SS SERVICE SPECIFICATIONS - TodoAutos

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SERVICE SPECIFICATIONS 


STANDARD BOLT 

HOW TO DETERMINE BOLT STRENGTH . . . . . . . . . . . . . . . . . . . . . . . . . 

SPECIFIED TORQUE FOR STANDARD BOLTS . . . . . . . . . . . . . . . . . . . . 

HOW TO DETERMINE NUT STRENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . 

LUBRICANTS AND COOLANTS 

SPECIFIED LUBRICANTS AND CAPACITY. . . . . . . . . . . . . . . . . . . . . . . . 

REFERENCE VALUES FOR PERIODIC MAINTENANCE 

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

APPARATUS FOR PREVENTING RELEASE OF HARMFUL GASES 

SUCH AS FUMES AND ODOROUS GASES. . . . . . . . . . . . . . . . . . . . . 

SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

DRIVING APPARATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

BRAKE APPARATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

STEERING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

OPERATION SETTING WHEN DISCONNECTING AND RECON- 

NECTING NEGATIVE BATTERY TERMINAL 

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

OPERATION SETTINGS WHEN INSTALLING, REMOVING AND 

REPLACING PARTS 

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

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SERVICE SPECIFICATIONS - STANDARD BOLT 

STANDARD BOLT 


HOW TO DETERMINE BOLT 

STRENGTH 

SS 

Bolt Types 

Hexagonal Bolt 

Normal Recess Bolt Deep Recess Bolt 

Stud Bolt 

Welded Bolt 

Class 

No Mark 

No Mark 

No Mark 

w/ Washer 

w/ Washer 

D025089J01



SPECIFIED TORQUE FOR STANDARD 

BOLTS 

1. SPECIFIED TORQUE 

HINT: 

The torque values listed below are the specifications for tightening 

unlubricated zinc-plated bolts. 

Class Diameter (mm) Pitch (mm) 

Specified Torque (Hexagon 

Head Bolt) 

(N*m [kgf*cm]) 

Hexagon Flange Bolt 


4T 6 1.0 5{55} 6{60} 


8 1.25 12.5{130} 14{145} 

10 1.25 26{260} 29{290} 

12 1.25 47{480} 53{540} 

14 1.5 74{760} 84{850} 

16 1.5 115{1150} 127{1300} 

5T 6 1.0 6.5{65} 7.5{75} 

8 1.25 15.5{160} 17.5{175} 

10 1.25 32{330} 36{360} 

12 1.25 59{600} 65{670} 

14 1.5 91{930} 100{1050} 

16 1.5 140{1400} 157{1600} 

6T 6 1.0 8{80} 9{90} 

8 1.25 19{195} 21{210} 

10 1.25 39{400} 44{440} 

12 1.25 71{730} 80{810} 

14 1.5 110{1100} 125{1250} 

16 1.5 170{1750} 191{1950} 

7T 6 1.0 10.5{110} 12{120} 

8 1.25 25{260} 28{290} 

10 1.25 52{530} 58{590} 

12 1.25 95{970} 105{1050} 

14 1.5 145{1500} 165{1700} 

16 1.5 230{2300} 255{2600} 

8T 6 1.0 12{125} 14{145} 

8 1.25 29{300} 33{330} 

10 1.25 61{620} 68{690} 

12 1.25 110{1100} 120{1250} 

14 1.5 170{1750} 195{2000} 

16 1.5 260{2700} 299{3050} 

9T 8 1.25 34{340} 37{380} 

10 1.25 70{710} 78{790} 

12 1.25 125{1300} 140{1450} 

10T 8 1.25 38{390} 42{430} 

10 1.25 78{800} 88{890} 

12 1.25 140{1450} 155{1600} 

11T 8 1.25 42{430} 47{480} 

10 1.25 87{890} 97{990}



Class Diameter (mm) Pitch (mm) 

Specified Torque (Hexagon 

Head Bolt) 


Hexagon Flange Bolt 


12 1.25 155{1600} 175{1800} 

SS



HOW TO DETERMINE NUT STRENGTH 

Standard Hexagonal Bolt 

Nut Types 

Old Standard Hexagon Nut 

Cold Forged Nut 

Cutting Processed Nut 

Class 


No Mark 

No Mark (w/ Washer ) 

No Mark (w/ Washer) 

No Mark 

No Mark 

More than one mark on the back of the nut 

D025090J01 

HINT: 

When replacing a nut, use a nut with a nut strength classification that is 

equal or higher than the strength classification number of the opposing bolt. 

(Example: Bolt = 4 T, Nut = 4 N or more)


SERVICE SPECIFICATIONS - LUBRICANTS AND COOLANTS 

LUBRICANTS AND COOLANTS 


SPECIFIED LUBRICANTS AND CAPAC- 

ITY 

1. ENGINE OIL 


Engine oil viscosity chart 

C -29 -18 -7 4 16 27 38 

TEMP. 

F -20 0 20 40 60 80 100 

Engin oil 

(4 stroke) 

5W-20* 

0W-20* 

10W-30,10W-40,10W-50 

20W-40,20W-50 

5W-30 

* Standard recommended oil 

30 

D101273 

Engine Model 

Oil Only Replacement 

Filling Volume (L) 

Oil and Oil Filter 

Filling Volume When 

Replacing (L) 

3SZ-VE 2.9 3.2 

K3-VE 2.0 3.5 

HINT: 

The filling volume when replacing the oil or the oil filer is the amount 

of oil that is drained from the drain plug. 

NOTICE: 

• Based on the table, use an oil with a viscosity that is best 

suited to the air temperature. 

• Close the drain plug after confirming that the old oil has been 

sufficiently drained. 

• With an oil level gauge, always perform a final check of the 

amount of oil. (After warming up the engine, with the engine 

stopped and after it has been allowed to idle for 5 minutes, 

check that the amount of oil is at the F level of the gauge.) 

2. LUBRICANTS AND COOLANTS OTHER THAN ENGINE OIL 

Item (Type) Capacity (L) (Reference) Specified Lubricant 

Coolant (3SZ-VE) M/T: 4.6 Ethylene glycol based anti-freeze solution 

A/T: 4.4 

Coolant (K3-VE) M/T: 4.3 

A/T: 4.2 

Automatic transmission fluid 

(Transmission) 

4.6 DEXRON-III 

Transfer oil 

(Four wheel drive vehicles with automatic transmission) 

1.6 

Manual Transmission Gear Oil 

(API GL-3 or GL-4, SAE 75W-90, 75W-85 or 75W-80) 

Manual transmission oil 

(FR vehicle) 

1.2 

Manual transmission oil 

(4WD) 

2.2 

(Including transfer) 

Front differential oil 0.45 

Rear differential oil (excluding vehicles equipped 

with limited slip differential) 

Rear differential oil 

(Vehicles equipped with limited slip differential) 

 

Differential Gear Oil 

(API GL-5, SAE 80W-90) 

1.8 

1.8 

Limited Slip Differential Gear Oil 

(API GL-5, SAE 80W-90) 

Power steering fluid 0.7 DEXRON-III 

Brake fluid - FMVSS116 DOT3 or DOT4 

Clutch fluid - 

A/C compressor oil - ND-OIL8

SERVICE SPECIFICATIONS - REFERENCE VALUES FOR PERIODIC MAINTENANCE 

REFERENCE VALUES FOR PERIODIC MAINTENANCE 


ENGINE 


1. ENGINE-RELATED 

Standard: 

Item 3SZ-VE K3-VE 

W/P pulley and P/S pump belt deflection (thrust force 100 N [10.2 kgf]) 

(mm): when installing new parts (when cold) 

9-11 

W/P pulley and P/S pump belt deflection (thrust force 100 N [10.2 kgf]) 

(mm): for maintenance (when cold) 

13-15 

W/P pulley and P/S pump belt tension (N [kgf]): when installing new parts 

(when cold) 

883 49{90 5} 637 49{65 5} 

W/P pulley and P/S pump belt tension (N [kgf]): for maintenance (when 

cold) 

441 98{45 10} 

Battery fluid specific gravity (fluid temperature 20C [68F]): specified 

values 

1.25-1.29 

Battery fluid specific gravity (fluid temperature 20C [68F]): difference 

between cells 

Below 0.04 

 

Ignition timing (BTDC)/(r/min): EFI-T short circuit (*1) 4-8/600-750 

Ignition timing (BTDC)/(r/min): EFI-T open circuit (*1) 0-15/600-750 

Ignition timing (using the DS-II): TC terminal ON BTDC 4-8CA 

Ignition timing (using the DS-II): TC terminal OFF BTDC 0-15CA 

Idle speed (N and P range) (r/min) 600-750 

IN valve clearance (when cold) (mm) 0.145-0.235 

EX valve clearance (when cold) (mm) 0.275-0.365 

Tightening torque [N*m{kgf*cm} ] 

Check is unnecessary due to tightening 

of plasticity area 

 

Intake manifold tightening torque (N*m [kgf*cm]) 19{194} 

Exhaust manifold tightening torque [N*m{kgf*cm}] 35{357} 


Compression pressure (330 r/min) (MPa [kgf/cm 2 ]): standard value 1.47{15.0} 

Compression pressure (330 r/min) (MPa [kgf/cm 2 ]): limit 1.08{11.0} 

Compression pressure (330 r/min) (MPa [kgf/cm 2 ]): difference between 

cylinders 

0.15 (1.5) or below 

Spark plug gap (mm): specified values 0.8-0.9(*2) 1.0-1.1 

Spark plug gap (mm): maximum 1.1 

Radiator cap valve opening pressure (kPa[kgf/cm 2 ]): specified values 93.3-122.7{0.95-1.25} 

Radiator cap valve opening pressure (kPa[kgf/cm 2 ]): maximum 78.5{0.8} 

(*1): 

Between terminals EFI-T and E of the DLC 

(*2): 

No adjustments required because the iridium plug is used.



APPARATUS FOR PREVENTING 

RELEASE OF HARMFUL GASES SUCH 

AS FUMES AND ODOROUS GASES 

1. EXHAUST GAS PREVENTION-RELATED APPARATUSES 

Standard: 


Item 3SZ-VE K3-VE 

Idle CO Concentration (%) Below 0.2 

Idle HC Concentration (ppm) Below 200 

SUSPENSION 

1. FRONT SUSPENSION-RELATED 

Standard: 

Item J200LG J210LG J211LG J200RG J210RG 

Front side slip (per 1 m) (mm) 0 5 

Front toe-in (mm) 0 2 

Front camber (degree) 030' 45' 

Front caster (degree) 447' 1 

Front steering axis inclination 

(degree) 

1225' 1 

Tire turning angle (vehicles 

with tire size of 

215/65 R16) 

Tire turning angle (vehicles 

with tire size of 

235/60 R16) 

Inside 4032' 2 

Outside 3405' 2 

Inside 3906' 2 - 3906' 2 

Outside 3306' 2 - 3306' 2 

DRIVING APPARATUS 

1. DRIVING APPARATUS 

Standard: 


Looseness of front axle hub (mm) Below 0.05 

Looseness of rear axle hub (mm) Below 0.8 

Wheel nut tightening torque 

(N*m[kgf*cm]) 

103{1050} 

Remaining tire groves (mm) 1.6 or more 

2. AIR PRESSURE 

(a) Same for both general and high speeds 

Standard: 

Tire Size 

Front wheels 

(kPa [kgf/cm 2 ]) 

Rear wheels 

(kPa [kgf/cm 2 ]) 

215 / 65R16 98S 200{2.0} 

235 / 60R16 100H 210{2.1}


BRAKE APPARATUS 


1. BRAKE-RELATED 

Standard: 


Brake pedal free play 

(without vacuum) (mm) 

0.5-2 

Brake pedal reserve 

distance (mm) 

Parking brake pedal 

release rate 

(Operating force of 196 

N [20 kgf] ) (number of 

notches) 

Parking brake engagement: 

braking force 

Thickness of rear drum 

brake shoe lining 

(mm): maximum 

Inner diameter of rear 

brake drum (mm): maximum 

Thickness of front disc 

brake pad (mm): maximum 

Thickness of front disc 

rotor (mm): maximum 

Brake engagement 

(braking force) (*): total 

of back wheels 


(braking force) (*): 

asymmetry in each 

wheel 


(braking force) (*): sum 

total 

122 or more 

(The engine is idling after 

warmed up, and pedaling force is 

294 N [30 kgf]) 

(*): 

For vehicles where all front wheels are locked and therefore 

difficult to measure, presume in such a situation that this conforms 

with the sum total. 

STEERING MECHANISM 

1. CHASSIS-RELATED 

Standard: 


 

4-7 

Above 20% of vehicle weight 

upon inspection 

1.0 

(Reference: 5.5 for a new product) 

229.6 


1.0 


15.0 (solid disc) 


21.0 (ventilated disc) 


 

 

 

 

 

Over 10% of the axle load 

Under 8% of the axle load 

Above 50% of vehicle weight 

upon inspection




Steering wheel free play 

(Outer circumference of wheel) 

(mm) 

0-30 

SS

SERVICE SPECIFICATIONS - OPERATION SETTING WHEN DISCONNECTING AND RECONNECTING NEGATIVE 

BATTERY TERMINAL 


OPERATION SERVICE SPECIFICATIONS 

SETTING WHEN DISCONNECTING AND 

RECONNECTING NEGATIVE BATTERY TERMINAL 

SERVICE 

Work item 

Initialization of power window 

system 

Work procedure 

1. Disconnect the negative (-) 

terminal of the battery or the 

connector to the power window 

master switch. 

2. After 5 seconds or more has 

elapsed, connect the negative 

(-) terminal of the battery 

or the connector to the power 

window master switch. 

3. Fully open the window of the 

driver seat door. 

4. Make the window of the driver 

seat door go up and continue 

to keep the switch in the UP 

direction for at least 2 seconds 

even after the window is 

fully closed. 

Non-compliant Behavior, Non-working 

Functions 

• Automatic opening and closing function 

of the door window 

• Jam protection function 

• Remote operation of each seat with 

the driver seat switch 

Remarks 

Settings are required for the 

driver seat master switch 

SS


SERVICE SPECIFICATIONS - OPERATION SETTINGS WHEN INSTALLING, REMOVING AND REPLACING PARTS 

OPERATION SETTINGS WHEN INSTALLING, REMOVING 


AND REPLACING PARTS 

SERVICE 

1. Replacement Work 


Replacement Part 

• Automatic transmission assembly 

• Valve body assembly 

• Engine assembly 

• Transmission wire 

Required Work 

1. Automatic transmission 

learned value initialization 

Non-compliant Behavior, Nonworking 

Functions 

• Transmission harsh engagement 

Remarks 

• Yaw rate sensor 

1. Acquire yaw rate sensor 

and G sensor and 

master cylinder pressure 

sensor zero point 

• Slip indicator light comes on 

• Buzzer sounds 

• VSC control prohibition or 

erroneous operation 

• Actuator assembly (equipped in skid 

control ECU) 









• Master cylinder pressure sensor 









• Immobiliser code computer (ID code 

box) 

1. Identification code 

registration (see the 

manual for registration 

method) 

• Wireless functions 

• Engine start 

• Power window master switch assembly 

• Power window regulator motor 

assembly (driver seat) 

• Front door window regulator (driver 

seat) 

1. Initialization of power 

window system 

• Automatic opening and closing 

function of the door window 

• Jam protection function 

• Remote operation of each 

seat with the driver seat 

switch 

• Settings are required for the 

driver seat master switch 

2. AUTOMATIC TRANSMISSION LEARNED VALUE INITIALIZATION 

NOTICE: 

Wait at least 1 minute after connecting the battery terminal 

before performing the initialization of the automatic transmission 

learned values. 

HINT: 

Learned values will not be initialized (erased) by simply disconnecting 

the negative (-) terminal of the battery. 

(a) After confirming that the shift position is in the P range, connect 

the DS-II to the DLC and turn the ignition switch ON and the 

DS-II power ON. 

NOTICE: 

Do not start the engine. 

(b) Conduct AT learned value initialization 

(1) To initialize learned values, follow the DS-II screen display, 

select MAIN MENU [OPERATION SUPPORT] OPERA- 

TION SUPPORT CLASSIFICATION [A/T] [AT LEARNED

SERVICE SPECIFICATIONS - OPERATION SETTINGS WHEN INSTALLING, REMOVING AND REPLACING PARTS 


VALUE INITIALIZATION] and run [AT LEARNED VALUE 

INITIALIZATION]. 

HINT: 

Initialization will complete in about 1 minute. 

3. ACQUIRE YAW RATE SENSOR AND G SENSOR AND MASTER 

CYLINDER PRESSURE SENSOR ZERO POINT 

NOTICE: 

Always measure the zero point on a level surface (incline of less 

than 1%). Do not open or close the doors or shake the vehicle 

during the operation. Also, do not start the engine to avoid idling 

vibration. 

(a) ACTIVATE SENSOR ZERO POINT ACQUISITION MODE 

(1) Stop the vehicle on a level surface. 

(2) Turn the ignition switch to the ON position, and press the 

TRC OFF switch to activate the sensor zero point acquisition 

mode. 

HINT: 

The slip indicator turns on and a buzzer will sound at the 

same time. 

(b) Acquire zero point for yaw rate sensor and master cylinder 

pressure sensor. 

(1) Leave the vehicle stationary and release the brake pedal 

for 1 second or more. 

HINT: 

When the zero point of the master cylinder pressure sensor 

is successfully acquired, only the buzzer will turn off. 

(2) When the zero point of each sensor is acquired, the zero 

point acquisition mode ends and the slip indicator turns off. 

HINT: 

• If wheel speed is detected, the acquire zero point mode 

will be canceled and the slip indicator light will go out. 

• If the TRC OFF switch is handled during the acquire 

zero point mode the slip indicator light will go out and 

the acquire zero point mode will be cancelled. (Turning 

off the ignition switch will cancel the acquire zero point 

mode as well.) 

• Pressing the TRC OFF switch again will restart the 

acquire zero point mode. However, the zero point acquisition 

mode will not be performed for the items which 

have been completed. 

• If malfunction items are detected, the acquire zero point 

mode is terminated due to handling of the TRC OFF 

switch, and the applicable items cannot be reexamined 

without restarting the acquire zero point mode. 


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SS SERVICE SPECIFICATIONS - TodoAutos

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