ engine vehicle) Reference value: 33 + 1 mm (1.3 + 0.039 in) Inspect the cable stroke when adjusting the ignition timing or replacing and adjust. ing the 1A. (AY engine vehicle) Reference value: 33 + 1 mm (1.3 + 0.039 in) Note: Loosen the throttle cam adjusting nuts and move the throttle cam for adjustment. Caution: Perform inspection in step (2) after the ad- justment. (4) Caulk the lock nut, and fix the nut. Inspecting the Tote Catbe (102) TAPS 05~1.5mm (0.0197 ~0.059 in.) ‘Throttle cam ‘Adjusting bott Inepecting the Throttle Cable (4¥) TA¥S252-16 NEUTRAL START SWITCH INSPEC- TION 2 Functional check (1) Apply the parking brake. (2) Check that the engine starts when the shift lever is shifted to the N range, and does not start in any other range. (3) Be sure that the backup lamp does not ‘come on unless the shift lever is in the R range. Adjustment (1) Loosen the neutral start switch set bolts (2) Set the shift lever to the N range. (3) Align the cut groove on the switch with the neutral reference line by moving the switch. (4) Tighten the set bolts T= 1.3 kg-m (9.4 ft-lb) [12.75 Nem] Sot bolt Neutral datum line ¢ Cut groove ‘Adjusting the N Position “Tars29ON-VEHICLE INSPECTION Caution: Conduct each test after the end of basic inspec- tion and adjustment. STALL TEST Caution: ‘© Conduct the test at the normal oil temper- ature (70 ~ 80°C) in ordinary traveling state. ‘© Do not continue the test over 5 seconds. ‘© Wait at least 1 minute between the tests in D and R ranges. Inspecting the Ol Temperature TARE 1. Carry out measurement according to the illus trated procedure. Stall speed Standard 1DZ engine: 2130 ~ 2430 rpm 4Y engine: 2100 ~ 2400 rpm ‘ial Teet, Note: Estimated defect as a result of stall test ‘Shift to the D(R) range. Depress the brake pedal withthe left fot. ‘and depress the accolerator pedal fully with the right foot. Quickly read the maximum engine speed at The throtie valve is not opened fuly est i in both ranges | # The engine output is insufficient eee eee ier ane stander | # The stator one-way clutch i detective. ram of more than the standard valve). (torque converter defect may be the reason ifthe stall speod is lower by 600 5 The front clutch sipping When the stall speedin the Drange is | § One-way etuch No. 2s defective ‘a 7 none The tine pressure is low. The rear clutch i sipping When the stl seed inthe R range is higher than the standard: @ The 1s 8 rovene cutch sipping When the stall speeds in both ranges | The line pres are higher than the standard The fluid level is outside the standard (insufficient)2.18 TIME LAG TEST Caution: © Conduct the test at the normal oil temper- ature (70 ~ 80°C) in ordinary traveling state. © Wait at least one minute between tests. ‘© Measure three times, and average the re- sults. (1) Cary out measurement according to the illustrated procedure. Time lag ———__—_______} Inspecting the Oil Temparatore ‘TAFS0 Standard: N-D range 0.7 sec max. N-R range 1.2 sec max. Measuring the Tie Lag TArMe Note: Estimated defect as a result of time lag test When the N — D time lag is longer | @ The line pressure is low. than the standard: @ The front clutch is wom. ‘¢ The line pressure is low. ‘¢ The reverse clutch is worn The 1st & reverse brake is worn, When the N + R time lag is longer ‘than the standard,HYDRAULIC PRESSURE TEST Caution: Conduct the test at the normal oil tempera- ture (70 ~ 80°C) in ordinary traveling state. 1. Governor pressure measurement (1) Carry out measurement according to the illustrated procedure. Measuring instrument: OPG-100 See the fold out hydrat gram at the Ipscing he i Fenpware Tara Standard Ourputshattspeed vom] 0 | 800 1000 wooo | Peleoncey ] Reteenced Travel- | 2nd speed km/h] 0 a3. | 86 129 17.2 21.5 Sted _[Scspeca svn] 0 | 81 103 154 208 756 Governor pressure Kalen e=08 | 33~27 | 36~40 | 53~60 | 75~88 (psi)} O | (7.1 ~ 114) | (31.2 ~ 38.3) | (51.1 ~ 96.8) | (75.3 ~ 85.2) | (106.5 ~ 1207) (kPa) [49 ~ 785} | [2157 ~ 2648) | [353 ~ 392.3] | [5198 ~ 5884] | [735.5 ~ 8336) Remove test plug and instal pressure gauge Note: Estimated defect as a result of pressure test, ‘¢ The line pressure is defective. When the governor pressure 15 im- | | 65 jeaking from the governor pressure hydraulic circuit. proper: The governor valve is defective2:20 2. Line pressure measurement (1) Carry out measurement according to the illustrated procedure. Measuring instrument: Oil pressure gauge Standard Engine speed | __D-range Rerange 33s agen tang specs | $23 8S) Maxmam | Mt =}28:gien speed r tiga aie, i729 ~ 6671 Pay remove test plug and inst pressure gauge (above neutral fart ewiteh). Note: Estimated defect as a result of the pressure test, Tarwe ‘When the oil pressures. in both ranges are higher than the stan- dards: ‘¢ The regulator valve is defective ‘© The throttle valve is detective. 2 Tho throttle cable adjustment is improper. When the oi pressures in both ranges ate lower than the standards: ‘© The oil pump is defective 1 The regulator valve is defective. © The throttle valve is detective. The throttle cable adjustment is improver When the oil pressures in the D. range are lower than the standards ‘lis leaking from the D-range hydraulic circuit ¢¢ The front clutch is defective. When the oi! pressure in the R. range are lower than the standards: ‘© Oil is leaking from the R-range hydraulic circuit, ‘© Tho 1st & reverse brake is defective. 1# The rear clutch is defective.221 DRIVING TEST Caution: Conduct the test at the normal oil tempera- ture (70 ~ 80°C) in ordinary traveling state, 1. D-range test (1) Shift to the D-range and start the vehicle at each valve opening (60% and full open. ing). Check each up-shift and shifting point in conformity with the automatic speed change curves. Note When1+2 | @ Thegovernor valve is defective. upshift is not | @ The 12 shift valve is defec- effected tive, When2+3 | eThe 243 shift valve is upshitt is not | defective. effected: 1 The governor valve is defective ‘© The throttle cable adjustment is. When the improper. shifting point | @ The throttle valve, 1+2 valve. is improper 2-43 valve or governor valve is detective (2) Inspect abnormal sound. slipping and shock upon shifting at the time of acceter- ation or deceleration Note: Estimated defect as a result of driving test When the «The line pressure is high. shock is ¢ The accumulator is defective, excessive The check ball is defective. (3) Cary out kickdown during traveling at each of 2nd and 3rd gear positions to inspect if the limit speed for 2-41. 3-»2 or 3-+1 kickdown matches that on the auto: ‘matic speed change curves. “Throttle valve fully open (100%) Throttle valve * half-way open (50%) ‘opening (%) Vehicle speed tkrn/h) ‘Automatic Speed Change Curves TAMIA slipping ‘Shock at shifting Inspection at Acceeration/Decelerstion ars208 z 2 & 8 Throttle valve s halfway open (50%) me Throtte valve 1E fully open (100%) Vehicle speed (ken/h) Automatic Speed Change Curves2:22 (4) Shift to each of the 2- and | -ranges diving driving in the D-range to inspect the en. gine braking effect in each range. Note: Estimated defect as a result of driving test No engine braking Pate artist 2nd brake malfunction ‘No engine braking Tst_& reverse brake | effect in L-range malfunction (8) Release the accelerator pedal from near 18 km/h (in 3-speed vehicle) while traveling in D-range and shift to the 2-range, Check if the 3 + 2 down-shift point matches the ‘automatic speed change curve. (6) Release the accelerator pedal from near 9 km/h (3-speed vehicle) or 13 km/h (2- ‘speed vehicle) while traveling in D-range ‘and shift to the L-range. Check if the 2 + 1 down-shift point matches the automatic speed change curve, 2. 2-range test (1) Start the vehicle at each throttle valve opening (50% and full opening) and check if the 1 -+ 2 up-shift point matches the automatic speed change curve. WV, ® yO ‘TArSIOO Inapecting the Engine Broking EMett a + z 3 é8 1 Se asaea vee ee os ‘Automatic Speed Change Curve TAPS2O7 fully open (100%) Throtile valve opening (&) Vobicte speed (ken/h) ‘Automatic Speed Change Cue rarer2.23 (2) During traveling at the 2nd gear position, release the accelerator pedal and check the engine brake function (3) Camy out kickdown from the 2nd gear state, and check if the speed allowing 2+ 1 kickdown matches the automatic speed change curve (4) Check abnormal sound or slipping during acceleration and deceleration 3. Lerange test (1) Check no up-shift to the 2nd gear ge. ae 3. Has — z Vehicle traveling speed (km/h) ‘iomatc Speed Change Guve Tareas ‘Acceleration Abnormal ‘ound Deceteration ®” shite @...-.:. Inapecting Abnormal Sound and Sipping aren? TARE224 (2) Release the accelerator pedal during trav eling at the first gear position, and check the engine brake funetion (3) Check abnormal sound or slipping during acceleration and deceleration 4. Rerange test (1) Start the vehigle with the throttle valve fully ‘opened, and check any slipping © & ) Engine brake Inspecting the Engine Brake Function Area ‘Acceleration | oweseaton ‘Slipping Inspecting Abnormal Sound and Sipping are ‘Teottle full opening © + Slipping Inspecting Sipping —2:25 AUTOMATIC SPEED CHANGE CURVES 16 6 10 10 speed (km/h) ‘Throttle valve opening (%) rd shite ‘and shift ‘Automatic Speed Change Curves Taraaiae2-26 ELECTRICAL CONTROL CIRCUIT DIAGRAM Circuit Diagram TARSzaR NEUTRAL SWITCH INSPECTION 1. Remove the toe board. 2. Inspect continuity between connector termi nals, ‘Standard Terminal Inspecting the Switch2.27 AUTOMATIC TRANSMISSION (ATM) REMOVAL & INSTALLATION (ENGINE ASSY w/ATM REMOVAL & INSTALLATION) ‘The jobs ate the same as in ENGINE ASSY REMOVAL & INSTALLATION. Only the operation procedure is described here, See page 1-10 for the operation points, Operation Procedure fl ‘Automatic Tanerisson Removal & Intalaion ares REMOVAL Drain cooting water Remove the engine hood @ Disconnect the batty terminals, and remove the battery. [Point 1] Disconnect the electrical wiring, fuel piping and power steering piping [B}_Disconnect the accelerator wie and automatic transmission throttle cable (ATM vehicle only) on the engine side Disconnect the exhaust pine (1) Remove the front gil [Remove the radiator ASSY and torque converter cooler. [Point 2] [B_Remove the engine mounting bracket set nuts @ Disconnect the shift leyer link rod.Disconnect the speedometer cable and each switch wiring. Disconnect the propeller shaft on the transmission side. Remove the toe board ‘¢ Remove the torque converter drive plate set bolts. [ATM vehicle] [Point 3] ‘# Disconnect the clutch release cylinder piping. [MTM vehicle] ‘Support the rear part of the transmission with a pantagraph jack. [Point 4] Disconnect the torque converter cooler hose. [Point 5] ‘ Slightiy hoist the engine ASSY w/automatic transmission. [Point 6] « Slightly hoist the engine ASSY w/manal transmission ¢ Remove the automatic transmission rear set bolts. [Point 7] ‘¢ Remove the manual transmission rear mounting bracket set bolts Remove the engine ASSY w/automatic transmission. [Point 8] @ Remove the engine ASSY w/manual transmission. «© Separate the engine ASSY from the automatic transmission [Point 9] «¢ Separate the engine ASSY w/clutch housing from the manuel transmission. ‘¢ Remove the clutch cover and clutch disc. [MTM vehicle] Remove the flywheel and drive plate housing [ATM vehicle] Remove the flywheel and clutch housing [MTM vehicle] INSTALLATION Base BB SB 8aa a The installation procedure is the reverse of the removal procedure. Caution: Operate as follows after installing the automatic transmission. ¢ Engine speed inspection and adjustment. (See page 1-12 ~ 1-16) ‘© Bleed air from the power steering system. (See page 9-11) ¢ Inspect the ATM oil level and add if insufficient. © Drive the vehicle to check the ATM feeling.2:29 AUTOMATIC TRANSMISSION REMOVAL & INSTALLATION (INDI- VIDUAL ATM REMOVAL & INSTALLATION) TRutomatic Tanemasion Removal & Installation TARE REMOVAL Disconnect the battery negative © terminal Disconnect the ATM throttle cable on the engine side. Remove the toe board, Disconnect the ATM electrical wiring and hydraulic piping, Disconnect the shift lever link rod, Disconnect the speedometer cable. Disconnect the propeller shaft on the ATM side. Remove the drive plate set bolts, ‘Support the engine with @ pantagraph jack placed under it Slightly hoist the ATM, Remove the ATM housing set bolts Remove the ATM rear set bolts. Remove the ATM ASSY SS8s0e88e88o 5888 INSTALLATION ‘The installation procedure is the reverse of the removal procedure.2:30 TORQUE CONVERTER ASSY 1. Remove the torque converter ASSY. (1) Torque converter ASSY Caution: Drain oil from the converter after removing the torque converter ASSY Removing the Torque Converter ASSY oar DISASSEMBLY 2. Remove the drive cover SUB-ASSY (1) Punch a match mark on the drive cover SUB-ASSY and pump impeller SUB- ASSY (2) Set oolts (3) Drive cover SUB-ASSY Caution: If drive cover removal is difficult, blow com- pressed air. The drive cover comes out easily. Be careful not to leak air. 3. Remove the turbne runner SUB-ASSY. (1) Turbine front washer (2) Turbine runner Removing the Turbine Runner YARD, 22Remove the stator ASSY. (1) Stator ASSY (2) Thrust bearing race (3) Thrust bearing (4) Thrust bearing race Remove the pump impeller extension. (1) Set bolts (2) Extension Disassemble the stator ASSY. (1) Snap ting (2) Thrust washer No. 1 (3) Thrust plate (4) Snap ring (5) Thrust washer No. 2 (6) Thrust plate gS a | Removing the Thrust Washer2:32 (7) Clutch hub (8) Rolier (9) Spring cap (10)Spxing Caution: Carefully remove the roller, spring cap and spring so as not to lose them. Removing he Clutch Hub raF22.10 INSPECTION a Caution: Wash each part thoroughly with washing fluid to remove dirt and dust perfectly. 1. Drive cover inspection (1) Crack and damage on cover (2) Damage at contact surface Inspecting the Drive Cover ar2.20 2. Pump impeller inspection (1) Crack and damage at impeller (2) Crack and damage at blade Inspecting the Purp Impeller yare2-27 3. Pump impeller extension inspection ; (1) Wear at sliding portion of extension (2) Crack in O-ring Inspecting the Extension ‘Taraa6. Thrust bearing race inspection Turbine runner inspection (1) Crack and damage (2) Loose fitting between turbine runner and hub (3) Damage on turbine runner hub: Inepecting the Turbine Runner Thrust bearing inspection (1) Crack and damage at cage (2) Damage at roller (3) Rotation status and abnormal sound Inspecting the Thrust Bearing (1) Damage at sliding contact surface Inspecting the Thrust Bearing Race Stator ASSY inspection (1) Crack and damage at stator wheel (2) Damage at inner and outer races of one- way clutch (3) Damage, deformation and seizure of thrust washer No 1 and thrust plate Inspecting the Stator ASSY (1) TaRRA4(4) Wear and damage of roller and spring cap (8) Fatigue and deformation of spring Pes Foetsans Inspecting the Roller and Spring vara 8. Turbine front washer inspection (1) Wear and damage of washer Inspecting the Turbine Front Washer aR2.99 REASSEMBLY 1. Install the pump impeller extension, (1) Coat grease thinly on the O-ring {nstaling the Extension (1) 1aF2.7 (2) Extension (3) Set bolt T= 0.4 ~ 0.7 kg-m (2.9 ~ 5.1 ft-lb) [3.9 ~ 6.7 Nm] Installing the Extension (2) rar2232.35 2 Assemble the stator ASSY a oo fp re ro vite 1 song Short a | Long Roller ris ere slp ni a ‘Thrust plates Caled Coat torque converter oil sufficiently on each stator part before reassembly. (1) Clutch hu (2) Spring (3) Spring cap (4) Roller (5) Installing direction check Check the stator rotation status by rotating it clockwise and counterclockwise. Fix the hub and see that the stator wheel rotates (in clockwise direction) when a force is ‘applied from outer side of the curved stator wheel blade and that it does not rotate (in counterclockwise direction) when a force is applied from the inner side of the blade. CChecking the Instaling Direction4 2:36 (6) Thrust plate (7) Thrust washer (8) Snap cing 3. Install the stator ASSY on the pump impeller. (1) Thrust bearing race (2) Thrust bearing (3) Thrust bearing race (4) Stator ASSY (8) Pay attention to the direction of the stator ASSY at the time of installation. (Check ‘clockwise rotation as viewed from the top ) (6) After stator installation, check no interfer- ‘ence by rotating the stator. Install the turbine runner SUB-ASSY. (7) Turbine runner SUB-ASSY Caution: When the turbine runner or turbine runner hub is replaced, be sure to link the turbine runner and turbine runner hub securely with a rivet. Installing the Turbine Runner5. Select the turbine front washer. (1) Place the SST on the turbine runner. SST 09230-30151-71 (2) Install the drive cover on the pump impel- ler, and measure clearance (A) at 3 places. Con the circumference Caution: Remove the O-ring from the drive cover. Standard clearance between drive cover and front washer 0.2 ~ 0.5 mm (0.00787 ~ 0.0197 in) (3) Determine the front washer according to the result of clearance (A) measurement and the table below. Instaling the SST ARS Front washer Thickness | Clearance (A) TRB] Zemm | 08-11 mm (O.1T im) | (0.031 ~0.043 int 32292-10510-71 | 3.1mm | 0.6~0.8 mm (12m | (0023-0031) 32293-10510-71 | 3.4 mm 0.8 mm (0.13 i) (0.0197 in} 3229410510-71 | 37mm | 0.1~0.2 mm {0.18 0) | (0.0039~ 0.0079 in) [Exemple] Select 2.8 mm front washer if clearance (A) is 0.6 mm, (4) Front washer 6. _ Install the drive cover (1) O-ring Caution: Coat MP grease on the O-ring. (2) Set bolts and nuts T=15 ~ 20kg-m (10.8 ~ 14.5 ft-ib) (14.7~ 19.6 Nem] ‘Measuring Clearance (A) TArSIOE Installing the Drive Cover rarn.952:38 es AUTOMATIC TRANSMISSION ASSY DISASSEMBLY Caution: © Always drain fluid before starting disassembly, © Store the removed automatic transmission to prevent the load of the transmission from being applied to the oil pan. When the load is applied to the oil pan, receive the load by the whole bottom surface of the oil pan. After installing the transmission on the vehicle, always replace the oil pan gasket. © Ciean sand or mud from the outer surface of the transmission before disassembly to prevent them from entering inside at the time of disassembly and reassembly. ‘© Work with bare hands or wear vinyl gloves and do not use working gloves or waste cloth. ‘© When disassembling a joint of light metal alloy parts such as the case, do not pry with a screwdriver but tap them lightly with a plastic hammer for disassembly. ‘© Arrange and store the disassembled parts in good order. © The part number of the SST set to be used for disassembly and reassembly is SST 09350-76001- 71 (SST 09360-36010). The SST part numbers used in the text are those for individual SSTs. 1. Remove the torque converter. Caution: Do not damage the oil seal of the oil pump. 2 Remove the oil level gauge and oil filer tube, Removing the Torque Converter rareaz 3. Remove the joint, (1) Uncaulk the joint (2) Lock nut (3) Washer (4) Joint yoke 4. Remove the control lever. (1) Lock nut and set aut (2) Control shaft lever Caution: ‘Take a note of the lever installation state. Removing the Contol Shaft Lever ars