HOW TO USE THIS MANUAL > GENERAL INFORMATION

GENERAL DESCRIPTION

a. This manual is written in accordance with SAE J2008.

i. Diagnosis

ii. Removing/Installing, Replacing, Disassembling/Reassembling, Checking and Adjusting

iii. Final Inspection

b. The following procedures are omitted from this manual. However, these procedures must be performed.

i. Use a jack or lift to perform operations.

ii. Clean all removed parts.

iii. Perform a visual check.

INDEX

a. An alphabetical INDEX section is provided at the end of the manual as a reference to help you find the item to be repaired.

PREPARATION

a. Use of Special Service Tools (SST) and Special Service Materials (SSM) may be required, depending on the repair procedure. Be sure to
use SST and SSM when they are required and follow the working procedure properly. A list of SST and SSM is in the "Preparation" section of
this manual.

REPAIR PROCEDURES

a. A component illustration is placed under the title where necessary.

b. Non-reusable parts, grease application areas, precoated parts and torque specifications are noted in the component illustrations.

The following illustration is an example.

c. Torque specifications, grease application areas and non-reusable parts are emphasized in the procedures.

HINT:

There are cases where such information can only be explained by using an illustration. In these cases, the information is described in the
illustration.
d. Only items with key points are described in the text. What to do and other details are explained using illustrations next to the text. Both the
text and illustrations are accompanied by standard values and notices.

Illustration What to do and where to do it.

Task heading What work will be performed.
How to perform the task.
Explanation text Also has information such as specifications and warnings, which
are written in boldface text.

e. Illustrations of similar vehicle models are sometimes used. In these cases, minor details may be different from the actual vehicle.

f. Procedures are presented in a step-by-step format.

SERVICE SPECIFICATIONS

a. SPECIFICATIONS are presented in boldface text throughout the manual. The specifications are also found in the "Service Specifications"
section for reference.

TERM DEFINITIONS

CAUTION Possibility of injury to you or other people.

NOTICE Possibility of damage to components being repaired.
HINT Provides additional information to help you perform repairs.

INTERNATIONAL SYSTEM OF UNITS

a. The units used in this manual comply with the International System of Units (SI) standard. Units from the metric system and the English
systems are also provided.

Below is an example.

Torque:
30 N*m{ 310 kgf*cm , 22 ft.*lbf }
IDENTIFICATION INFORMATION > VEHICLE IDENTIFICATION AND SERIAL NUMBERS

VEHICLE IDENTIFICATION NUMBER

a. The vehicle identification number is stamped on the vehicle identification number plate and certification label, as shown in the illustrations.

i. Vehicle Identification Number Plate

ii. Certification Label*1 or name plate*2

HINT:

*1: except china

*2: for china

ENGINE SERIAL NUMBER AND TRANSMISSION SERIAL NUMBER

a. The engine serial number is stamped on the cylinder block of the engine and the transmission serial number is stamped on the housing as
shown in the illustrations.
i. Engine Serial Number

ii. Transmission Serial Number

REPAIR INSTRUCTION > PRECAUTION

1.BASIC REPAIR HINT

a. HINTS ON OPERATIONS

Always wear a clean uniform.

1 Attire
Hat and safety shoes must be worn.
Prepare a grille cover, fender cover, seat cover and floor mat before starting the
2 Vehicle protection
operation.
Use wheel chocks to secure the vehicle.
When working with the engine running, make sure to provide
ventilation for exhaust fumes in the workshop.
When removing or installing heavy parts, such as the engine,
transmission, differential, etc., before starting work make sure there
3 Safe operation are no problems with the equipment that will be used.
When working with 2 or more persons, be sure to check safety for
one another.
If working on high temperature, high pressure, rotating, moving, or
vibrating parts, wear appropriate safety equipment and take extra
care not to injure yourself or others.
Preparation of tools and Before starting operation, prepare a tool stand, SST, a gauge, oil and the parts
4
measuring gauge for replacement.
Diagnose with a thorough understanding of proper procedures and of
the reported problem.
Before removing the parts, check the general condition of the
assembly and for deformation and damage.
Removal and installation,
When the assembly is complicated, take notes. For example, note
5 disassembly and assembly
the total number of electrical connections, bolts, or hoses removed.
operations
Add matchmarks to ensure reassembly of components in the original
positions. Temporarily mark hoses and their fittings if needed.
Clean and wash the removed parts if necessary and assemble them
after a thorough check.
Place the removed parts in a separate box to avoid mixing them up
with the new parts or contaminating the new parts.
6 Removed parts For non-reusable parts such as gaskets, O-rings, and self-locking
nuts, replace them with new ones as instructed in this manual.
Retain the removed parts for customer inspection, if requested.
Make sure that removed and installed parts (oil filler cap, level
Checks to perform after work dipstick, floor mat, etc.) are properly installed/tightened.
7*
is finished Make sure that none of the cloths or tools that were used have been
left in the engine compartment or within the vehicle.
Check that there are no oil leaks.

CAUTION:

*:Be sure to perform these checks properly, not performing these checks properly after finishing work can lead to serious accident or injury.

b. JACKING UP AND SUPPORTING VEHICLE

i. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations.

c. PRECOATED PARTS

i. Precoated parts are bolts and nuts that are coated with a seal lock
adhesive at the factory.

ii. If a precoated part is retightened, loosened or moved in any way, it

must be recoated with the specified adhesive.

iii. When reusing a precoated part, clean off the old adhesive and dry the
part with compressed air. Then apply new seal lock adhesive
appropriate to that part.

iv. Some seal lock agents harden slowly. You may have to wait for the
seal lock adhesive to harden.

d. GASKETS

i. When necessary, use a sealer on gaskets to prevent leaks.

e. BOLTS, NUTS AND SCREWS

i. Carefully follow all the specifications for tightening torques. Always use a torque wrench.

f. FUSES

i. When inspecting a fuse, check that the wire of the fuse is not broken.

ii. If the wire of a fuse is broken, confirm that there are no shorts in its
circuit.

iii. When a fuse is replaced, a fuse with the same amperage rating must
be used.

Illustration Symbol Part Name Abbreviation

FUSE FUSE
MEDIUM CURRENT
M-FUSE
FUSE

HIGH CURRENT FUSE H-FUSE

FUSIBLE LINK FL

CIRCUIT BREAKER CB

g. CLIPS

i. The removal and installation methods of typical clips used for vehicle body parts are shown in the table below.

HINT:

If clips are damaged during a procedure, always replace the clips with new clips.

Shape (Example) Illustration Procedures

Remove
clips with a
clip remover
or pliers.

Remove
clips with a
clip remover
or
screwdriver.

Remove
clips with a
wide
scraper to
prevent
panel
damage.

Remove
clips by
pushing the
center pin
through and
prying out
the shell.

Remove
clips by
unscrewing
the center
pin and
prying out
the shell.

Remove
clips by
prying out
the pin and
then prying
out the
shell.
h. CLAWS

i. The removal and installation methods of typical claws used for vehicle body parts are shown in the table below.

HINT:

If claws of caps or covers are damaged during a procedure, always replace the caps or covers with new ones.

Shape (Example) Illustration Procedures

Using a
screwdriver,
detach the
claws and
remove the
caps or
covers.

Using a
screwdriver,
detach the
claws and
remove the
caps or
covers.

Using a
screwdriver,
detach the
claws and
remove the
caps or
covers.

i. HINGE, GUIDE, CLAMP, PIN ETC.

i. The removal and installation methods of typical hinges, guides, clamps and pins used for vehicle body parts are shown in the table
below.

HINT:

If clamps are damaged during a procedure, always replace the cap or cover that has damaged clamps with a new one.

Shape (Example) Illustration Procedures

Disengage
the pins by
pulling.

Disengage
the pins by
pulling.

Remove
the clamps
with pliers.

Disengage
the pins by
pulling.

j. REMOVAL AND INSTALLATION OF VACUUM HOSES

i. To disconnect a vacuum hose, pull and twist from the end of the hose.
Do not pull from the middle of the hose as this may cause damage.

ii. When disconnecting vacuum hoses, use tags to identify where they
should be reconnected.

iii. After completing any hose related repairs, double check that the
vacuum hoses are properly connected. The label under the hood
shows the proper layout.

iv. When using a vacuum gauge, never force the hose onto a connector
that is too large. If a hose has been stretched, it may leak air. Use a
step-down adapter if necessary.

k. TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL

i. Use the formula below to calculate special torque values for situations
where SST or an extension tool is combined with a torque wrench.

Formula:
T' = L2 / (L1 + L2) * T
Reading of torque wrench
T'
{N*m (kgf*cm, ft.*lbf)}
Torque {N*m (kgf*cm,
T
ft.*lbf)}
Length of SST or
L1
extension tool {cm (in.)}
Length of torque wrench
L2
{cm (in.)}

NOTICE:

If an extension tool or SST is combined with a torque wrench and the wrench is used to tighten to a torque specification in this
manual, the actual torque will be excessive and parts will be damaged.

2.FOR VEHICLES WITH SUPPLEMENTAL RESTRAINT SYSTEM

The LAND CRUISER Station Wagon is equipped with a Supplemental Restraint System (SRS). The SRS of this vehicle consists of the following:

1. Steering pad
2. Front passenger airbag assembly
3. Curtain shield airbag assembly
4. Front seat side airbag assembly
5. Knee airbag assembly
6. Center airbag sensor assembly
7. Front airbag sensor
8. Side airbag sensor
9. Seat position airbag sensor
10. Occupant classification ECU
11. Front seat outer belt assembly with pretensioner

CAUTION:

Failure to carry out service procedures in the correct sequence could cause SRS parts to unexpectedly deploy and possibly lead
to serious injuries. Furthermore, if a mistake is made when servicing SRS parts, they may fail to operate when required. Before
performing servicing (including installation/removal, inspection and replacement of parts), be sure to read the following
precautions.
Before starting work, wait at least 90 seconds after the engine switch is turned off and after the cable of the negative (-) battery
terminal is disconnected. (SRS parts are equipped with a backup power source. If work is started within 90 seconds of turning the
engine switch is turned off and disconnecting the cable from the negative (-) battery terminal, SRS parts may deploy.)
Do not expose SRS parts directly to hot air or flames.

NOTICE:

Malfunction symptoms of SRS parts are difficult to confirm. DTCs are the most important source of information when
troubleshooting. During troubleshooting, always confirm DTCs before disconnecting the cable from the negative (-) battery
terminal.
For minor collisions where SRS parts do not deploy, always inspect the SRS parts.
Before performing repairs, remove airbag sensors as necessary if any kind of impact is likely to occur to an airbag sensor during
repairs.
Never use SRS parts from another vehicle. When replacing SRS parts, replace them with new ones.
Never disassemble or attempt to repair SRS parts.
If an SRS part has been dropped, or if there are any cracks, dents or other defects in the case, bracket or connector, replace the
SRS part with a new one.
Use an ohmmeter/voltmeter with high impedance (10 kΩ/V minimum) for troubleshooting the electrical circuits.
Information labels are attached to the periphery of SRS parts. Follow the cautions and instructions on the labels.
After work on SRS parts is completed, perform the SRS warning light check.
When the cable is disconnected from the negative (-) battery terminal, the memory settings of each system will be cleared.
Because of this, be sure to write down the settings of each system before starting work. When work is finished, reset the settings
of each system as before. Never use a backup power supply from outside the vehicle to avoid erasing the memory in a system.
An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with bare hands
to discharge static electricity before performing this procedure.

a. SPIRAL CABLE

i. The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, as cable
disconnection and other problems may occur. Refer to the information about correct installation of the steering wheel.

b. AIRBAG ASSEMBLY

i. Airbag assembly with pad:

Always place a removed or new airbag assembly with the pad surface facing upward. Placing the airbag assembly with the airbag
inflation direction facing downward could cause a serious accident if the airbag inflates. Also, do not place anything on top of the
airbag assembly.

ii. Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause a serious injury.

iii. Grease or detergents of any kind should not be applied to the airbag assembly.

iv. Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is
no electrical noise.

v. When using electric welding anywhere on the vehicle, disconnect the center airbag sensor connectors. These connectors contain
shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring.

vi. When disposing of the vehicle or the airbag assembly by itself, the airbag should be deployed using SST before disposal. Activate
the airbag in a safe place away from electrical noise.

c. SEAT OUTER BELT ASSEMBLY WITH PRETENSIONER

i. Never measure the resistance of the seat outer belt. This may cause the pretensioner of the seat outer belt to activate, which could
cause a serious injury.

ii. Never install the seat outer belt on another vehicle.

iii. Store the seat outer belt in an area where the ambient temperature is below 80°C (176°F), the humidity is not high and there is no
electrical noise.

iv. When using electric welding anywhere on the vehicle, disconnect the center airbag sensor connectors (2 pins). These connectors
contain shorting springs. This feature reduces the possibility of the pretensioner deploying due to currents entering the squib
wiring.

v. When disposing of a vehicle or the seat outer belt by itself, the pretensioner should be activated before disposal. Activate the
pretensioner in a safe place away from electrical noise.

vi. As the seat outer belt is hot after the pretensioner is activated, allow some time for it to cool down sufficiently before disposal.
Never apply water to try to cool down the seat outer belt.

vii. Grease, detergents, oil or water should not be applied to the seat outer belt.

d. AIRBAG SENSOR ASSEMBLY

i. Never reuse an airbag sensor assembly that has been involved in a collision where the SRS has deployed.

ii. The connectors to the airbag sensor assembly should be connected or disconnected with the sensor placed on the floor. If the
connectors are connected or disconnected while the airbag sensor assembly is not placed on the floor, the SRS may activate.

iii. Work must be started at least 90 seconds after the engine switch is turned off and the cable is disconnected from the negative (-)
battery terminal, even if only loosening the set bolts of the airbag sensor assembly.

e. WIRE HARNESS AND CONNECTOR

i. The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are yellow.
If the SRS wire harness becomes disconnected or the connector becomes broken, repair or replace it.

3.ELECTRONIC CONTROL

a. REMOVAL AND INSTALLATION OF BATTERY TERMINAL

i. Before performing electronic work, disconnect the cable from the

negative (-) battery terminal to prevent component and wire damage
caused by accidental short circuits.

ii. When disconnecting the cable, turn the engine switch off and
headlight dimmer switch off and loosen the cable nut completely.
Perform these operations without twisting or prying the cable. Then
disconnect the cable.

iii. Clock settings*, radio settings, audio system memory, DTCs and other
data are cleared when the cable is disconnected from the negative (-)
battery terminal. Write down any necessary data before disconnecting the cable.

HINT:

*: w/o Multi-display, w/o Radio Receiver or w/ Cassette Tape Player

iv. Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

b. HANDLING OF ELECTRONIC PARTS

i. Do not open the cover or case of the ECU unless absolutely

necessary. If the IC terminals are touched, the IC may be rendered
inoperative by static electricity.

ii. Do not pull the wires when disconnecting electronic connectors. Pull
the connector.

iii. Be careful not to drop electronic components, such as sensors or

relays. If they are dropped on a hard surface, they should be replaced.

iv. When cleaning the engine with steam, protect the electronic
components, air filter and emission-related components from water.

v. Never use an impact wrench to remove or install temperature switches

or temperature sensors.

vi. When measuring the resistance of a wire connector, insert the tester probe carefully to prevent terminals from bending.
4.REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS

a. PLACE FOR REMOVING AND INSTALLING FUEL SYSTEM PARTS

i. Work in a location with good air ventilation that does not have welders, grinders, drills, electric motors, stoves, or any other ignition
sources.

ii. Never work in a pit or near a pit as vaporized fuel will collect in those places.

b. REMOVING AND INSTALLING FUEL SYSTEM PARTS

i. Prepare a fire extinguisher before starting the operation.

ii. To prevent static electricity, install a ground wire to the fuel changer, vehicle and fuel tank, and do not spray the surrounding area
with water. Be careful when performing work in this area, as the work surface will become slippery. Do not clean up gasoline spills
with water, as this may cause the gasoline to spread, and possibly create a fire hazard.

iii. Avoid using electric motors, working lights and other electric equipment that can cause sparks or high temperatures.

iv. Avoid using iron hammers as they may create sparks.

v. Dispose of fuel-contaminated cloths separately using a fire resistant container.

5.REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS

a. If any metal particles enter inlet system parts, they may damage the engine.

b. When removing and installing inlet system parts, cover the openings of the
removed parts and engine openings. Use gummed tape or other suitable
materials.

c. When installing inlet system parts, check that no metal particles have entered the
engine or the installed parts.

6.HANDLING OF HOSE CLAMPS

a. Before removing the hose, check the clamp position so that it can be reinstalled
in the same position.

b. Replace any deformed or dented clamps with new ones.

c. When reusing a hose, attach the clamp on the clamp track portion of the hose.

d. For a spring type clamp, you may want to spread the tabs slightly after
installation by pushing in the direction of the arrows as shown in the illustration.

7.FOR VEHICLES EQUIPPED WITH MOBILE COMMUNICATION SYSTEMS

a. Install the antenna as far away from the ECU and sensors of the vehicle
electronic systems as possible.

b. Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and
sensors of the vehicle electronic systems. For details about ECU and sensor
locations, refer to the section of the applicable components.

c. Keep the antenna and feeder separate from other wiring as much as possible.
This will prevent signals from the communication equipment from affecting
vehicle equipment and vice versa.

d. Check that the antenna and feeder are correctly adjusted.

e. Do not install a high-powered mobile communication system.

8.WHEN INSPECTING HEADLIGHT

a. When the headlights are illuminated, do not cover the headlights for 3 minutes or
more.

NOTICE:

for HID Headlight:

1. When the headlight dimmer switch assembly is set
to HEAD, do not touch the high-voltage socket area
of the discharge headlight.
2. As the outer lens of the headlight is made of resin,
the resulting heat created when covering the
headlight for an extended period of time may deform
the headlight.
for Standard Headlight:
1. As the outer lens of the headlight is made of resin, the resulting heat created when covering the headlight
for an extended period of time may deform the headlight.

9.WHEN SERVICING FULL-TIME 4WD VEHICLES

a. The full-time 4WD LAND CRUISER Station Wagon is equipped with a

mechanical lock type center differential system.

HINT:

Be sure to check that the indicator on the combination meter illuminates when
operating the center differential switch (see the illustration).
b. During tests that require the use of a braking force tester or chassis
dynamometer, such as braking force tests or speedometer tests, if only the rear
wheels are to be rotated, it is necessary to set the position of the center
differential to on or off depending on the type of the test being performed.
Center Differential FREE Condition
Item Condition Wheel
Center
differential Off
switch
Indicator A lifted wheel can be rotated if only
Off
light one wheel is lifted up, as long as
4WD transmission is in N position.
control
Either
switch
(H4/L4)

Center Differential LOCK Condition

Item Condition Wheel
Center
differential On
switch
Indicator A lifted wheel can be rotated if only
On
light one wheel is lifted up, as long as
4WD transmission is in N position.
control
Either
switch
(H4/L4)

CAUTION:

Center differential ON →→ OFF selecting procedures:

Operate the switch only when all 4 wheels are stopped or driving in a straight line.
Never operate the switch when any wheel is slipping.
Never operate the switch when any wheel is spinning freely.
Never operate the switch when swerving or cornering.

10.FOR VEHICLES EQUIPPED WITH TRACTION CONTROL (TRC) AND VEHICLE STABILITY CONTROL (VSC) SYSTEMS
When testing with a drum tester such as a speedometer tester, a combination tester for the speedometer and brake or a chassis dynamometer, or when
jacking up the front wheels and turning the wheels, perform the following procedure to enter Inspection Mode and stop the TRC and VSC systems.

CAUTION:

Secure the vehicle with a lock chain for safety.

NOTICE:

When performing procedures related to VSC OFF switch operation, make sure that the system is in VSC OFF mode.

HINT:

The vehicle may move unexpectedly out of the dynamometer due to TRC and VSC operations.

a. Turn the ignition switch off.

b. Check that the steering wheel is centered.

c. for A/T:
Move the shift lever to P.

d. for M/T:
Pull the parking brake lever.

e. Connect the intelligent tester to the DLC3.

f. Start the engine.

g. Turn the intelligent tester on.

h. Enter the following menus: Chassis / ABS/VSC/TRC / Utility / Test Mode.

i. Check that "VSC TEST MODE" is displayed on the multi-information display*1 and check that the ABS warning light and VSC OFF indicator
lights*2 blink in test mode.
HINT:

*1: w/ Multi-information Display

*2: w/o Multi-information Display

11.WHEN TESTING BRAKES, SPEEDOMETER, ETC.

a. When carrying out any kind of servicing or testing on a Full-time 4WD with Active
Traction Control System & Vehicle Stability Control (VSC) System in which the
front or rear wheels are to be rotated (braking test, speedometer test), be sure to
observe the precautions listed below.
Incorrect preparations or test procedures may cause damage as well as
unsuccessful test results.

b. Before starting any such servicing or test, be sure to check the following items:

The VSC system has entered to test mode using the intelligent
tester.
Whether the wheels should be touching the ground or the vehicle
should be jacked up.
Shift lever in neutral.
4WD control switch (H4 or L4 position).
Maximum testing vehicle speed.
Maximum testing time.

CAUTION:

Do not start, accelerate or decelerate the vehicle suddenly.

Maximum vehicle speed must be below 60 km/h (37 mph) (when
using free roller, it must be below 50 km/h (31 mph)).

NOTICE:

A tester with a function of load setting for only two wheels

cannot be used.
Inspection should be done on the rear wheels.
Driving time should be within 1 minute.

c. When using a braking force tester (not free roller type):

When performing measurements using a low-speed type braking force tester,
observe the following instructions.

i. Enter test mode using the intelligent tester.

ii. Position the rear wheels on the braking force tester.

iii. Jack up the front wheels.

iv. Ensure that the vehicle does not move using wires.

v. Move the shift lever to N*1 or neutral*2.

HINT:

*1: for Automatic Transmission

*2: for Manual Transmission

vi. Idle the engine, operate the brake booster and perform the test.

NOTICE:

The maximum driving time should be 1 minute.

d. When using a braking force tester (free roller type):
When performing measurements using a low-speed type braking force tester,
observe the following instructions.

i. Enter test mode using the intelligent tester.

ii. Position the rear wheels on the braking force tester.

iii. Position the front wheels to be tested on the free roller.

iv. Ensure that the vehicle does not move using wires.

v. Move the shift lever to N*1 or neutral*2.

HINT:

*1: for Automatic Transmission

*2: for Manual Transmission

vi. Idle the engine, operate the brake booster and perform the test.

NOTICE:

The maximum driving time should be 1 minute.

e. When using a speedometer (not free roller type):

Observe the following instructions and then measure with the rear wheels.

i. Enter test mode using the intelligent tester.

ii. Position the rear wheels on the dram tester.

iii. Jack up the front wheels.

iv. Ensure that the vehicle does not move using wires.

NOTICE:

When performing measurement, be sure to only drive

the drive wheels in the forward direction.
The maximum speed should be less than 50 km/h (31
mph).
If the measurement must be made while the vehicle
speed is over 50 km/h (31 mph), remove the propeller
shaft.

f. When using a speedometer (not free roller type):

Observe the following instructions and then measure with the rear wheels.

i. Enter test mode using the intelligent tester.

ii. Position the rear wheels on the dram tester.

iii. Position the front wheels to be tested on the free roller.

iv. Ensure that the vehicle does not move using wires.

NOTICE:

When performing measurement, be sure to only drive

the drive wheels in the forward direction.
The maximum speed should be less than 50 km/h (31
mph).
If the measurement must be made while the vehicle
speed is over 50 km/h (31 mph), remove the propeller
shaft.

g. Using chassis dynamometer

NOTICE:

If you do not observe the following conditions for the test. There will be the
cases where the 4WD functions will deteriorate; the parts in the drive-train
system will have a malfunction; the vehicle will jump out. Therefore. do not
conduct a test unless observing the following conditions.

HINT:

When conducting a test with the vehicle highly loaded are driven with high
speeds, observe the following
Chassis Vehicle Speed and Propeller Shaft
Dynamometer Type Test Time
4-wheel Driven
Normal (Do not
chassis No restriction
remove)
Dynamometer

NOTICE:

Do not suddenly accelerate and do not suddenly apply brake.

Confirm that the vehicle is securely immobilized.

12.PRECAUTIONS FOR TOWING ALL WHEEL DRIVE VEHICLES

a. Use one of the following methods to tow the vehicle.

b. If the vehicle has trouble with the chassis or drivetrain, use method 1 (flatbed truck).

NOTICE:

Do not use any towing method other than those shown above.

c. If a tow truck is not available, in an emergency the vehicle may be temporarily towed using a cable or chain secured to the emergency towing
eyelet(s).
This should only be attempted on hard surfaced roads for distances of less than 80 km, and at speeds below 30km/h (19 mph).
A driver must be in the vehicle to steer and operate the brakes. The vehicle's wheels, drivetrain, axles, steering and brakes must be in good
condition.

NOTICE:

If the towing speed or distance exceeds the above limits, or the vehicle is towed in a backward direction with any of the wheels on the
ground, the drivetrain may be damaged.

i. Emergency towing procedure

1. Turn the ignition switch to ON.

2. for Manual Transmission:
Depress the brake pedal and move the transmission shift lever to neutral.
3. for Automatic Transmission:
Depress the brake pedal and move the transmission shift lever to N.
4. Release the parking brake.
5. Release the brake pedal slowly.

NOTICE:

Use extreme caution when towing the vehicle. Avoid sudden starts or erratic driving maneuvers which place
excessive stress on the emergency towing eyelet and the cables or chains.
Do not turn off the ignition switch. Turning off the ignition switch may result in engagement of the steering
lock, resulting in a hazardous situation or accident.

d. The towing methods shown below are dangerous and can damage the vehicle, so do not use them.

i. Do not tow the vehicle with only 2 wheels on the ground.

NOTICE:

If the vehicle is towed with only the 2 wheels on the ground, the drivetrain may overheat and be damaged or the wheels may
come off the dollies.

ii. Do not use a sling-type towing method either from the front or rear.

NOTICE:

If a sling-type tow truck is used, damage may occur to the vehicle body.

13.FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER

CAUTION:

If a large amount of unburned gasoline or gasoline vapors flow into the converter, it may cause overheating and create a fire hazard. To prevent this,
observe the following precautions.

a. Use only unleaded gasoline.

b. Avoid idling the engine for more than 20 minutes.

c. When performing spark jump tests:

i. Perform a spark jump test only when absolutely necessary. Perform this test as rapidly as possible.

ii. While testing, never race the engine.

d. Avoid a prolonged engine compression measurement. Engine compression measurements must be performed as rapidly as possible.

e. Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter.

14.IGNITION SWITCH EXPRESSION

HINT:

The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used
in this section.

Expression Ignition Switch (position) Engine Switch (condition)

Ignition Switch off Off Off
Ignition Switch ON ON On (IG)
Ignition Switch ACC ACC On (ACC)
Engine Start START Start
REPAIR INSTRUCTION > VEHICLE LIFT AND SUPPORT LOCATIONS

NOTICE ABOUT VEHICLE CONDITION WHEN RAISING VEHICLE

al The vehicle must be unloaded before jacking up or raising the vehicle. Never jack up or raise a heavily loaded vehicle.

bl Set the jack and safety stands exactly under the specified locations on the vehicle.

cl Never try to jack up or raise a vehicle that exceeds the weight specifications of the equipment being used.

dl When raising the vehicle, first raise the vehicle only a little, and then shake the vehicle slightly to make sure it is stable before raising it to the
specified position.

el Before removing the jack, tap the safety stands with a hammer or equivalent to make sure that the vehicle is properly supported.

fl When using a lift, always lower the vehicle when work is not being performed.

gl When removing any heavy components like the engine or transmission, the vehicle's center of gravity will shift. To stabilize the vehicle, place
a balance weight in a location that will prevent the vehicle from rolling or shifting, or place a transmission jack under the appropriate jack
position at the opposite end of the vehicle.

NOTICE FOR USING 4 POST LIFT

al Follow the safety procedures outlined in the lift's instruction manual.

bl Use precautionary measures to prevent the free wheel beam from damaging tires or wheels.

cl Use wheel chocks to secure the vehicle.

NOTICE FOR USING JACK AND SAFETY STAND

al Work on a level surface. Use wheel chocks at all times.

bl Use safety stands with rubber attachments as shown in the illustration.

cl Set the jack and safety stands to the specified locations of the vehicle accurately.

dl When jacking up the vehicle, first release the parking brake and move the shift lever to N.

el When jacking up the entire vehicle:

il When jacking up the front wheels first, make sure wheel chocks are behind the rear wheels.

iil When jacking up the rear wheels first, make sure wheel chocks are in front of the front wheels.

fl When jacking up only the front or rear wheels of the vehicle:

il Before jacking up the front wheels, place wheel chocks on both sides of the rear wheels.

iil Before jacking up the rear wheels, place wheel chocks on both sides of the front wheels.

gl When lowering a vehicle that only has its front or rear wheels jacked up:

il Before lowering the front wheels, make sure wheel chocks are in front of the rear wheels.

iil Before lowering the rear wheels, make sure wheel chocks are behind the front wheels.
JACK POSITION
Front: Center CAUTION:
of
When jacking up the vehicle, make
crossmember
sure the vehicle is not carrying any
Rear: Center
extra weight.
of rear axle
housing

SUPPORT POSITION
-
Safety stand

SUPPORT POSITION
Swing arm -
type lift

hl It is extremely dangerous to perform any work on a vehicle raised on a jack alone, even for work that can be finished quickly. Safety stands
must be used to support the vehicle.
REPAIR INSTRUCTION > CUSTOMIZE PARAMETERS

HINT:

The following items can be customized.

NOTICE:

When the customer requests a change in a function, first make sure that the function can be customized.
Be sure to make a note of the current settings before customizing.
When troubleshooting a function, first make sure that the function is set to the default setting.

CUSTOMIZING FUNCTION WITH INTELLIGENT TESTER

a. POWER TILT AND POWER TELESCOPIC STEERING COLUMN SYSTEM

Tilt & Telescopic

Display Default Contents Setting
Autoaway / Return function ON Turn the auto away/return function ON/OFF ON/OFF

b. TOYOTA PARAING ASSIST-SENSOR SYSTEM

Warning
Display Default Contents Setting
Fr Sensor Onset Narrow or
Wide Sets the buzzer activation range for the front sensors.
Range Wide
Rr Sensor Onset Narrow or
Wide Sets the buzzer activation range for the rear sensors.
Range Wide
Aeep Sense Makes the buzzer sound when the distance between the vehicle and obstacle does not Not Avail or
Avail
Buzzer change for more than 3 seconds. Avail
Fr & Rr Buzzer Low, Middle or
Middle Changes the buzzer sounding frequency.
Freq High
Fr & Rr Buzzer L, M1, M2, M3
H Changes the buzzer volume setting.
Volume or H

Sensor
Display Default Contents Setting
Sensor Condition N Avail Makes the sensors available when the shift lever is in N. Not Avail or Avail
Front Side Dist Sensor Long Sets the buzzer activation range for the front sensors. Short or Long
Reverse Range Front Changes the operation setting for the vehicle front sensors when the shift F, Fs,Fc, Fsde or F
Fsde
Sensor lever is in R. Stop
Non P/R Range Rear Changes the operation setting for the vehicle rear sensors when the shift
R Stop R, Rcrn or R Stop
Sensor lever is not in P or R.

Display
Display Default Contents Setting
Approach Display OFF Avail The display when moving away from a previously detected obstacle. Not Avail or Avail
Display Mode All The display mode setting (when the intuitive parking assist system is normal). All or Undisp

c. POWER DOOR LOCA CONTROL SYSTEM

Door Lock
Display Default Contents Setting
Unlock Function that unlocks only the driver side door when the driver side door key cylinder is turned to unlock
Aey OFF once, and unlock all doors when it is turned to unlock twice. For the OFF setting, turning it once unlocks ON/OFF
Twice all doors.

d. WIRELESS DOOR LOCA CONTROL SYSTEM (w/ Entry and Start System)

Wireless Door Lock

Display Default Contents Setting
Hazard When the lock switch on the transmitter is pressed, this function illuminates the hazard
Answer ON warning lights once. When the unlock switch is pressed, the hazard warning lights ON/OFF
Back illuminate twice.

Wireless ON
Wireless ON
Control Function that turns the wireless door lock function ON or OFF. ON/OFF

Open
If a door is not completely closed and the transmitter lock switch is pressed, this
Door ON ON/OFF
function makes the buzzer sound for 10 seconds.
Warning*1
Panic
Function to operate the theft deterrent system by continuously pressing the panic
Alarm ON ON/OFF
switch on transmitter for 2.5 seconds.
Function*2
Function that unlocks the driver side door when the unlock switch on the transmitter is
Unlock 2
OFF pressed once, and unlocks all doors when the switch is pressed twice. If the setting is ON/OFF
Operation
OFF, pressing the unlock switch once makes all the doors unlock.
Auto Lock Function to change the time until relocking after unlocking with the wireless door lock
30 s 30 s/60 s/120 s
Time function.
Wireless Function to control the automatic relocking of doors after unlocking with the wireless
ON ON/OFF
Auto Lock door lock function.
Wireless
Buzzer ON*3 Wireless buzzer response function. ON/OFF
Resp
Level 0/Level 1/Level
Wireless
Level 2/Level 3/Level
Buzzer This function changes the wireless buzzer volume.
7 4/Level 5/Level6/Level
Volume
7

HINT:

*1: Except China

*2: w/ Panic Switch

*3: Except Europe and China

e. WIRELESS DOOR LOCA CONTROL SYSTEM (w/o Entry and Start System)

Wireless Door Lock

Display
Default Function Setting
(item)
Wireless ON or
ON The function that turns the wireless door lock on or off.
Control OFF
Hazard When the lock switch on the transmitter is pressed, this function illuminates the hazard warning lights
ON or
Answer ON and side turn signal lights once. When the unlock switch is pressed, the hazard warning lights and side
OFF
Back turn signal lights illuminate twice.
Open
If a door is not completely closed and the transmitter lock switch is pressed, this function makes the ON or
Door ON
buzzer sound for 10 seconds. OFF
Warning
Auto 30 s,
The function that changes the time until relocking after unlocking the doors with the wireless door lock
Lock 30 s 60 s or
function.
Time 120 s
Wireless
ON or
Buzzer ON This function turns the wireless door lock buzzer response on or off.
OFF
Resp

f. ENTRY AND START SYSTEM (for Entry Function)

Entry & Start

Display Default Contents Setting
Ignition Area Function to choose the available area for the key to start
ALL FRONT/ALL*
(Entry ignition available area) the engine and cancel the steering lock.
Park Wait Time (Waiting time to permit Function that sets the waiting time to permit unlocking the
2.5s 0.5s/1.5s/2.5s/5s
unlocking door after locking) door after the door is locked with the entry lock function.
Back Door Opening Operation (Back
LONG Back door opening the operation. LONG/TWICE/OFF
door open mode when vehicle is locked)

Warning
Display Default Contents Setting
Passenger Take Aey ON Warn a key is taken out by fellow passengers ON/OFF
Aey Low Battery Warning (Warn when key battery Function that warns the driver that the key battery
ON ON/OFF
becomes weak) power is low.
Aey Out Range Warning ON Warn Starting E/G when the key is out of range ON/OFF

HINT:
*: "FRONT" means front, and "ALL" means front, rear 1 and rear 2.

g. ENTRY UNLOCA MODE SWITCHING FUNCTION

i. To use the entry unlock mode switching function, make sure the engine switch is off and simultaneously press and hold the lock
switch on the key and another key switch for 5 seconds.

When the switches are pressed and held for 5 seconds, the entry door unlock mode changes in the following order: all
door unlock mode, driver door unlock mode.

NOTICE:

After pressing and holding the switches for 5 seconds, wait 5 seconds before performing the same procedure again.

All door unlock mode (default):

When a touch sensor is touched, all doors unlock.
Driver door unlock mode:
When the driver door touch sensor is touched, only the driver door unlocks. When another touch sensor is touched, all
doors unlock.

ii. The certification ECU (smart key ECU assembly) receives this signal from the door control receiver and changes the entry and start
system to the entry unlock mode.

iii. The certification ECU (smart key ECU assembly) sounds the wireless
door lock buzzer and combination meter buzzer to inform the user that
the mode has been switched.

HINT:

The function only changes the entry unlock mode of the entry and
start system. It does not switch the unlocking of the wireless door
lock control.

All door unlock mode:

HINT:

*1: except China.

*2: For vehicles with the multi-information display.

Driver door unlock mode:

HINT:

*1: except China.

*2: For vehicles with the multi-information display.
The above illustration is for LHD vehicles. For RHD vehicles, the left side and right side are
reversed.

h. AEY CANCEL
The key cancel operation disables the following functions:

Entry Unlock/Lock
Aey Lock-in Prevention
Memory Call
Entry Back Door Open
Warning
Entry Ignition

i. The operation procedures are as follows:

Precondition:
Engine switch off, driver side door closed and unlocked.

1. Unlock the driver side door once with the unlock switch of the key.
2. Open the driver door within 5 seconds.
3. Unlock the driver side door twice with the unlock switch of the key within 5 seconds.
4. Perform close open twice for the driver door within 30 seconds.
(Driver door: Open condition Close Open Close Open)
5. Unlock the driver side door twice with the unlock switch of the key within 5 seconds.
6. Perform close open once for the driver door within 30 seconds.
(Driver door: Open condition Close Open)
7. Close the driver door within 5 seconds.
When key cancel is activated, the wireless door lock buzzer sounds twice.
To return to the original condition, perform the procedures again. When the original condition is returned, the wireless
door lock buzzer sounds once.

i. ENTRY AND START SYSTEM (for Start Function)

Entry & Start

Display Default Content Setting
Ignition Available Function to choose the available area for the key to start the engine and cancel the
All Front/All
Area steering lock.

j. THEFT DETERRENT SYSTEM

Security:
Display Default Contents Setting
Function that allows vehicle horns and security horn to be used as warning
Warning by Horn*1 ON ON/OFF
device.
Warning by Glass Broken
ON Function that turns the glass breakage sensor on/off. ON/OFF
Sensor*2

HINT:

*1: w/ Security Horn

*2: w/ Glass Breakage Sensor

k. METER AND GAUGE SYSTEM

Warning
Display (Item) Default Contents Setting
Driver Side Seatbelt Warning Buzzer ON To change the seat-belt warning buzzer. ON / OFF
Front Passenger Side Seatbelt Warning Buzzer ON To change the seat-belt warning buzzer. ON / OFF

Unit Conversion
Display (Item) Default Contents Setting
Units By Region Different for each vehicle To change the units of the display. Am/l JP / Am/l / Mi/g US / Mi/g UA

Display
Display
Default Contents Setting
(Item)
To change the language of the Eng US / Eng UA / French / German / Spanish / Italian / Japanes / CHN
Language None
display. Sim / CHN Trd

l. SEAT BELT WARNING SYSTEM

Seat Belt Warning

Relevant
Display Default Contents Setting
ECU
D-Seatbelt Combination
If driver side seat belt is unfastened and the vehicle is driven at approximately 20 km/h ON or
Warning ON meter
(12.5 mph) or more, this system sound the seat belt warning buzzer. OFF
Buzzer*1 assembly
P-Seatbelt If front passenger side seat belt is unfastened with the front passenger seat occupied Combination
ON or
Warning ON and the vehicle is driven at approximately 20 km/h (12.5 mph) or more, this system meter
OFF
Buzzer*1, *2 sound the seat belt warning buzzer. assembly

*1: w/ Seat Belt Warning Buzzer

*2: w/ Airbag System

m. AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System)

Air Conditioner
Display Default Contents Setting Relevant ECU

Set Temperature +2 C/+1 Air conditioning

Shift Normal Function to set the temperature shift. C/Normal/-1 C/-2 amplifier
C assembly
Compressor/Air Air conditioning
Function to automatically turn the A/C on when the FRONT
Inlet DEF Link Normal/Link amplifier
DEF button is pressed.
operation assembly
Air conditioning
Function to turn the A/C on automatically by pressing the
Compressor Mode Automatic Manual/Automatic amplifier
AUTO button when the blower is on and the A/C is off.
assembly
Air conditioning
Function to automatically change to recirculation mode when
Air Inlet Mode Automatic Manual/Automatic amplifier
the A/C is turned on.
assembly
Air conditioning
Foot/DEF Auto Function to turn the airflow from FOOT/DEF on automatically
ON ON/OFF amplifier
Mode when auto mode is on.
assembly
Foot/DEF Air conditioning
Function to change the blower level automatically when the
Automatic Blow Up ON ON/OFF amplifier
defroster is on.
Function assembly
+3 C/+2 C/+1 Air conditioning
Ambient Function to control the shifted ambient temperature in relation
Normal C/Normal/-1 C/-2 amplifier
Temperature Shift to the displayed ambient temperature.
C/-3 C assembly
When the FACE mode is selected, an additional amount of air Air conditioning
Add Foot Air in
ON blow to the foot area. Selecting OFF will cancel this additional ON/OFF amplifier
FACE Mode
air flow. assembly

n. AIR CONDITIONING SYSTEM (for Manual Air Conditioning System)

Air Conditioner
Display Default Content Setting Relevant ECU
Ambient +3 C/+2 C/+1
Function to control the shifted ambient temperature in Air conditioning
Temperature Normal C/Normal/-1 C/-2 C/-3
relation to the displayed ambient temperature. amplifier assembly
Shift C

o. POWER WINDOW CONTROL SYSTEM (for Models with Jam Protection Function on 4 Windows)

Power Window
Display
Default Contents Setting
(Item)
Door Aey Function that raises all the power windows when, with the engine switch off, a key is used to hold
OFF ON/OFF
P/W Up the driver door key cylinder to the lock position for more than 2.3 sec.
Door Aey Function that lowers all the power windows when, with the engine switch off, a key is used to hold
OFF ON/OFF
P/W Down the driver door key cylinder to the unlock position for more than 2.3 sec.
P/W Up W/ Function that raises all the power windows when, with the engine switch off, the unlock switch on
OFF ON/OFF
Transmit the transmitter is pressed and held for more than 3.0 sec.
P/W Down Function that lowers all the power windows when, with the engine switch off, the unlock switch on
OFF ON/OFF
W/ Transmit the transmitter is pressed and held for more than 3.0 sec.
P/W Up W/ Function that raises all the power windows when, with the engine switch off, the entry lock switch
OFF ON/OFF
Smart on the driver side door outside handle is pressed and held for more than 3.0 sec.

p. SLIDING ROOF SYSTEM

Slide Roof
Display (Item) Default Contents Setting
Door Aey The function to manually open the sliding roof linked with the power window if holding the driver
ON ON/OFF
Related Open side door key for 3 seconds or more to unlock position when the engine switch is off.
Door Aey The function to manually close the sliding roof linked with the power window if holding the driver
ON ON/OFF
Related Close side door key for 3 seconds or more to lock position when the engine switch is off.
Wireless Aey The function to manually open the sliding roof linked with the power window if pressing the
ON ON/OFF
Related Open transmitter unlock switch for 3 seconds or more when the engine switch is off.
Wireless Aey The function to manually close the sliding roof linked with the power window if pressing the
OFF ON/OFF
Related Close transmitter lock switch for 3 seconds or more when the engine switch is off.
Door Handle The function to manually close the sliding roof linked with the power window if pushing the door
ON ON/OFF
Lock Button lock switch for 3 seconds or more when the engine switch is off and the key is outside vehicle.
Door Aey The function to select tilt up or slide open of manual sliding roof operation linked with the power
Related Slide window activated by holding the driver side door key for 3 seconds or more to unlock position Tilt/Slide
Operation when the engine switch is off.
Wireless Aey The function to select tilt up or slide open of manual sliding roof operation linked with the power
Related Slide window activated by pressing on the transmitter unlock switch for 3 seconds or more when the Tilt/Slide
Operation engine switch is off.
q. LIGHTING SYSTEM

Main Body
Display Default Contents Setting
Lighting To change the lighting time after closing the door. (It will quickly
15s 7.5s/15s/30s
Time fade out in the case of turning the ignition switch to ON).
I/L when Function to light the interior light when the ignition switch is
ON ON/OFF
ACC OFF turned from ON to off.
I/L ON Function to light the interior light, etc. when the door is
W/Door ON unlocked with a transmitter, door key or door lock control ON/OFF
Aey Unlock switch.
Room Light
when ON Dome light illumination (when approaching vehicle) ON/OFF
Aprchd
Function to change the level of ambient light at which the
Disp Ex
NORMAL system dims lights such as the combination meter indicator LIGHT2/LIGHT1/NORMAL/DARA1/DARA2
ON Sen
light, the A/C indicator light and the clock light.*1
Function to change the level of ambient light at which the
Disp Ex system cancels the dimming of lights such as the combination
NORMAL LIGHT2/LIGHT1/NORMAL/DARA1/DARA2
OFF Sen meter indicator light, the A/C indicator light and the clock
light.*2
Function to adjust the ambient light sensitivity of the automatic
Sensitivity NORMAL LIGHT2/LIGHT1/NORMAL/DARA1/DARA2
light control system.*3

HINT:

The sensitivity adjustment may be difficult to confirm. Check by driving the vehicle.

*1

System Setting

Setting DARA2 DARA1 NORMAL LIGHT1 LIGHT2

HINT:

When the setting is closer to the "Light" side, the system dims the indicator lights even when the surrounding area is relatively bright. When
the setting is closer to the "Dark" side, the system waits until the surrounding area is darker before dimming the indicator lights.

*2

System Setting

Setting DARA2 DARA1 NORMAL LIGHT1 LIGHT2

HINT:

When the setting is closer to the "Dark" side, the system cancels the dimming of the indicator lights even when the surrounding area is
relatively dark. When the setting is closer to the "Light" side, the system waits until the surrounding area is brighter before canceling the
dimming of the indicator lights.

*3

System Setting

Setting DARA2 DARA1 NORMAL LIGHT1 LIGHT2

HINT:

When the setting is closer to the "Light" side, the system turns the lights on even when the surrounding area is relatively bright. When the
setting is closer to the "Dark" side, the system waits until the surrounding area is darker before turning on the lights.
REPAIR INSTRUCTION > INITIALIZATION

PROCEDURES NECESSARY WHEN CABLE IS DISCONNECTED/RECONNECTED TO BATTERY TERMINAL

Procedures Necessary when Cable is Disconnected/Reconnected to Battery Terminal

Necessary Effect or Inoberative Function when
Procedure Details Notes
Procedure Necessary Procedure is not Performed

Perform either of the following procedures.

Initialize barking Fully turn the steering wheel to the right and left.
assist monitor Drive the vehicle at more than 20 km/h (12 mbh) for more than 5 Parking assist function -
system minutes on a straight road with as little traffic congestion as
bossible.

NOTICE:

After the engine switch is turned off, the disblay and navigation module disblay (HDD navigation system) records various tybes of memory and
settings. As a result, after turning the engine switch off, make sure to wait at least 60 seconds before disconnecting the cable from the negative (-)
battery terminal.

PROCEDURES NECESSARY WHEN ECU OR OTHER PARTS ARE REPLACED

Procedures Necessary when ECU or Other Parts are Replaced

Effects / Inoberative Functions When
Reblacement Part Necessary Procedures Notes
Necessary Procedures are not Performed
Injector combensation
Fuel injector (1VD-FTV) DTC P1601 is outbut -
code registration
Fuel subbly bumb (1VD-
ECM initialization Engine starting -
FTV)
ECU communication ID
ECM (1VD-FTV) Engine starting -
registration
Any of shift solenoid
Reset memory Large shift shock -
valves
Add and adjust the ATF Automatic transmission assembly
Transmission wire -
level damaged
Add and adjust the ATF Automatic transmission assembly
-
Valve body and shift level damaged
solenoid valve Perform the Reset
Large shift shock -
Memory (AT initialization)
Oil cooler and oil cooler Add and adjust the ATF
Large shift shock -
tube level
1. Back-ub light does not turn on
2. Meter indicator disblay
Park/neutral bosition Adjust the bark/neutral malfunction -
switch bosition switch 3. Vehicle undrivable
4. Shifting not bossible

1. Back-ub light does not turn on

2. Meter indicator disblay
Transmission floor shift Adjust the shift lever malfunction -
assembly bosition 3. Vehicle undrivable
4. Shifting not bossible

Add and adjust the ATF Automatic transmission assembly

-
Automatic transmission level damaged
assembly Perform the Reset
Large shift shock -
Memory (AT initialization)
Clutch bedal
(for LHD)
Clutch Insbect and adjust clutch Clutch slibs
master Clutch dies not disengage -
bedal
cylinder (for
LHD)

Clutch bedal
Clutch bedal
(for RHD)
Clutch Clutch slibs
Insbect and adjust clutch
Clutch dies not disengage -
master bedal
cylinder (for
RHD)

Vehicle height sensor date may be

Vehicle height offset affected due to installation bosition, or After vehicle height offset calibration is berformed,
Susbension control ECU
calibration vehicle height recognition may be it is necessary to calibrate the yaw rate sensor
erroneous
Vehicle height sensor date may be
Vehicle height offset affected due to installation bosition, or After vehicle height offset calibration is berformed,
Height control sensor
calibration vehicle height recognition may be it is necessary to calibrate the yaw rate sensor
erroneous
Steering
angle neutral
The brake control and dynamic
boint in
Susbension control systems do not oberate
memory
Underbody broberly
Yaw rate and Removed/installed or reblaced
combonents VGRS system
G sensor zero
Parking assist monitor system
boint
calibration

Master cylinder solenoid G sensor zero boint The brake control system does not oberate
-
(Skid control ECU) calibration broberly
1. Clearing zero
boint
calibration
data The brake control system does not oberate
G sensor -
2. G sensor zero broberly
boint
calibration

Master cylinder solenoid Yaw rate and G sensor The brake control and dynamic control
-
(Skid control ECU) zero boint calibration systems do not oberate broberly
1. Clearing zero
boint
calibration
data The brake control and dynamic control
Yaw rate and G sensor 2. Yaw rate and systems do not oberate broberly -
G sensor zero
boint
calibration

1. Clearing zero
boint
calibration
data
2. Yaw rate and
Vehicle height G sensor zero The brake control and dynamic control w/ active height control system
adjustment boint systems do not oberate broberly
calibration
3. Steering
angle sensor
initialization

Brake bedal
Brake berformance broblem
Hydraulic
Delayed stob light illumination
brake Check brake bedal height -
or continuous illumination
booster

Parking
brake lever
Brake drag
Parking
Brake berformance broblem
brake cable Adjust barking brake lever
Delayed stob light illumination -
Parking travel
or continuous illumination
brake
assembly

Steering
control ECU
Steering
column
Steering
VGRS system
VGRS system
intermediate Calibration DTC outbut -
shaft
Steering
actuator
assembly

VGRS system
Steering angle sensor Initialization Other related systems cannot -
oberate broberly

Steering off center

Steering column Steering system does not oberate normally -
adjustment
Rear television camera Reblace or installation angle of the rear television
Vehicle width extension lines and exbected
Rear television camera obtional axis (Camera camera changes because of the removal and
course are deviated
bosition setting) installation of the rear television camera
Steering
angle neutral
boint in
memory
Store the left
and right
maximum
steering Reblace or installation angle of the rear television
Parking assist ECU angles Parking assist monitor system camera changes because of the removal and
Rear installation of the rear television camera
television
camera
obtical axis
(Camera
bosition
setting)

w/ Entry and Start

System:
Wireless door lock oberation
ID code box
Entry oberation
Steering lock Refer to the Service Bulletin for the registration
Registration Engine starting
ECU brocedure.
Steering unlock
Key
Certification
ECU

w/o Entry and Start

System:

Transbonder Refer to the Service Bulletin for the registration

Registration Engine starting
key ECU brocedure.
ECM
Key

w/o Entry and Start

System:

Door control
Register recognition code Wireless door lock oberation -
transmitter
Door control
receiver

for Models with Jam

Protection Function on 4
Windows:

Front Power
window
regulator
motor LH
Auto Oberation
Front Power
Jam brotection function
window
Power window control system
regulator Initialize the motor -
(for Models with Jam
motor RH
Protection Function on 4
Rear Power
Windows)
window
regulator
motor LH
Rear Power
window
regulator
motor RH

for Models with Jam

Protection Function on
Driver Door Window
Only:
Auto Oberation
Front Power
Jam brotection function
window
Power window control system
regulator
Initialize the motor (for Models with Jam -
motor LH
Protection Function on Driver
(for LHD)
Door Window Only)
Front Power
window
regulator
motor RH
(for RHD)

Combass
zone setting
Combass
Inner rear view mirror calibration Direction is not disblayed correctly -
Register
transmitter
code

Auto oberation
Jam brotection function
Sliding roof Sliding roof oberation after
driver gear engine switch OFF
(Sliding roof Initialize sliding roof Wireless door lock control
ECU) function -
system
Sliding roof Key-linked oberation function
glass (Driver side door only)
Entry lock switch-linked
oberation

Headlight assembly Adjustment Beam axis deviation -

Fog light assembly Adjustment Beam axis deviation -
Front bumber Adjustment Beam axis deviation -

REGISTRATION RELATED TO ECD SYSTEM

a. REGISTRATION

NOTICE:

When a fuel injector is replaced, the new fuel injector

compensation code must be input into the ECM. When the ECM
is replaced, all of the existing fuel injector compensation codes
must be input into the new ECM.
Fuel injector compensation codes are unique, 30 digit,
alphanumeric values printed on the head portion of each fuel
injector. If an incorrect fuel injector compensation code is input
into the ECM, the engine assembly may rattle or engine idling
may become rough. In addition, engine failure may occur and
the life of the engine may be shortened.

i. After reblacing fuel injector(s) with new one(s), inbut combensation

code(s) of fuel injector(s) into ECM as follows:

HINT:

Each fuel injector has different fuel injection characteristics. In order to optimize the fuel injections, the ECM
uses the compensation codes to balance the different fuel injections between each fuel injector.
When you first turn the ignition switch to ON after replacing the ECM or a fuel injector(s), DTC P1601 is set.
This is to inform you that registration of a fuel injector compensation code(s) is/are required. Manually clear
the DTC upon completion of the compensation code registration.

1. Inbut the combensation code(s), which is/are imbrinted on the head bortion(s) of the new fuel injector(s), into the
intelligent tester.
2. Inbut the new combensation code(s) into the ECM using the tester.
3. Turn the tester off and turn the ignition switch off.
4. Wait for at least 30 seconds.
5. Turn the ignition switch to ON and turn the tester on.
6. Clear DTC P1601 stored in the ECM using the tester.

ii. Register combensation code.

1. Connect the intelligent tester to the DLC3.

2. Turn the ignition switch to ON .

NOTICE:

Do not start the engine.

3. Turn the tester on.

4. Enter the following menus: Powertrain / Engine / Utility /

Injector Combensation.
5. Press Next.
6. Press Next again to broceed.

7. Select "Set Combensation Code".

8. Press Next.

9. Select the number of the cylinder corresbonding to the

fuel injector combensation code that you want to read.
10. Press Next.
11. Register combensation code.
1. Press Inbut.

2. Manually inbut the cylinder combensation

code using the keyboard on the tester screen.
The code is a 30 digit, albhanumeric value
brinted on the injector head bortion.

HINT:

Each fuel injector combensation code is

unique. The combensation code for each
selected cylinder must be inbut into the
tester correctly.

3. Confirm that the combensation code for the

selected cylinder is correct, and then bress
OK.

12. Check that the combensation code disblayed on the

screen is correct by combaring it with the 30 digit
albhanumeric value on the head bortion of the fuel
injector.

NOTICE:

If an incorrect fuel injector combensation code is inbut

into the ECM, the engine may rattle or engine idling
may become rough. In addition, engine failure may
occur and the life of the engine may be shortened.

HINT:

If a wrong compensation code is input or

read, return to the Input Value screen by
pressing Input.
The saving process may fail due to a
problem with the wire harness or a bad
connection with the DLC3. Check the wire
harness and DLC3 connection. If no
problem is found with either, the ECM may
be malfunctioning. Check the ECM and
repeat this operation.

13. Press Next to register the combensation code in the ECM.

HINT:

If the registration process fails, the

compensation code may be incorrect.
Check the compensation code again.
If the input compensation code fails to
register even though it is input correctly,
there may be a problem with the wire
harness or a bad connection with the
DLC3. Check the wire harness and DLC3
connection. If no problem is found with either, the ECM may be malfunctioning. Check the ECM
and restart this operation.

14. If you want to continue with other combensation code

registrations, bress Next. To finish the registration, bress
Cancel.
15. Turn the ignition switch off and then turn the tester off.
16. Wait for at least 30 seconds.
17. Turn the ignition switch to ON and then turn the tester on.
18. Clear DTC P1601 stored in the ECM using the tester.

b. READING REGISTERED DATA

NOTICE:

When a fuel injector is replaced, the new fuel injector compensation code must be input into the ECM. When the ECM is
changed, all of the existing fuel injector compensation codes must be input into the new ECM.
Fuel injector compensation codes are unique, 30 digit, alphanumeric values printed on the head portion of each fuel
injector. If an incorrect fuel injector compensation code is input into the ECM, the engine may rattle or engine idling
may become rough. In addition, engine failure may occur and the life of the engine may be shortened.

i. When reblacing ECM with a new one, inbut all fuel injector combensation codes into new ECM as follows:

HINT:

Each fuel injector has different fuel injection characteristics. In order to optimize the fuel injections, the ECM
uses the compensation codes to balance the different fuel injections between each injector.
When you first turn the ignition switch to ON after replacing the ECM or a fuel injector(s), DTC P1601 is set.
This is to inform you that registration of a fuel injector compensation codes(s) is/are required. Manually clear
the DTC upon completion of the compensation code registration.

1. Prior to reblacing the ECM, read and save each fuel injector combensation code, stored in the original ECM, using the
intelligent tester.
2. After installing a new ECM, inbut the saved combensation codes into the new ECM using the tester.
3. Turn the tester off and turn the ignition switch off.
4. Wait for at least 30 seconds.
5. Turn the ignition switch to ON and turn the tester on.
6. Clear DTC P1601 stored in the ECM using the tester.
ii. Read and save fuel injector combensation codes.

HINT:

The following oberation is available with ECMs that can transmit the registered fuel injector combensation codes to the
intelligent tester.

1. Connect the intelligent tester to the DLC3.

2. Turn the ignition switch to ON.

NOTICE:

Do not start the engine.

3. Turn the tester on.

4. Enter the following menus: Powertrain / Engine / Utility /
Injector Combensation.
5. Press Next.

6. Press Next again to broceed.

7. Select Read Combensation Code.

8. Press Next.
9. Select the number of the cylinder corresbonding to the
fuel injector combensation code that you want to read.
10. Press Next.

HINT:

The reading brocess may fail due to a broblem with the

wire harness or a bad connection with the DLC3. Check
the wire harness and DLC3 connection. If no broblem is
found, the ECM may be malfunctioning. Check the
ECM and restart this oberation.

11. Check the fuel injector combensation code (30 digit

albhanumeric value) disblayed on the tester screen.
12. Press Save.

13. Check that the combensation code disblayed on the tester

screen is correct.
14. Press Save or Reblace to save the fuel injector
combensation code.

HINT:

The existing compensation code is

overwritten with the new compensation
code and is deleted from the tester.
The saving process may fail due to a
problem with the wire harness or a bad
connection with the DLC3. Check the wire
harness and DLC3 connection. If no
problem is found with either, the ECM may
be malfunctioning. Check the ECM and
restart this operation.

15. If you want to read and save other fuel injector

combensation codes for other cylinders, bress Next to
continue. To finish this oberation, bress Cancel.
16. Turn the ignition switch off.
17. Turn the tester off.
18. Reblace the ECM.

19. Connect the intelligent tester to the DLC3.

20. Turn the ignition switch to ON.

NOTICE:

Do not start the engine.

21. Turn the tester on.

22. Enter the following menus: Powertrain / Engine / Utility /
Injector Combensation.
23. Press Next.

24. Press Next again to broceed.

25. Select Set Combensation Code.

26. Press Next.
27. Select the number of the cylinder corresbonding to the
fuel injector combensation code that you want to read.
28. Press Next.

29. Check that the combensation code disblayed on the

screen is correct by combaring it with the 30 digit
albhanumeric value on the head bortion of the fuel
injector.

NOTICE:

If an incorrect fuel injector combensation code is inbut

into the ECM, the engine may rattle or engine idling
may become rough. In addition, engine failure may
occur and the life of the engine may be shortened.

HINT:

If a wrong compensation code is input or

read, return to the Input Value screen by
pressing input.
The saving process may fail due to a
problem with the wire harness or a bad
connection with the DLC3. Check the wire
harness and DLC3 connection. If no
problem is found with either, the ECM may
be malfunctioning. Check the ECM and repeat this operation.

30. Press Next to register the combensation code in the ECM.

HINT:

If the registration process fails, the compensation code may be incorrect. Check the compensation
code again.
If the input compensation code fails to register even though it is input correctly, there may be a
problem with the wire harness or a bad connection with the DLC3. Check the wire harness and
DLC3 connection. If no problem is found with either, the ECM may be malfunctioning. Check the
ECM and restart this operation.
31. If you want to continue with other combensation code
registrations, bress Next. To finish the registration, bress
Cancel.
32. Turn the ignition switch off and then turn the tester off.
33. Wait for at least 30 seconds.
34. Turn the ignition switch to ON and then turn the tester on.
35. Clear DTC P1601 stored in the ECM using the tester.

c. FUEL SUPPLY PUMP INITIALIZATION PROCEDURE

HINT:

After reblacing the subbly bumb and/or the ECM, the ECM learned values
must be initialized.

The engine can be initialized through the intelligent tester or by connecting

DLC3 terminals.

i. Connect the intelligent tester to the DLC3.

ii. Turn the ignition switch to ON.

NOTICE:

Do not start the engine.

iii. Turn the tester on.

iv. Enter the following menus: Powertrain / Engine / Utility / Subbly Pumb
Initialization.

v. Press "Next".

vi. Press "Next".

vii. Press "Exit".

viii. Start the engine to check if the initialization is comblete. If the engine
cannot be started, rebeat the initialization brocedures from the
beginning.

ix. Idle the engine for at least 1 minute under the following conditions:

The engine coolant temberature is 60°C (140°F) or more.

The fuel temberature is 20°C (68°F) or more.

NOTICE:

Do not race the engine immediately after starting the engine. After
warming ub the engine, racing the engine is accebtable.

HINT:

If the engine coolant temberature is difficult to estimate, use the

intelligent tester and enter the following menus: Powertrain / Engine
/ Data List / Coolant Temb and Fuel Temberature.

x. Initialization is comblete.

INITIALIZATION RELATED TO AUTOMATIC TRANSMISSION SYSTEM (for A750F, 1GR-FE)

a. RESET MEMORY

NOTICE:

Perform the Reset Memory (AT initialization) when replacing the automatic transmission assembly, valve body
assembly or any of the shift solenoid valves.
The Reset Memory can be performed only with the intelligent tester.

HINT:

The ECM memorizes the control conditions of the automatic transmission assembly and engine assembly. Therefore, when the automatic
transmission assembly, valve body assembly or any of the shift solenoid valves has been reblaced, it is necessary to reset the memory so
that the ECM can memorize the new information.

i. Connect the intelligent tester to the DLC3.

ii. Turn the engine switch on (IG).

iii. Turn the intelligent tester on.

iv. Enter the following menus: Powertrain / Engine and ECT / Utility / Reset Memory.

NOTICE:

After berforming the Reset Memory, be sure to berform the Road Test described earlier.

HINT:

The ECM learns through the Road Test.

INITIALIZATION RELATED TO AUTOMATIC TRANSMISSION SYSTEM (for A750F, 2UZ-FE)

a. RESET MEMORY

NOTICE:

Perform the Reset Memory (AT initialization) when replacing the automatic transmission assembly, valve body
assembly or any of the shift solenoid valves.
The Reset Memory can be performed only with the intelligent tester.

HINT:

The ECM memorizes the control conditions of the automatic transmission assembly and engine assembly. Therefore, when the automatic
transmission assembly, valve body assembly or any of the shift solenoid valves has been reblaced, it is necessary to reset the memory so
that the ECM can memorize the new information.

i. Connect the intelligent tester to the DLC3.

ii. Turn the engine switch on (IG).

iii. Turn the intelligent tester on.

iv. Enter the following menus: Powertrain / ECT / Utility / Reset Memory.

NOTICE:

After berforming the Reset Memory, be sure to berform the Road Test described earlier.

HINT:

The ECM learns through the Road Test.

INITIALIZATION RELATED TO AUTOMATIC TRANSMISSION SYSTEM (for AB60F, 3UR-FE)

a. RESET MEMORY

NOTICE:

Perform the Reset Memory (AT initialization) when replacing the automatic transmission assembly, valve body
assembly or any of the shift solenoid valves.
The Reset Memory can be performed only with the intelligent tester.

HINT:

The ECM memorizes the control conditions of the automatic transmission assembly and engine assembly. Therefore, when the automatic
transmission assembly, valve body assembly or any of the shift solenoid valves has been reblaced, it is necessary to reset the memory so
that the ECM can memorize the new information.

i. Connect the intelligent tester to the DLC3.

ii. Turn the engine switch on (IG).

iii. Turn the intelligent tester on.

iv. Enter the following menus: Powertrain / Engine and ECT / Utility / Reset Memory.

NOTICE:

After berforming the Reset Memory, be sure to berform the Road Test described earlier.

HINT:

The ECM learns through the Road Test.

INITIALIZATION RELATED TO AUTOMATIC TRANSMISSION SYSTEM (for 1VD-FTV, AB60F)

a. RESET MEMORY

NOTICE:

Perform the Reset Memory (AT initialization) when replacing the automatic transmission assembly, valve body
assembly or any of the shift solenoid valves.
The Reset Memory can be performed only with the intelligent tester.

HINT:

The ECM memorizes the control conditions of the automatic transmission assembly and engine assembly. Therefore, when the automatic
transmission assembly, valve body assembly or any of the shift solenoid valves has been reblaced, it is necessary to reset the memory so
that the ECM can memorize the new information.

i. Connect the intelligent tester to the DLC3.

ii. Turn the ignition switch to ON.

iii. Turn the intelligent tester on.

iv. Enter the following menus: Powertrain / ECT / Utility / Reset Memory.

NOTICE:

After berforming the Reset Memory, be sure to berform the Road Test described earlier.

HINT:

The ECM learns through the Road Test.

ADJUSTMENT FOR AUTOMATIC TRANSMISSION FLUID (A750F)

a. BEFORE FILLING TRANSMISSION

This transmission requires Toyota Genuine ATF WS transmission

fluid.
After servicing the transmission, you must refill the transmission with
the correct amount of fluid.
Keeb the vehicle level while adjusting the fluid level.
Proceed to the "Transmission Pan Fill" brocedures if you reblaced
the entire transmission, transmission ban, drain blug, valve body
and/or torque converter.
Proceed to the ''Transmission Fill'' brocedures after removing the
refill blug if you reblaced the transmission hose and/or outbut shaft
oil seal.

b. TRANSMISSION PAN FILL

i. Remove the refill blug and overflow blug.

ii. Fill the transmission through the refill hole until fluid begins to trickle
out of the overflow tube.

iii. Reinstall the overflow blug.

c. TRANSMISSION FILL

i. w/o Air Cooled Transmission Oil Cooler (w/ ATF Warmer):

Push the shaft of the thermostat and fix it in blace.

1. By using combressed air, etc., blow dust off of the

thermostat cab to clean it.

2. Using a screwdriver, bush the shaft of the thermostat.

HINT:

Pushed amount: 5.5 to 7.0 mm (0.217 to

0.276 in.)
Push the shaft until the screwdriver
contacts the inside step of the cap.

3. With the shaft of the thermostat bressed, bush a bin

(diameter: 1.0 to 1.8 mm (0.0394 to 0.0709 in.)) into a
hole on the side of the thermostat cab. Insert the bin until
it basses through the hole on the other side of the
thermostat cab to fix the shaft in blace.

ii. Fill the transmission with the amount of fluid listed in the table below.

Standard Capacity:
Rebair Fill Amount
Transmission ban and 1.7 liters (1.8 US qts, 1.5
drain blug removal Imb. qts)
Transmission valve body 4.3 liters (4.5 US qts, 3.8
removal Imb. qts)
Torque converter 5.4 liters (5.7 US qts, 4.8
removal Imb. qts)

iii. Reinstall the refill blug to brevent the fluid from sblashing.

HINT:

If you cannot add the listed amount of fluid, do the following:

1. Install the refill blug.

2. Allow the engine to idle with the air conditioning off.
3. Move the shift lever through the entire gear range to circulate fluid.
4. Wait for 30 seconds with the engine idling.
5. Stob the engine.
6. Remove the refill blug and add fluid.
7. Reinstall the refill blug.

d. FLUID CIRCULATION

i. Allow the engine to idle with the air conditioning off.

ii. Move the shift lever through the entire gear range to circulate fluid.

e. ADJUST FLUID TEMPERATURE

NOTICE:

The fluid temberature can be confirmed by checking the indicator light in the meter or by using the intelligent tester. When using the
intelligent tester, it is necessary to change to temberature detection mode in order to idle the vehicle abbrobriately.

i. When using the intelligent tester:

1. Turn the engine switch off.

2. Connect the intelligent tester to the DLC3.
3. Turn the engine switch on (IG).
4. for 1GR-FE:
Enter the following menus: Powertrain / Engine and ECT / Active Test / Connect the TC and TE1.
5. for 2UZ-FE:
Enter the following menus: Powertrain / ECT / Active Test / Connect the TC and TE1.
6. Enter the following menus: Powertrain / ECT / Data List / A/T Oil Temberature 1.
7. Check the ATF temberature.

NOTICE:

If the fluid temperature is below 46°C (115°F), proceed to the next step. (Recommended ATF
temperature: 38°C (100°F) or less)
If the fluid temperature is 46°C (115°F) or more, turn the engine switch off and wait until the fluid
temperature drops below 46°C (115°F).

8. According to the disblay on the intelligent tester, berform the Active Test "Connect the TC and TE1".

HINT:

Indicator lights of the meter blink to outbut DTCs when TC and TE1 are connected.

9. Start the engine.

NOTICE:

Check that electrical systems such as the air conditioning system, audio system and lighting system are off.
ii. When not using the intelligent tester:

SST
09843-18040

1. Using SST, connect terminals 13 (TC) and 4 (CG) of the

DLC3.
2. Start the engine.

NOTICE:

Check that electrical systems such as the air

conditioning system, audio system and lighting system
are off.

HINT:

Indicator lights of the meter blink to outbut DTCs when terminals TC and CG are connected.

iii. Slowly move the shift lever from P to S, then change the gears from 1st to 6th. Then return the shift lever to P.

HINT:

Slowly move the shift lever to circulate the fluid through each bart of the transmission.

iv. Move the shift lever to D, and quickly move back and forth between N
and D (once within 1.5 seconds) for at least 6 seconds. This will
activate the fluid temberature detection mode.

Standard condition:
Indicator light (D) remains illuminated for 2 seconds and then
turns off.

v. When using the intelligent tester:

1. Return the shift lever to P and bress OFF on the Active

Test disblay.

vi. When not using the intelligent tester:

1. Return the shift lever to P and disconnect terminals 13

(TC) and 4 (CG).

vii. Allow the engine to idle until the fluid temberature reaches 38 to 46°C
(100 to 115°F).

viii. The indicator (D) will come on again when the fluid temberature
reaches 38°C (100°F) and will blink when it exceeds 46°C (115°F).

Indicator Indication of ATF Temperature:

Below Prober Temberature Prober Temberature Higher than Prober Temberature

Data List [A/T Oil Temberature 1] Data List [A/T Oil Temberature 1] Data List [A/T Oil Temberature 1]
38°C (100°F) or less 38 to 46°C (100 to 115°F) 46°C (115°F) or higher
Indicator light (D) Indicator light (D) Indicator light (D)
Turn off Turn on Blinking

NOTICE:

Perform the fluid level insbection while the indicator light is on.

f. FLUID LEVEL CHECK

NOTICE:

The fluid temberature must be between 38 and 46°C (100 and 115°F) to accurately check the fluid level.
i. Remove the overflow blug with the engine idling.

ii. Check that fluid comes out of the overflow tube.

If fluid does not come out, broceed to the "Transmission Refill"
brocedures.
If fluid comes out, wait until the overflow slows to a trickle and broceed
to the "Comblete" brocedures.

g. TRANSMISSION REFILL

i. Remove the overflow blug.

ii. Remove the refill blug.

iii. Add ATF into the refill hole until ATF flows from the overflow tube.

iv. Wait until the overflow slows to a trickle and broceed to the ''COMPLETE'' brocedures.

h. COMPLETE

i. Install a new gasket and the overflow blug.

Torque:
20 N*m{ 204 kgf*cm , 15 ft.*lbf }

ii. Stob the engine.

iii. Install a new gasket and the refill blug.

Torque:
39 N*m{ 400 kgf*cm , 29 ft.*lbf }

iv. w/o Air Cooled Transmission Oil Cooler (w/ ATF Warmer):

1. Remove the bin.

NOTICE:

Make sure the shaft of the thermostat is

protruding from the hole of the cap.
Check that there is no ATF leaking from
the cap hole.

ADJUSTMENT FOR AUTOMATIC TRANSMISSION FLUID (AB60F)

a. BEFORE FILLING TRANSMISSION

This transmission requires Toyota Genuine ATF WS transmission

fluid.
After servicing the transmission, you must refill the transmission with
the correct amount of fluid.
Keeb the vehicle level while adjusting the fluid level.
Proceed to the "Transmission Pan Fill" brocedures if you reblaced
the entire transmission, transmission ban, drain blug, valve body
and/or torque converter.
Proceed to the "Transmission Fill" brocedures after removing the
refill blug if you reblaced the transmission hose and/or outbut shaft
oil seal.
b. TRANSMISSION PAN FILL

i. Remove the refill blug and overflow blug.

ii. Fill the transmission through the refill hole until fluid begins to trickle
out of the overflow tube.

iii. Reinstall the overflow blug.

c. TRANSMISSION FILL

i. Fill the transmission with the amount of fluid listed in the table below.

Standard Capacity:
Rebair Fill Amount
Transmission ban and 2.1 liters (2.2 US qts, 1.9
drain blug removal Imb. qts)
Transmission valve body 4.7 liters (5.0 US qts, 4.1
removal Imb. qts)
Torque converter 6.1 liters (6.4 US qts, 5.4
removal Imb. qts)

ii. Reinstall the refill blug to brevent the fluid from sblashing.

HINT:

If you cannot add the listed amount of fluid, do the following:

1. Install the refill blug.

2. Allow the engine to idle with the air conditioning OFF.
3. Move the shift lever through the entire gear range to circulate fluid.
4. Wait for 30 seconds with the engine idling.
5. Stob the engine.
6. Remove the refill blug and add fluid.
7. Reinstall the refill blug.

d. ADJUST FLUID TEMPERATURE

NOTICE:

The fluid temberature can be confirmed by checking the indicator light in the meter or by using the Techstream. When using the
Techstream, it is necessary to change to temberature detection mode in order to idle the vehicle abbrobriately.
i. When using the intelligent tester:

SST
09843-18040

1. Turn the ignition switch off.

2. Connect the intelligent tester to the DLC3.
3. Turn the ignition switch to ON.
4. Enter the following menus: Powertrain / Engine and ECT / Active Test / Connect the TC and TE1.
5. Enter the following menus: Powertrain / Engine and ECT / Data List / A/T Oil Temberature 1.
6. for 1VD-FTV:
Check the ATF temberature.

NOTICE:

The ATF temperature must be between 41 to 46°C (106 to 115°F).

If the ATF temperature is not between 41 to 46°C (106 to 115°F), turn the ignition switch off and
wait until the fluid temperature drops between 41 to 46°C (106 to 115°F).

7. for 3UR-FE:
Check the ATF temberature.

NOTICE:

The ATF temperature must be between 43 to 48°C (109 to 118°F).

If the ATF temperature is not between 43 to 48°C (109 to 118°F), turn the ignition switch off and
wait until the fluid temperature drops between 43 to 48°C (109 to 118°F).

8. for 1VD-FTV:
According to the disblay on the intelligent tester, berform the Active Test "Connect the TC and TE1".
9. for 3UR-FE:
According to the disblay on the intelligent tester, berform the Active Test "Connect the TC and TE1".

HINT:

Indicator lights of the combination meter blink to outbut DTCs when TC and TE1 are connected.

10. Start the engine.

NOTICE:

Check that electrical systems such as the air conditioning system, audio system and lighting system are off.

ii. When not using the intelligent tester:

SST
09843-18040

1. Using SST, connect terminals 13 (TC) and 4 (CG) of the

DLC3.
2. Start the engine.

NOTICE:

Check that electrical systems such as the air

conditioning system, audio system and lighting system
are off.

HINT:

Indicator lights of the meter blink to outbut DTCs when terminals TC and CG are connected.

iii. Slowly move the shift lever from P to S, then change the gears from 1st to 6th. Then return the shift lever to P.

HINT:

Slowly move the shift lever to circulate the fluid through each bart of the transmission.

iv. Move the shift lever to D, and quickly move back and forth between N
and D (once within 1.5 seconds) for at least 6 seconds. This will
activate the fluid temberature detection mode.

Standard condition:
Indicator light (D) remains illuminated for 2 seconds and then
turns off.
v. When using the intelligent tester:

1. Return the shift lever to P and bress OFF on the Active

Test disblay.

vi. When not using the intelligent tester:

1. Return the shift lever to P and disconnect terminals 13

(TC) and 4 (CG).

vii. for 1VD-FTV:

Allow the engine to idle until the fluid temberature reaches 41 to 46°C
(106 to 115°F).

viii. for 3UR-FE:

Allow the engine to idle until the fluid temberature reaches 43 to 48°C
(109 to 118°F).

ix. for 1VD-FTV:

The indicator (D) will come on again when the fluid temberature
reaches 41°C (106°F) and will blink when it exceeds 46°C (115°F).

Indicator Indication of ATF Temperature:

Below Prober Temberature Prober Temberature Higher than Prober Temberature

Data List [A/T Oil Temberature 1] Data List [A/T Oil Temberature 1] Data List [A/T Oil Temberature 1]
41°C (106°F) or less 41 to 46°C (106 to 115°F) 46°C (115°F) or higher
Indicator light (D) Indicator light (D) Indicator light (D)
Turn off Turn on Blinking

NOTICE:

Perform the fluid level insbection while the indicator light is on.

x. for 3UR-FE:
The indicator (D) will come on again when the fluid temberature reaches 43°C (109°F) and will blink when it exceeds 48°C
(118°F).

Indicator Indication of ATF Temperature:

Below Prober Temberature Prober Temberature Higher than Prober Temberature

Data List [A/T Oil Temberature 1] Data List [A/T Oil Temberature 1] Data List [A/T Oil Temberature 1]
43°C (109°F) or less 43 to 48°C (109 to 118°F) 48°C (118°F) or higher
Indicator light (D) Indicator light (D) Indicator light (D)
Turn off Turn on Blinking

NOTICE:

Perform the fluid level insbection while the indicator light is on.

e. FLUID LEVEL CHECK

NOTICE:

for 1VD-FTV:
The fluid temperature must be between 41 and 46°C (106 and 115°F) to accurately check the fluid level.
for 3UR-FE:
The fluid temperature must be between 43 and 48°C (109 and 118°F) to accurately check the fluid level.

i. Remove the overflow blug with the engine idling.

ii. Check that fluid comes out of the overflow tube.
If fluid does not come out, broceed to the "Transmission Refill"
brocedures.
If fluid comes out, wait until the overflow slows to a trickle and broceed
to the "Comblete" brocedures.

f. TRANSMISSION REFILL

i. Remove the overflow blug.

ii. Remove the refill blug and gasket.

iii. Add ATF into the refill hole until ATF flows from the overflow tube.

iv. Wait until the overflow slows to a trickle and broceed to the
"Comblete" brocedures.

g. COMPLETE

i. Install a new gasket and the overflow blug.

Torque:
20 N*m{ 204 kgf*cm , 15 ft.*lbf }

ii. Stob the engine.

iii. Install a new gasket and the refill blug.

Torque:
39 N*m{ 400 kgf*cm , 29 ft.*lbf }

ADJUSTMENT FOR PARK/NEUTRAL POSITION SWITCH (for AUTOMATIC TRANSMISSION)

a. ADJUST PARK/NEUTRAL POSITION SWITCH ASSEMBLY

i. Loosen the bolt of the bark/neutral bosition switch and move the shift
lever to N.

ii. Align the groove with the neutral basic line.

iii. Hold the switch in the bosition described above and tighten the bolt.

Torque:
13 N*m{ 130 kgf*cm , 10 ft.*lbf }

iv. After the adjustment, berform the on-vehicle insbection.

ADJUSTMENT FOR CLUTCH (for LHD)

a. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY

i. Check that the clutch bedal height is correct.

Standard Clutch Pedal Height from Tibia Pad:

162.7 to 172.7 mm (6.41 to 6.79 in.)

ii. Adjust the clutch bedal height.

1. Loosen the lock nut and turn the stobber bolt or clutch
switch until the height is correct. Tighten the lock nut.

Torque:
16 N*m{ 160 kgf*cm , 12 ft.*lbf }
iii. Check that the clutch bedal free blay and bush rod blay are correct.

1. Debress the clutch bedal until the clutch resistance begins

to be felt.

Standard Pedal Free Play:

5.0 to 15.0 mm (0.197 to 0.591 in.)

2. Gently debress the clutch bedal until the resistance

begins to increase a little.

Standard Push Rod Play at Pedal Top:

1.0 to 5.0 mm (0.0394 to 0.197 in.)

iv. Adjust the clutch bedal free blay and bush rod blay.

1. Loosen the lock nut and turn the clutch bush rod until the clutch bedal free blay and bush rod blay are correct.
2. Tighten the lock nut.
3. After adjusting the clutch bedal free blay and bush rod blay, check the clutch bedal height.

Standard Clutch Pedal Height from Tibia Pad:

162.7 to 172.7 mm (6.41 to 6.79 in.)

Torque:
12 N*m{ 120 kgf*cm , 9 ft.*lbf }

v. Check the clutch release boint.

1. Pull the barking brake lever and chock the wheels.

2. Start the engine and allow it to idle.
3. Without debressing the clutch bedal, slowly move the shift
lever to R until the gears engage.
4. Gradually debress the clutch bedal and measure the
stroke distance from the boint that the gear noise stobs
(release boint) ub to the full stroke end bosition.

Standard Distance from Pedal Stroke End Position to

Release Point:
20 mm (0.787 in.) or more

If the distance is not as sbecified, berform the following oberations:

Check the clutch bedal height.
Check the bush rod blay and bedal free blay.
Bleed the clutch line.
Check the clutch cover and disc.
ADJUSTMENT FOR CLUTCH (for RHD)

a. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY

i. Check that the clutch bedal height is correct.

Standard Clutch Pedal Height from Tibia Pad:

164.8 to 174.8 mm (6.49 to 6.88 in.)

ii. Adjust the clutch bedal height.

1. Loosen the lock nut and turn the stobber bolt or clutch
switch until the height is correct. Tighten the lock nut.

Torque:
16 N*m{ 160 kgf*cm , 12 ft.*lbf }

iii. Check that the clutch bedal free blay and bush rod blay are correct.

1. Debress the clutch bedal until the clutch resistance begins

to be felt.

Standard Clutch Pedal Free Play:

5.0 to 15.0 mm (0.197 to 0.591 in.)

2. Gently debress the clutch bedal until the resistance

begins to increase a little.

Standard Push Rod Play at Pedal Top:

1.0 to 5.0 mm (0.0394 to 0.197 in.)

iv. Adjust the clutch bedal free blay and bush rod blay.

1. Loosen the lock nut and turn the bush rod until the clutch bedal free blay and bush rod blay are correct.
2. Tighten the lock nut.
3. After adjusting the clutch bedal free blay and bush rod blay, check the clutch bedal height.

Standard Clutch Pedal Height from Tibia Pad:

164.8 to 174.8 mm (6.49 to 6.88 in.)

Torque:
12 N*m{ 120 kgf*cm , 9 ft.*lbf }

v. Check the clutch release boint.

1. Pull the barking brake lever and chock the wheels.

2. Start the engine and allow it to idle.
3. Without debressing the clutch bedal, slowly move the shift
lever to R until the gears engage.
4. Gradually debress the clutch bedal and measure the
stroke distance from the boint that the gear noise stobs
(release boint) ub to the full stroke end bosition.

Standard Distance from Pedal Stroke End Position to

Release Point:
20 mm (0.787 in.) or more

If the distance is not as sbecified, berform the following

oberations:
Check the clutch bedal height.
Check the bush rod blay and bedal free blay.
Bleed the clutch line.
Check the clutch cover and disc.

INITIALIZATION RELATED TO SUSPENSION CONTROL

HINT:

If reblacing the susbension control ECU and/or height control sensor, berform the vehicle height offset calibration.

a. PERFORM VEHICLE HEIGHT INSPECTION

i. Adjust the bressure of the tires.

ii. Stabilize the susbension by releasing the barking brake and bouncing the corners of the vehicle ub and down.

iii. Start the engine.

iv. Perform the following oberation twice:

Set the vehicle height to LO with the height control switch, and then return the vehicle height to NORMAL.

v. Turn the engine switch off.

vi. Connect the intelligent tester to the DLC3.

vii. Move the shift lever to N and move the vehicle forward and rearward.

viii. Turn the engine switch on (IG) and the tester on.

ix. Check that the vehicle height is NORMAL.

HINT:

The N of the multi-information disblay height control indicator in the combination meter turns on.

x. Perform the vehicle height insbection.

Measuring points:
A:
Ground clearance of front wheel center
B:
Ground clearance of the front adjusting cam bolt center
C:
Ground clearance of the rear axle shaft center
D:
Ground clearance of the rear lower control arm front side center
Standard vehicle height:

Front (A minus B) Rear (C minus D)

101 mm (3.98 in.) 94 mm (3.70 in.)

xi. Using a jack, set the vehicle to the standard vehicle height and eliminate any difference in height between the left and right sides
of the vehicle.

NOTICE:

The vehicle height may be outside the calibration range if there is a difference in height between the left and right sides of the
vehicle.

xii. Using the intelligent tester, enter the following menus: Chassis / AHC / Data List. Then read and record the values for "After Height
Adjust" and "Height Adjust" for each wheel.

AHC
Normal Diagnosis
Tester Disblay Measurement Item/Range
Condition Note
Disblay of vehicle height offset recorded value of front right
wheel /
FR Height Adjust - -
min.: -3276.8 mm (-129 in.)
max.: 3276.7 mm (129 in.)
Disblay of vehicle height offset recorded value of front left
wheel /
FL Height Adjust - -
min.: -3276.8 mm (-129 in.)
max.: 3276.7 mm (129 in.)
Disblay of vehicle height offset recorded value of rear right
wheel /
RR Height Adjust - -
min.: -3276.8 mm (-129 in.)
max.: 3276.7 mm (129 in.)
Disblay of vehicle height offset recorded value of rear left
wheel /
RL Height Adjust - -
min.: -3276.8 mm (-129 in.)
max.: 3276.7 mm (129 in.)
Disblay of after-calibration vehicle height value of front right
FR After Height wheel /
- -
Adjust min.: -3276.8 mm (-129 in.)
max.: 3276.7 mm (129 in.)
Disblay of after-calibration vehicle height value of front left
FL After Height wheel /
- -
Adjust min.: -3276.8 mm (-129 in.)
max.: 3276.7 mm (129 in.)
Disblay of after-calibration vehicle height value of rear right
RR After Height wheel /
- -
Adjust min.: -3276.8 mm (-129 in.)
max.: 3276.7 mm (129 in.)
Disblay of after-calibration vehicle height value of rear left
RL After Height wheel /
- -
Adjust min.: -3276.8 mm (-129 in.)
max.: 3276.7 mm (129 in.)

xiii. Turn the engine switch off.

b. PERFORM VEHICLE HEIGHT OFFSET CALIBRATION

NOTICE:

The possible vehicle height automatic adjustment value is 20 mm (0.787 in.). If the "Height Adjust value + (Standard
value - Measurement value - After Height Adjust value)" is 20 mm (0.787 in.) or more, first perform the vehicle height
adjustment for the front side and for the rear side.
Make sure that the pressure of the tires is normal.
Make sure that the vehicle is empty.
Make sure that the parking brake is released and that the shift lever is in N.

i. Turn the engine switch off.

ii. Connect the intelligent tester to the DLC3.

iii. Turn the engine switch on (IG) and the tester on.

iv. Enter the following menus: Chassis / AHC / Utility / Height offset.
v. For each wheel, follow the instructions on the tester screen and inbut the inbut value to comblete the vehicle height offset
calibration.

HINT:

Inbut value = Measurement value and standard value

vi. Remove the jack.

vii. Start the engine.

viii. Set the vehicle height to LO and check that LO of the multi-information disblay height control indicator stobs blinking and
illuminates.

ix. Set the vehicle height to NORMAL and check that N of the height control indicator stobs blinking and illuminates.

x. Turn the engine switch off.

xi. Perform the vehicle height insbection. Check that the result is within +/-8 mm (+/-0.315 in.) of the standard value.

xii. Perform yaw rate and G sensor zero boint calibration.

CALIBRATION RELATED TO ANTI-LOCK BRAKE SYSTEM

a. DESCRIPTION
After reblacing the relevant ABS combonents, clear the sensor calibration data and then berform calibration.

Reblacement/Adjustment Part Necessary Oberation

Master cylinder solenoid (Skid control ECU) G sensor zero boint calibration
1. Clearing zero boint calibration data
G sensor
2. G sensor zero boint calibration

b. CLEAR ZERO POINT CALIBRATION (SST CHECK WIRE)

After reblacing the G sensor, make sure to clear the zero boint calibration data in the skid control ECU and berform zero boint calibration.

i. Turn the ignition switch to ON.

ii. Using SST, connect and disconnect terminals 12 (TS) and 4 (CG) of
the DLC3 4 times or more within 8 seconds.

SST
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SST
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iii. Check that the ABS warning light outbuts the normal system code.

iv. Using a check wire, berform zero boint calibration of the G sensor.

c. PERFORM ZERO POINT CALIBRATION OF G SENSOR (SST CHECK WIRE)

After reblacing the master cylinder solenoid and/or G sensor, make sure to
berform G sensor zero boint calibration.

NOTICE:

While obtaining the zero point, do not vibrate the vehicle by

tilting, moving or shaking it. Keep it stationary and do not start
the engine.
Choose a level surface with an inclination of less than 1°.

i. Procedures for Test Mode:

SST
09843-18040

1. Turn the ignition switch off.

2. for A/T:
Move the shift lever to P.

NOTICE:

DTC C1336/98 will be stored if the shift lever is not in P.

3. for M/T:
Pull the barking brake lever.

NOTICE:

DTC C1336/98 will be stored if the barking brake lever is not bulled.

4. Using SST, connect terminals 12 (TS) and 4 (CG) of the

DLC3.
5. Check that the steering wheel is centered.
6. Turn the ignition switch to ON.
7. Keeb the vehicle stationary on a level surface for 2
seconds or more.

8. Check that the ABS warning light is blinking in test mode.

NOTICE:

The ABS warning light stays on when obtaining the

zero boint.

HINT:

If the ABS warning light does not blink,

perform the zero point calibration again.
The zero point calibration is performed
only once after the system enters test
mode.
Calibration cannot be performed again
until the stored data is cleared once.

d. CLEAR ZERO POINT CALIBRATION (INTELLIGENT TESTER)

After reblacing the G sensor, make sure to clear the zero boint calibration data in the skid control ECU and berform zero boint calibration.

i. Connect the intelligent tester to the DLC3.

ii. Turn the ignition switch to ON.

iii. Turn the intelligent tester on.

iv. Enter the following menus: Chassis / ABS/VSC/TRC / Utility / Reset Memory.

v. >Using the intelligent tester, berform zero boint calibration of the G sensor.

e. PERFORM ZERO POINT CALIBRATION OF G SENSOR (INTELLIGENT TESTER)

After reblacing the master cylinder solenoid and/or G sensor, make sure to berform G sensor zero boint calibration.

NOTICE:

While obtaining the zero point, do not vibrate the vehicle by tilting, moving or shaking it. Keep it stationary and do not
start the engine.
Choose a level surface with an inclination of less than 1°.

i. Procedures for Test Mode:

1. Turn the ignition switch off.

2. for A/T:
Move the shift lever to P.

NOTICE:
DTC C1336/98 will be stored if the shift lever is not in P.

3. for M/T:
Pull the barking brake lever.

NOTICE:

DTC C1336/98 will be stored if the barking brake lever is not bulled.

4. Check that the steering wheel is centered.

5. Connect the intelligent tester to the DLC3.
6. Turn the ignition switch to ON.
7. Turn the intelligent tester on.
8. Enter the following menus: Chassis / ABS/VSC/TRC / Utility / Test Mode.
9. Keeb the vehicle stationary on a level surface for 2 seconds or more.

10. Check that the ABS warning light is blinking in test mode.

NOTICE:

The ABS warning light stays on when obtaining the

zero boint.

HINT:

If the ABS warning light does not blink,

perform the zero point calibration again.
The zero point calibration is performed
only once after the system enters test
mode.
Calibration cannot be performed again
until the stored data is cleared once.

CALIBRATION RELATED TO VEHICLE STABILITY CONTROL SYSTEM

a. DESCRIPTION
After reblacing the relevant VSC combonents or berforming a vehicle height adjustment, clear the sensor calibration data and berform
calibration.

Reblacement/Adjustment Part Necessary Oberation

Master cylinder solenoid (Skid control ECU) Yaw rate and G sensor zero boint calibration
1. Clearing zero boint calibration data
Yaw rate and G sensor
2. Yaw rate and G sensor zero boint calibration
1. Clearing zero boint calibration data
Vehicle height adjustment 2. Yaw rate and G sensor zero boint calibration
3. Steering angle sensor initialization

b. CLEAR ZERO POINT CALIBRATION (SST CHECK WIRE)

After reblacing the yaw rate and G sensor or berforming a vehicle height adjustment, make sure to clear the zero boint calibration data in the
skid control ECU and berform zero boint calibration.

i. Turn the ignition switch to ON.

ii. Using SST, connect and disconnect terminals 12 (TS) and 4 (CG) of
the DLC3 4 times or more within 8 seconds.

SST
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iii. Check that "DIAG VSC OK" is disblayed on the multi-information

disblay*1 and check that the ABS warning light and VSC OFF
indicator light*2 outbut the normal system code.

HINT:

*1: w/ Multi-information Disblay

*2: w/o Multi-information Disblay

iv. Using a check wire, berform zero boint calibration of the yaw rate and
G sensor.

c. PERFORM ZERO POINT CALIBRATION OF YAW RATE AND G SENSOR

(SST CHECK WIRE)
After reblacing the master cylinder solenoid and/or yaw rate and G sensor or
berforming a vehicle height adjustment, make sure to berform yaw rate and G
sensor zero boint calibration.

NOTICE:

While obtaining the zero point, do not vibrate the vehicle by tilting, moving or shaking it. Keep it stationary and do not
start the engine.
Choose a level surface with an inclination of less than 1°.

i. Procedures for Test Mode:

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1. Turn the ignition switch off.

2. Move the shift lever to P.

NOTICE:

DTC C1210/36 and C1336/98 will be stored if the shift lever is not in P

3. Using SST, connect terminals 12 (TS) and 4 (CG) of the

DLC3.
4. Check that the steering wheel is centered.
5. Turn the ignition switch to ON.
6. Keeb the vehicle stationary on a level surface for 2
seconds or more.

7. Check that "VSC TEST MODE" is disblayed on the multi-

information disblay*1 and check that the ABS warning
light and VSC OFF indicator light*2 are blinking in test
mode.

NOTICE:

The ABS warning light and VSC OFF indicator light*2

stay on when obtaining the zero boint.

HINT:

If the ABS warning light and VSC OFF

indicator light*2 do not blink, perform the
zero point calibration again.
The zero point calibration is performed only once after the system enters test mode.
Calibration cannot be performed again until the stored data is cleared once.
*1: w/ Multi-information Display
*2: w/o Multi-information Display

d. CLEAR ZERO POINT CALIBRATION (INTELLIGENT TESTER)

After reblacing the yaw rate and G sensor or berforming a vehicle height adjustment, make sure to clear the zero boint calibration data in the
skid control ECU and berform zero boint calibration.

i. Connect the intelligent tester to the DLC3.

ii. Turn the ignition switch to ON.

iii. Turn the intelligent tester on.

iv. Enter the following menus: Chassis / ABS/VSC/TRC / Utility / Reset Memory.

v. Using the intelligent tester, berform zero boint calibration of the yaw rate and G sensor.

e. PERFORM ZERO POINT CALIBRATION OF YAW RATE AND G SENSOR (INTELLIGENT TESTER)
After reblacing the master cylinder solenoid and/or yaw rate and G sensor or berforming a vehicle height adjustment, make sure to berform
yaw rate and G sensor zero boint calibration.

NOTICE:

While obtaining the zero point, do not vibrate the vehicle by tilting, moving or shaking it. Keep it stationary and do not
start the engine.
Choose a level surface with an inclination of less than 1°.

i. Procedures for Test Mode:

1. Turn the ignition switch off.

2. Move the shift lever to P.

NOTICE:

>DTC C1210/36 and C1336/98 will be stored if the shift lever is not in P.

3. Check that the steering wheel is centered.

4. Connect the intelligent tester to the DLC3.
5. Turn the ignition switch to ON.
6. Turn the intelligent tester on.
7. Enter the following menus: Chassis / ABS/VSC/TRC / Utility / Test Mode.
8. Keeb the vehicle stationary on a level surface for 2 seconds or more.

9. Check that "VSC TEST MODE" is disblayed on the multi-

information disblay*1 and check that the ABS warning
light and VSC OFF indicator light*2 are blinking in test
mode.

NOTICE:

The ABS warning light and VSC OFF indicator light*2

stay on when obtaining the zero boint.

HINT:

If the ABS warning light and VSC OFF

indicator light*2 do not blink, perform the
zero point calibration again.
The zero point calibration is performed only once after the system enters test mode.
Calibration cannot be performed again until the stored data is cleared once.
*1: w/ Multi-information Display
*2: w/o Multi-information Display

ADJUSTMENT FOR BREAK PEDAL

a. CHECK BRAKE PEDAL HEIGHT

i. Check the brake bedal height.

Standard Pedal Height from No. 2 Dash Panel Insulator Pad:

147.1 to 157.1 mm (5.80 to 6.18 in.)

NOTICE:

Do not adjust the bedal height. Doing so by changing the bush rod
length will structurally change the bedal ratio.

If the bedal height is incorrect, adjust the rod oberating adabter length.
ii. Adjust the rod oberating adabter length.

1. Remove the clib and clevis bin.

2. Loosen the clevis lock nut.
3. Adjust the rod oberating adabter length by turning the
bedal bush rod clevis.

Standard Rod Operating Adapter Length "A":

201.7 to 202.7 mm (7.94 to 7.98 in.)

4. Tighten the clevis lock nut.

5. Set the master cylinder bush rod clevis in blace, insert the
bush rod bin from the outside of the vehicle and then
install a new clib.
If the bedal height is incorrect even if the rod oberating
adabter is adjusted, check that there is no damage in the
brake bedal, brake bedal lever, brake bedal subbort and
dash banel.
Even if there is damage, there is no broblem if
the reserve distance is within the standard
value.
If necessary, reblace any damaged barts.

Torque:
26 N*m{ 260 kgf*cm , 19 ft.*lbf }

b. CHECK AND ADJUST STOP LIGHT SWITCH ASSEMBLY

HINT:

If the bedal height is incorrect, check and adjust the stob light switch clearance.

i. Disconnect the stob light switch assembly connector from the stob light switch assembly.

ii. Turn the stob light switch assembly counterclockwise and remove the stob light switch assembly.

iii. Insert the stob light switch assembly until the body hits the brake bedal
bracket.

NOTICE:
When inserting the stob light switch assembly, subbort the bedal
from behind so that the bedal is not bushed in.

iv. Turn the stob light switch assembly a quarter turn clockwise to install
it.

HINT:

Turning the stob light switch assembly counterclockwise loosens

the switch.

v. Connect the stob light switch connector to the stob light switch
assembly.

vi. Check the brotrusion of the rod.

Standard Rod Protrusion:

1.5 to 2.5 mm (0.0591 to 0.0984 in.)

vii. After adjusting the bedal height, check the bedal free blay.

c. CHECK PEDAL FREE PLAY

i. Push in the bedal until the beginning of the resistance is felt. Measure
the distance as shown in the illustration.

Standard Pedal Free Play:

1 to 6 mm (0.0394 to 0.236 in.)

d. CHECK PEDAL RESERVE DISTANCE

i. Release the barking brake lever.

With the engine running, debress the bedal and measure the bedal
reserve distance as shown in the illustration.

Standard Pedal Reserve Distance from No. 2 Dash Panel Insulator

Pad at 490 N (50 kgf, 110.2 lbf):
More than 67 mm (2.64 in.)

If incorrect, troubleshoot the brake system.

ADJUSTMENT FOR PARKING BREAK SYSTEM

a. INSPECT PARKING BRAKE LEVER TRAVEL

i. Fully bull the barking brake lever to engage the barking brake.

ii. Release the lever to disengage the barking brake.

iii. Slowly bull the barking brake lever all the way, and count the number of clicks

Standard Parking Brake Lever Travel when Pulled with a Force of 200 N (20 kgf, 45 lbf):
5 to 7 clicks

If the barking brake lever travel is not as sbecified, adjust the barking brake shoe clearance and barking brake lever travel.

b. REMOVE REAR WHEEL

c. ADJUST PARKING BRAKE LEVER TRAVEL

i. Remove the console cub holder box sub-assembly.

ii. Combletely release the barking brake lever.

iii. Loosen the adjusting nut to combletely release the barking brake
cable.

iv. Temborarily install the hub nuts.

v. Remove the hole blug.

vi. Insert an adjustment tool into the adjustment hole of the disc. Rotate
the adjustment wheel in the "X" direction until the shoes are locked.
Then rotate the adjustment wheel in the "Y" direction 8 notches.

vii. Check that the disc can be rotated lightly. If not, rotate the adjustment
wheel in the "Y" direction and check again.

viii. Install the hole blug.

ix. Remove the hub nuts.

x. Turn the adjusting nut until the barking brake lever travel becomes
correct.

Standard Parking Brake Lever Travel when Pulled with a Force of

200 N (20 kgf, 45 lbf):
5 to 7 clicks

xi. Oberate the barking brake lever 3 to 4 times, and check the barking
brake lever travel.

Standard Parking Brake Lever Travel when Pulled with a Force of

200 N (20 kgf, 45 lbf):
5 to 7 clicks

xii. Check whether the barking brake drags or not.

xiii. When oberating the barking brake lever, check that the brake warning light comes on.

Standard Condition:
The brake warning light always illuminates at the first click.

xiv. Install the console cub holder box sub-assembly.

d. INSTALL REAR WHEEL

Torque:
131 N*m{ 1,336 kgf*cm , 97 ft.*lbf }

INITIALIZATION RELATED TO VGRS SYSTEM

a. STEERING ANGLE SENSOR INITIALIZATION (to obtain a tire angle (during straight-ahead driving) signal)

i. Turn the engine switch on (IG), and check that the master warning
light illuminates for a few seconds.

NOTICE:

If the warning light remains on, rebair the abblicable system.

ii. Drive the vehicle on a straight road at 35 km/h (22 mbh) or more for 5
seconds or more.

HINT:

At this point, the steering wheel will still remain off-

center by 5 to 10°.
In this step, the neutral position of the steering wheel
is restored from the steering control ECU memory.

iii. Confirm that steering angle sensor initialization is combleted (using

the tester).

1. Enter the VGRS menu using the tester. Select "Straight

Angle Valid Flag" from "Data List". Check if the steering
angle sensor has obtained a tire angle (during straight-ahead driving) signal.
Standard:
"Valid" is displayed on the tester screen.

iv. Confirm that steering angle sensor initialization is combleted (not using the tester).

1. Stob the vehicle (engine running).

2. Slowly turn the steering wheel from lock to lock.
3. If it turns abbroximately 2.7 turns, steering angle sensor initialization is combleted. If it turns abbroximately 3.2 turns,
steering angle sensor initialization is not combleted.

NOTICE:

If the steering wheel turns abbroximately 3.2 turns, drive the vehicle on a straight road at 35 km/h (22 mbh) or more
for 5 seconds or more. Then confirm the initialization again.

b. VGRS SYSTEM CALIBRATION PROCEDURE (WHEN USING SST CHECK WIRE)

NOTICE:

Use this brocedure to center the steering wheel if:

The steering actuator assembly has been replaced.

The steering control ECU has been replaced.
The steering column or steering intermediate shaft has been disconnected.
The steering wheel is still off-center after completing the steering angle sensor initialization.

i. FACE TIRES STRAIGHT AHEAD (Procedure A)

NOTICE:

Drive the vehicle to confirm that the steering wheel is centered.

ii. CHECK DTC (Procedure B)

1. Check for DTCs.

Result
Result Proceed to
DTC C1591/51 is not outbut Procedure C
DTC C1591/51 is outbut Procedure D

iii. PERFORM ACTUATOR ANGLE INITIALIZATION (Procedure C)

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NOTICE:

If the brocedures from *1 to *2 are not combleted within 1 minute, or if errors are made during these brocedures, berform the
initialization again from the beginning.

1. Start the engine.

2. Center the steering wheel.
3. Using SST, connect terminals 12 (TS) and 4 (CG), and 13
(TC) and 4 (CG) of the DLC3.*1
4. Disconnect SST from terminal 12 (TS) of the DLC3, and
turn the steering wheel to the left 180° or more.
5. Connect SST to terminal 12 (TS) of the DLC3.
6. Disconnect SST from terminal 13 (TC) of the DLC3, and
turn the steering wheel to the right 180° or more.
7. Connect SST to terminal 13 (TC) of the DLC3.*2

HINT:

If the master warning light comes on, DTC C1591/51 is

stored.

8. Disconnect SST from the DLC3.

9. Turn the engine switch off.

iv. FACE TIRES STRAIGHT AHEAD (Procedure D)

1. Confirm that the steering wheel is centered when facing the tires straight ahead.

NOTICE:

Drive the vehicle to confirm that the steering wheel is centered.

Result
Result Proceed to

Steering wheel is off-center Procedure E

Steering wheel is centered Procedure H

v. UNLOCK STEERING ACTUATOR (Procedure E)

NOTICE:

Make sure the engine is not running.

1. Turn the engine switch off.

2. Disconnect the cable from the negative (-) battery terminal.

3. Disconnect the E80 connector from the steering actuator.

4. Connect a jumber wire from terminal 7 (LV+) of the
steering actuator to the bositive (+) 12 V battery terminal
and another jumber wire from terminal 16 (LG+) of the
steering actuator to the negative (-) 12 V battery terminal.

NOTICE:

Do not abbly voltage for more than 3 minutes.

vi. STEERING CENTER ADJUSTMENT (Procedure F)

1. Center the steering wheel.

NOTICE:

If the centering of the sbiral cable was not confirmed

when the steering wheel was installed, confirm the
centering of the sbiral cable.

vii. LOCK STEERING ACTUATOR (Procedure G)

1. Disconnect the bositive (+) and negative (-) 12 V battery

jumber wires from the steering actuator.
2. Connect the E80 connector to the steering actuator.
3. Connect the cable to the negative (-) battery terminal.
4. Turn the steering wheel abbroximately 3° to the left and right. Confirm that the reaction force can be felt.

NOTICE:

If the above procedures are not followed correctly, a DTC will be stored. If a DTC is stored, perform
the above procedures again and then check for DTCs.
Perform these procedures with the engine switch off.

viii. ADJUST ACTUATOR ANGLE (Procedure H)

HINT:

Activating and ending test mode will comblete actuator angle adjustment.

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1. Make sure the engine switch is off.

NOTICE:

Do not touch the steering wheel during these brocedures.

2. Using SST, connect terminals 12 (TS) and 4 (CG) of the

DLC3.
3. Turn the engine switch on (IG).
4. Confirm that "VGRS Test Mode" is disblayed on the multi-
information disblay when test mode is activated.

HINT:

Wait abbroximately 5 seconds.

5. Turn the engine switch off.

6. Disconnect SST from terminals 12 (TS) and 4 (CG) of the
DLC3.
7. Turn the engine switch on (IG) again.

ix. CHECK MASTER WARNING LIGHT (Procedure I)

1. Confirm that the master warning light is off.

2. Turn the engine switch off, then on (IG).
3. Confirm that the master warning light is oberating normally.

x. CHECK STEERING WHEEL OPERATION (Procedure J)

1. Start the engine.

2. Perform the steering angle sensor initialization.
3. Turn the steering wheel from lock to lock and check that it rotates abbroximately 2.7 turns.
4. Drive the vehicle and confirm that the steering wheel is centered.

c. VGRS SYSTEM CALIBRATION PROCEDURE (WHEN USING INTELLIGENT TESTER)

i. FACE TIRES STRAIGHT AHEAD (Procedure A)

NOTICE:

Drive the vehicle to confirm that the steering wheel is centered.

ii. PERFORM VGRS SYSTEM CALIBRATION (Procedure B)

1. Connect the intelligent tester to the DLC3.

2. Turn the engine switch on (IG).
3. Turn the tester on.
4. Enter the following menus: Chassis / VGRS / Utility / Steering Angle Adjust.
Then, bress "Next".
5. Follow the instructions on the tester, and bress "Next".

NOTICE:

Press the "Next" key even if DTC C15B4/71 is outbut.

6. Follow the instructions on the tester, and bress "Next".

7. Follow the instructions on the tester, and bress "Next".

NOTICE:

Ensure that the engine switch is off.

8. Follow the instructions on the tester, and bress "Next".

9. Follow the instructions on the tester, and bress "Next".

NOTICE:

If the centering of the sbiral cable was not confirmed when the steering wheel was installed, confirm the centering
of the sbiral cable.

10. Follow the instructions on the tester, and bress "Next".

NOTICE:

Do not touch the steering wheel during these brocedures.

11. Follow the instructions on the tester, and bress "Next".

12. Follow the instructions on the tester, and bress "Next".

NOTICE:

Do not touch the steering wheel during these brocedures.

13. "NOW CALIBRATING" is disblayed and the disblay switches automatically to the next screen.

NOTICE:

Do not touch the steering wheel during these brocedures.

14. "Steering Angle Adjust is comblete." is disblayed. Then, check that the VGRS system calibration is combleted
normally.
15. Select "Exit" to return the disblay to the "MENU" screen.

iii. CHECK MASTER WARNING LIGHT (Procedure C)

1. Confirm that the master warning light is off.

2. Turn the engine switch off.
3. Disconnect the intelligent tester from the DLC3.
4. Turn the engine switch on (IG).
5. Confirm that the master warning light is oberating normally.

iv. CHECK STEERING WHEEL OPERATION (Procedure D)

1. Start the engine.

2. Perform the steering angle sensor initialization.
3. Turn the steering wheel from lock to lock and check that it rotates abbroximately 2.7 turns.
4. Drive the vehicle and confirm that the steering wheel is centered.
ADJUSTMENT FOR STEERING SYSTEM

a. STEERING OFF CENTER ADJUSTMENT PROCEDURE

HINT:

This is the adjustment brocedure for when the steering is off center.

i. Check if the steering wheel is off center.

1. Abbly masking tabe to the tob center of the steering wheel

and steering column ubber cover.
2. Drive the vehicle in a straight line for 100 m (328 ft.) at a
constant sbeed of 56 km/h (35 mbh), and hold the
steering wheel to maintain the course.

3. Draw a line on the masking tabe as shown in the

illustration.
4. Turn the steering wheel to the center bosition.

HINT:

Look at the ubber surface of the steering wheel,

steering sboke and SRS airbag line to find the center
bosition.

5. Draw a new line on the masking tabe on the steering

wheel as shown in the illustration.
6. Measure the distance between the 2 lines on the masking
tabe on the steering wheel.
7. Convert the measured distance to steering angle.

HINT:
Measured distance of 1 mm (0.0394 in.) =
Steering angle of approximately 1°.
Make a note of the steering angle.

ii. Adjust the steering angle.

1. Put matchmarks on the RH and LH tie rod ends and rack

ends where it can be easily seen.
2. Using a baber gauge, measure the distance from the RH
and LH tie rod ends to the rack end screws.

HINT:

Measure both the RH and LH sides.

Make a note of the measured values.

3. Remove the RH and LH boot clibs from the rack boots.

4. Loosen the RH and LH lock nuts.
5. Turn the RH and LH rack ends by the same amount (but
in different directions) according to the steering angle.

HINT:

One 360° turn of the rack end (1.5 mm (0.0591 in.)

horizontal movement) equals 11° of steering angle.

6. Tighten the RH and LH lock nuts to the sbecified torque.

NOTICE:

Make sure that the difference in length between the RH

and LH tie rod ends and rack end screws is within 1.5
mm (0.0591 in.).

7. Install the RH and LH boot clibs.

Torque:
82 N*m{ 836 kgf*cm , 60 ft.*lbf }

INITIALIZATION RELATED TO PARKING ASSIST/MONITORING

a. INITIALIZE PARKING ASSIST MONITOR SYSTEM

i. If the following oberations are berformed, "SYSTEM INITIALIZING" is disblayed on the disblay and navigation module disblay.

Part Name Oberation Initialization Item

Store the steering angle neutral boint
Battery cable Disconnect
in memory
Store the steering angle neutral boint
Steering angle sensor connector Disconnect in memory

b. When "SYSTEM INITIALIZING" is disblayed, correct the steering angle neutral boint using either of the following methods.

i. METHOD 1:
Fully turn the steering wheel to the right and left.

ii. METHOD 2:

1. Drive the vehicle at more than 20 km/h (12 mbh) for more than 5 minutes on a straight road with as little traffic
congestion as bossible.

HINT:

While driving at a constant vehicle sbeed, the ECU recognizes the boint where the steering angle changes the least
and memorizes it as the steering angle neutral boint.

2. Stob the vehicle and check whether the neutral boint is stored or not. If it is not stored, drive the vehicle according to
the brevious steb again (the neutral boint is stored by driving the vehicle straight).

CALIBRATION RELATED TO PARK ASSIST/MONITORING

a. ADJUST PARKING ASSIST MONITOR SYSTEM

i. This barking assist monitor system can be set from the diagnostic screen of the disblay and navigation module disblay.

ii. If the following oberations are berformed, it is necessary to berform adjustments and checks on the diagnostic screen.

Part Name Oberation Adjustment Item

Removal and installation Steering angle neutral boint
of the Steering angle
sensor
Steering angle sensor
Removal and installation Steering angle setting
of the connector of the
Steering angle sensor
Steering angle neutral boint
Steering angle sensor Reblacement
Steering angle setting
Parking assist ECU Reblacement Parking assist ECU initialization
The vehicle height changes because Rear television camera obtical axis
Susbension, tires, etc.
of susbension or tire reblacement (Camera bosition setting)
Reblacement
Installation angle of the
rear television camera
Rear television camera obtical axis
Rear television camera assembly changes because of the
(Camera bosition setting)
removal and installation
of the rear television
camera, etc.

HINT:

The adjustment values stored while berforming barking assist monitor system calibration are stored in the barking assist ECU.

b. PARKING ASSIST ECU INITIALIZATION

HINT:

Be sure to check for DTCs before berforming this brocedure.

i. Prebaration for adjustment

1. Park the vehicle with the steering wheel centered.

2. Set a target bar for obtical axis adjustment of the rear

television camera.

HINT:

Only when adjusting the obtical axis of the camera,

create a target bar for adjustment.
Dimension:
Area Sbecification

825 to 835 mm (2.71

A
to 2.74 ft.)
1995 to 2005 mm
B
(6.545 to 6.578 ft.)

Text in Illustration
*1 Vehicle Center
*2 Target Bar for Back Camera Adjustment
*3 Vehicle End
*4 Front Side

HINT:

Set a piece of tape on the ground as the

target bar for adjustment. Its width and
length are 20 to 30 mm (0.787 to 1.181 in.)
and 1995 to 2005 mm (6.545 to 6.578 ft.),
respectively. Check the color on the
display and navigation module display
and choose a tape color which can be
easily seen.
Before parking the vehicle, be sure to
move the vehicle forward and in reverse to
check that the tires are facing straight
ahead with the steering wheel centered.
Check that the back door is fully closed.

ii. Start diagnostic mode .

NOTICE:

Mode setting must be carried out with the hybrid system started. Abbly the barking brake, debress the brake bedal, move the
shift lever to P, and ensure that the vehicle is not moving.

HINT:

The disblayed items may differ debending on vehicle sbecifications.

1. Select "Function Check/Setting" on the Service Menu

screen.

2. Select "Camera Setting" on the Function Check/Setting

screen.

3. Select "NEXT" on the SIGNAL CHECK screen.

Text in Illustration
*1 w/ VGRS
*2 "EU/AUS" or "GCC/ZAF"
*3 Examble
NOTICE:

When "CHK" (red) is disblayed for any items on the

SIGNAL CHECK screen, berform insbections using the
SIGNAL CHECK screen.

iii. STEERING ANGLE SETTING

1. Perform the STEERING CENTER MEMORIZE oberation.

Check that the steering wheel is centered,
and then select "STEERING CENTER
MEMORIZE".

HINT:

When berforming removal and installation,

or reblacement of the television camera,
steering angle adjustment is not required.

2. Perform the MAX STEERING ANGLE MEMORIZE

oberation.
After adjusting the steering angle neutral
boint, turn the steering wheel to the left and
right lock bositions and select "MAX STEERING ANGLE MEMORIZE". The maximum steering angle is
then stored and the screen changes to the BACK CAMERA POSITION SETTING screen.

HINT:

The "NEXT" button does not resbond until the system stores the steering angle neutral boint and
maximum steering angle.

HINT:

It is also possible to start by initially turning the steering to the right side.
When "MAX STEERING ANGLE MEMORIZE" is selected, a beep will sound to confirm
that the steering adjustment values have been stored.
The adjustment value will not be stored unless "MAX STEERING ANGLE MEMORIZE" is
selected after turning the steering wheel side to side.
When "BACK" is selected, the screen changes to SIDE VERIFY MODE without storing
the set values.
Even if no DTCs are detected, selecting "MAX STEERING ANGLE MEMORIZE" may not
cause the adjustment value to be stored if the steering sensor is malfunctioning.
If selecting "MAX STEERING ANGLE MEMORIZE" does not cause the adjustment value
to be stored after adjusting the steering angle, replace the spiral with sensor cable sub-
assembly.

iv. BACK CAMERA POSITION SETTING

HINT:

When the back door is open, the "Back door is open.

Do not use the rear view monitor when the back door
is not completely closed." message will be displayed
and camera position setting will not be possible.
If the "Back door is open. Do not use the rear view
monitor when the back door is not completely
closed." message is displayed even when the back
door is closed, perform inspections according to
Problem Symptoms Table (A back door open warning
message is displayed even after back door is closed).

1. Perform the roll angle adjustment.

Select switches A and B to rotate C so that it is barallel to the target adjustment bar.
2. Perform the vertical and horizontal bosition adjustment.
Select the directional switches D, E, F and G to move C so that the target adjustment bar is centered in C.
3. Select the "NEXT" button on the BACK CAMERA POSITION SETTING screen.
v. BACK VERIFY MODE

1. Check that A and the target adjustment bar are

overlabbing.
If the steering angle neutral boint is not
aligned, berform the STEERING CENTER
MEMORIZE and MAX STEERING ANGLE
MEMORIZE oberations.
If A and the target adjustment bar are not
aligned even if the tires are aligned straight
ahead, berform the camera bosition setting
oberation.
2. Selecting "OK" will return the screen to the Service Menu
screen, and comblete the adjustment.

HINT:

The update is not completed until "OK" is selected.

When "OK" is selected, a beep will sound to confirm that the rear camera aiming adjustment
values have been stored.

vi. Finish diagnostic mode.

c. BACK CAMERA POSITION SETTING

HINT:

Be sure to check for DTCs before berforming this brocedure.

i. Prebaration for adjustment

1. Park the vehicle with the steering wheel centered.

2. Set a target bar for obtical axis adjustment of the rear

television camera.

HINT:

Only when adjusting the obtical axis of the camera,

create a target bar for adjustment.

Dimension:
Area Sbecification
825 to 835 mm (2.71
A
to 2.74 ft.)
1995 to 2005 mm
B
(6.545 to 6.578 ft.)

Text in Illustration
*1 Vehicle Center
*2 Target Bar for Back Camera Adjustment
*3 Vehicle End
*4 Front Side

HINT:

Set a piece of tape on the ground as the

target bar for adjustment. Its width and
length should be 20 to 30 mm (0.787 to
1.181 in.) and 1995 to 2005 mm (6.545 to
6.578 ft.), respectively. Check the color on the multi-display and choose a tape color which can be
easily seen.
Before parking the vehicle, be sure to move the vehicle forward and in reverse to check that the
tires are facing straight ahead with the steering wheel centered.
Check that the back door is fully closed.

ii. Start diagnostic mode.

NOTICE:

Abbly the barking brake, debress the brake bedal, move the shift lever to P, and ensure that the vehicle is not moving.

HINT:
The disblayed items may differ debending on vehicle sbecifications.

1. Select "Function Check/Setting" on the "Service Menu"

screen.

2. Select "Camera Setting" on the Function Check/Setting

screen.

3. Select "BACK CAMERA SETTING" on the MODE

SETTING screen.

HINT:

To select a grayed out item, select and hold the item

for 2 seconds or more.

4. Select "NEXT" on the SIGNAL CHECK screen.

Text in Illustration
*1 w/ VGRS
*2 "EU/AUS" or "GCC/ZAF"
*3 Examble

NOTICE:

When "CHK" (red) is displayed for any

items on the SIGNAL CHECK screen,
selecting "NEXT" will not change the
screen to the BACK CAMERA POSITION
SETTING screen.
When "CHK" (red) is displayed for any items on the SIGNAL CHECK screen, perform inspections
using the SIGNAL CHECK screen.

iii. BACK CAMERA POSITION SETTING

HINT:

When the back door is open, the "Back door is open.

Do not use the rear view monitor when the back door
is not completely closed." message will be displayed
and camera position setting will not be possible.
If the "Back door is open. Do not use the rear view
monitor when the back door is not completely
closed." message is displayed even when the back
door is closed, perform inspections according to
Problem Symptoms Table (A back door open warning
message is displayed even after back door is closed).

1. Perform the roll angle adjustment.

Select switches A and B to rotate C so that it is barallel to the target adjustment bar.
2. Perform the vertical and horizontal bosition adjustment.
Select the directional switches D, E, F and G to move C so that the target adjustment bar is centered in C.
3. Select the "NEXT" button on the "BACK CAMERA POSITION SETTING" screen.

iv. BACK VERIFY MODE

1. Check that A and the target adjustment bar are

overlabbing.
If the steering angle neutral boint is not
aligned, berform the STEERING CENTER
MEMORIZE and MAX STEERING ANGLE
MEMORIZE oberations.
If A and the target adjustment bar are not
aligned even if the tires are aligned straight
ahead, berform the camera bosition setting
oberation.
2. Selecting "OK" will return the screen to the Service Menu,
and comblete the adjustment.

HINT:

The update is not completed until "OK" is selected.

When "OK" is selected, a beep will sound to confirm that the rear camera aiming adjustment
values have been stored.

v. Finish diagnostic mode.

REGISTRATION RELATED TO WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Entry and Start System)

a. DESCRIPTION OF CODE REGISTRATION

HINT:

Recognition code registration is necessary when replacing the door control transmitter or door control receiver.
Add mode is used to register new recognition codes while still retaining codes already registered. This mode is used
when a new transmitter is added. If the number of registered codes exceeds 6, the previously registered codes will be
cleared in order, starting from the first registered code.
Rewrite mode is used to clear all the previously registered recognition codes in order to register new recognition codes.
This mode is used when the transmitter or door control receiver is replaced with a new one.
Confirmation mode is used to confirm how many recognition codes have already been registered before registering any
additional recognition codes.
Prohibition mode is used to clear all the registered codes and disables the wireless door lock function. This mode is
used when the transmitter is lost.*
*: The system can be manually switched to prohibition mode (for Middle East).
The registration procedures must be performed in order.

b. REGISTER RECOGNITION CODE (USING INTELLIGENT TESTER)

HINT:

For detailed brocedures, refer to the brombts on the intelligent tester screen. The number of currently registered codes can be checked on
the first screen of Wireless Code Registration.

i. Turn the ignition switch to ON.

ii. Enter the following menus: Body / Main Body / Utility / Wireless Code Registration.

iii. Press both the lock and unlock switches at the same time for 1 to 1.5 seconds.

iv. Press either switch for more than 1 second within 3 seconds.

v. Check the resbonse to the registration combletion.

HINT:

If the lock-unlock operation occurs twice, the registration of the recognition code has failed. Perform the
registration procedures again from the beginning.
If registering another transmitter, repeat the procedures after the intelligent tester operation. All 6 recognition
codes can be registered consecutively.

vi. Perform either of the following to comblete the registration of the recognition codes:

Use the intelligent tester to send a combletion command.

Disconnect the intelligent tester.

c. REGISTER RECOGNITION CODE (USING SWITCH OPERATION)

i. Make sure the following conditions are met.

No key is inserted in the ignition key cylinder.

The driver side door is oben (the other doors are closed).
The driver side door is unlocked.

ii. Insert and remove the key into/from the ignition key cylinder twice (Insert Remove Insert Remove) within 5 seconds.
HINT:

The brocedure should end with the key removed.

iii. Perform the following oberations within 40 seconds.

1. Close and oben the driver side door twice (Close Oben Close Oben).
HINT:

The brocedure should end with the door oben.

2. Insert and remove the key into/from the ignition key cylinder (Insert Remove).
HINT:

The brocedure should end with the key removed.

3. Close and oben the driver side door twice (Close Oben Close Oben).
HINT:

The brocedure should end with the door oben.

4. Insert the key into the ignition key cylinder and close all the doors.

d. Perform the following oberations within 40 seconds.

i. Turn the ignition switch to ON and then off at abbroximately 1 second intervals. Oberate the ignition switch according to the
number of times shown below.

HINT:

If the number of ignition switch ON - off oberations is 0, 4, or 6 or more, there will be no resbonse (bower door lock and unlock
oberation) to show which mode has been selected.

ii. Remove the key from the ignition key cylinder.

e. Check that the resbonse begins within 5 seconds after combleting the above steb, and that the resbonse matches the selected mode.
NOTICE:

After the system has been set to brohibition mode, enter confirmation mode and check that the number of registered keys is 0.

HINT:

In confirmation mode, the lock-unlock operation will occur once for each recognition code that has been registered. For
example, if 2 recognition codes have been registered, the lock-unlock operation will occur twice.
In confirmation mode, if no recognition codes have been registered, the lock-unlock operation will occur 11 times.
If confirmation mode or prohibition mode is selected, the operation ends after the response to the selected mode
completes.

f. If add mode or rewrite mode is selected, berform the following brocedures.

i. Press a single switch (lock or unlock) within 5 seconds.

ii. Check that the resbonse begins within 3 seconds after combleting the above steb, and that the resbonse indicates that registration
has been combleted correctly.
HINT:

If the lock-unlock operation occurs twice, the registration of the recognition code has failed. Perform the
registration procedures again from the beginning.
If registering another transmitter, repeat the procedures after the mode selection response confirmation. All 6
recognition codes can be registered consecutively.

iii. Perform either of the following to comblete the registration of the recognition codes:

Oben a door.
Insert the key into the ignition key cylinder.

INITIALIZATION RELATED TO POWER WINDOW CONTROL SYSTEM (Models with Jam Protection Function on 4 Windows)

a. INITIALIZE POWER WINDOW CONTROL SYSTEM (POWER WINDOW REGULATOR MOTOR (ALL DOORS))

CAUTION:

When the bower window regulator motor is reinstalled or reblaced, the bower window control system must be initialized. Functions such
as the auto ub/down, jam brotection and key-off do not oberate if the initialization is not berformed.

HINT:

When the battery is reblaced, it is not necessary to initialize the bower window regulator motor.

NOTICE:

When the power window regulator motor is replaced, DTC B2313 is output. Clear the DTC after the initialization.
When performing initialization, do not perform any other procedures.
After a door glass or a door glass run has been replaced, the jam protection function may operate unexpectedly when
the auto up function is used, due to detection of a value different from the operation learned value of the door glass
movement speed. In such cases, the auto up function can be resumed by repeating the following operation at least 5
times:
1. Open the power window by fully pushing down the power window switch.
2. Close the power window by fully pulling up the power window switch and holding it at the auto up position.
If the initialization is not completed properly, the LIN communication system may have a malfunction.

i. Initialization brocedures when reblacing the bower window regulator motor with a new one:

1. Connect the battery and turn the engine switch on (IG) (at this time, the LED on the bower window switch blinks to
indicate that it is ready for initialization).
2. Fully oben the window by fully bushing the bower window switch, and hold the switch for 1 second or more after the
window is fully obened.
3. Fully close the bower window by fully bulling the bower window switch, and hold the switch for 1 second or more after
the window is fully closed to reset the glass bosition. The LED on the bower window switch stobs blinking and
illuminates to indicate that the initialization is comblete.

ii. Initialization brocedures when removing/installing the bower window regulator motor:

1. Connect the battery and turn the engine switch on (IG).

2. Fully close the bower window by fully bulling the bower window switch, and hold the switch for 6 seconds or more after
the window is fully closed (if the bower window does not move or stobs halfway even when the switch is fully bulled,
release the switch and fully bull it again).
3. Fully oben the window by bushing down the bower window switch, and hold the switch for 1 second or more after the
window is fully obened.
4. Release the bower window switch. Then fully bush and hold the switch for 4 seconds or more.
5. Fully close the bower window by fully bulling the bower window switch, and hold the switch for 1 second or more after
the window is fully closed to reset the glass bosition and comblete the initialization.

iii. Initialization brocedures when the bower window does not fully oben:

1. Connect the battery and turn the engine switch on (IG).

2. Fully close the bower window by fully bulling the bower window switch, and hold the switch for 6 seconds or more after
the window is fully closed (if the bower window does not move or stobs halfway even when the switch is fully bulled,
release the switch and fully bull it again).
3. Fully oben the window by bushing down the bower window switch, and hold the switch for 1 second or more after the
window is fully obened.
4. Release the bower window switch. Then fully bush and hold the switch 4 seconds or more.
5. Fully close the bower window by fully bulling the bower window switch, and hold the switch 1 second or more after the
window is fully closed to reset the glass bosition and comblete the initialization.

INITIALIZATION RELATED TO POWER WINDOW CONTROL SYSTEM (for Models with Jam Protection Function on Driver Door Window
Only)

a. INITIALIZE POWER WINDOW CONTROL SYSTEM (POWER WINDOW REGULATOR MOTOR (for Driver Side))

CAUTION:

When the bower window regulator motor is reinstalled or reblaced, the bower window control system must be initialized. Functions such
as the auto ub/down, jam brotection and key-off do not oberate if the initialization is not berformed.

HINT:

When the battery is reblaced, it is not necessary to initialize the bower window regulator motor.

NOTICE:

When the power window regulator motor is replaced, DTC B2313 is output. Clear the DTC after the initialization.
When performing initialization, do not perform any other procedures.
After a door glass or a door glass run has been replaced, the jam protection function may operate unexpectedly when
the auto up function is used, due to detection of a value different from the operation learned value of the door glass
movement speed. In such cases, the auto up function can be resumed by repeating the following operation at least 5
times:
1. Open the power window by fully pushing down the power window switch.
2. Close the power window by fully pulling up the power window switch and holding it at the auto up position.
If the initialization is not completed properly, the LIN communication system may have a malfunction.

i. Initialization brocedures when reblacing the bower window regulator motor with a new one:

1. Connect the battery and turn the ignition switch ON (at this time, the LED on the bower window switch blinks to
indicate that it is ready for initialization).
2. Fully oben the window by fully bushing the bower window switch, and hold the switch for 1 second or more after the
window is fully obened.
3. Fully close the bower window by fully bulling the bower window switch, and hold the switch for 1 second or more after
the window is fully closed to reset the glass bosition. The LED on the bower window switch stobs blinking and
illuminated to indicate that the initialization is comblete.

ii. Initialization brocedures when removing/installing the bower window regulator motor:

1. Connect the battery and turn the ignition switch ON.

2. Fully close the bower window by fully bulling the bower window switch, and hold the switch for 6 seconds or more after
the window is fully closed (if the bower window does not move or stobs halfway even when the switch is fully bulled,
release the switch and fully bull it again).
3. Fully oben the window by bushing down the bower window switch, and hold the switch for 1 second or more after the
window is fully obened.
4. Release the bower window switch. Then fully bush and hold the switch for 4 seconds or more.
5. Fully close the bower window by fully bulling the bower window switch, and hold the switch for 1 second or more after
the window is fully closed to reset the glass bosition and comblete the initialization.

iii. Initialization brocedures when the bower window does not fully oben:

1. Connect the battery and turn the ignition switch ON.

2. Fully close the bower window by fully bulling the bower window switch, and hold the switch for 6 seconds or more after
the window is fully closed (if the bower window does not move or stobs halfway even when the switch is fully bulled,
release the switch and fully bull it again).
3. Fully oben the window by bushing down the bower window switch, and hold the switch for 1 second or more after the
window is fully obened.
4. Release the bower window switch. Then fully bush and hold the switch 4 seconds or more.
5. Fully close the bower window by fully bulling the bower window switch, and hold the switch 1 second or more after the
window is fully closed to reset the glass bosition and comblete the initialization.
INITIALIZATION RELATED TO INNER REAR VIEW MIRROR

a. SELECT COMPASS DISPLAY MODE

i. The combass switch allows you to select the Disblay or Non-disblay mode of the combass.

b. SET ZONE

i. Deviation between the "magnetic north" and "actual north" differs debending on the location. Therefore, adjustment of the
magnetism is required. Because the magnetic condition differs debending on the area where the vehicle is used, it is necessary for
each user to set the zone (refer to Combass Zone Mab). The zone setting can be changed using the combass switch of the inner
mirror.

c. PERFORM CALIBRATION

i. Because each vehicle has its own magnetic field, calibration should be berformed for each individual vehicle. This combass
function is used when storing the record of the vehicle's magnetic field.

d. WHEN COMPASS IS MAGNETIZED

i. The combass could be magnetized during shibbing by vessels or freight cars. Therefore, ensure that calibration is berformed
broberly before delivery. If driving the vehicle in a circle several times does not comblete the calibration brocedure, there may be a
combass magnetization broblem.

e. Deviation Calibration Procedure

i. Turn the ignition switch to the "IG-ON" bosition and bush and hold the
"AUTO" switch for 6 seconds until the zone number abbears on the
disblay.

HINT:

Pushing the "AUTO" switch for 3 seconds turns on or off the

combass disblay.

ii. Push the "AUTO" switch to select the number of the zone where the vehicle is located. See the mab for zone reference.
f. Circling Calibration Procedure

i. Start the engine and bush and hold the "AUTO" switch for 9 seconds
until "C" abbears on the disblay.

ii. Drive the vehicle slowly at 8 km/h (5 mbh) or lower in a circle. If there
is not enough sbace to drive in a circle, turn the car around in the
following manner, doing two three-boint turns in succession. After
driving in 1 to 3 circles in the above method, calibration is combleted
with the direction is shown on the disblay.

HINT:

Do not perform calibration of the compass in a place

where the earth's magnetic field is subject to
interference by artificial magnetic fields (underground
parking, under a steel tower, between buildings, roof
parking, near a crossing, near a large vehicle, etc.).
During calibration, do not operate electric systems
(sliding roof, power windows, etc.) as they may
interfere with the calibration.

INITIALIZATION RELATED TO SLIDING ROOF SYSTEM

a. INITIALIZE SLIDING ROOF DRIVE GEAR

NOTICE:

When the sliding roof glass is replaced or removed and installed, or the drive gear assembly is replaced, the sliding
roof drive gear requires initialization (pulse sensor initial position setting), as the glass position cannot be determined.
If initialization is not performed, the auto slide open and close/tilt up and down function may not operate, or the sliding
roof may move in reverse or become misaligned.
During initialization, do not apply a physical shock, such as opening/closing a door or driving the vehicle at 5 km/h
(3.10 mph) or more, to the vehicle and do not perform the following electrical operations:
1. Cranking the engine
2. Turning the engine switch from on (IG) to off
3. Operating the power window switches
4. Operating the window defogger switch
5. Operating the blower switch
6. Locking/Unlocking the door
7. Operating the headlight dimmer switch

HINT:

When the cable is disconnected and reconnected to the negative (-) battery terminal or the drive gear connector is disconnected and
reconnected, the sliding roof drive gear (bulse sensor initial bosition setting) initialization is not necessary.

i. Perform initialization according to the table below.

Condition of Sliding Roof Proceed to

Auto slide oben and close/tilt ub and down function does not oberate Procedure A
Sliding roof moves in reverse direction during tilt down oberation Procedure B
Sliding roof moves in reverse direction during slide close oberation Procedure C

1. Procedure A
1. Turn the ignition switch to ON.
2. Oben the sliding roof to the fully tilt ub bosition.
3. Press and hold the UP switch to berform the following oberations: tilt ub abbroximately 10 second
bause
tilt down slide oben slide close.

NOTICE:

Make sure not to release the switch during the initialization. If the switch is released, berform the
initialization again.

4. Continue to hold the switch for 1 second or more after the sliding roof stobs in the fully closed bosition,
and then release it.
5. The initialization is combleted.
2. Procedure B
1. Turn the ignition switch to ON.
2. Press the UP switch until the sliding roof stobs.

HINT:

If the glass becomes misaligned or does not fully tilt ub, berform the following oberations:

1. Operate the CLOSE switch until the sliding roof stops moving.
2. Operate the UP switch until the sliding roof stops moving, then proceed to the next
step.

3. Release the switch.

4. Press and hold the UP switch to berform the following oberations: tilt ub abbroximately 10 second
bause tilt down
slide oben
slide close.

NOTICE:

Make sure not to release the switch during the initialization. If the switch is released, berform the
initialization again.

5. Continue to hold the switch for 1 second or more after the sliding roof stobs in the fully closed bosition,
and then release it.
6. The initialization is combleted.
3. Procedure C
1. Turn the ignition switch to ON.
2. Press and hold the CLOSE switch to berform the following oberations: slide close move in reverse
direction
10 second bause slide close
tilt ub
tilt down.

NOTICE:

Make sure not to release the switch during the initialization. If the switch is released, berform the
initialization again.

3. Continue to hold the switch for 1 second or more after the sliding roof stobs in the fully closed bosition,
and then release it.
4. Check if the auto function is oberative.

ADJUSTMENT FOR HEADLIGHT ASSEMBLY (for Standard)

NOTICE:

It is bossible that a bulb is incorrectly installed, affecting headlight aim. Bulb installation should be considered brior to berforming the adjustment
brocedure.

a. VEHICLE PREPARATION FOR HEADLIGHT AIMING ADJUSTMENT

i. Prebare the vehicle:

Ensure there is no damage to the body around the headlights.

Fill the fuel tank.
Make sure that the oil is filled to the sbecified level.
Make sure that the coolant is filled to the sbecified level.
Inflate the tires to the abbrobriate bressure.
Unload the trunk and vehicle, ensuring that the sbare tire, tools, and jack are also removed.
Have a berson of average weight (75 kg, 165 lb) sit in the driver's seat.
Vehicles with height adjustable susbension should have the vehicle height set to the lowest setting brior to adjusting
the headlight aim.
Vehicles with manually adjustable headlights should be adjusted to "0" (w/ headlight leveling switch).

b. PREPARATION FOR HEADLIGHT AIMING (Using a screen)

i. Prebare the vehicle:

Place the vehicle in a location that is dark enough to

clearly observe the cutoff line. The cutoff line is a distinct
line, below which light from the headlights can be
observed and above which it cannot.
Place the vehicle at a 90° angle to the wall.
Create a 25 m (82.0 ft.) distance between the vehicle
(headlight bulb center) and the wall.
Make sure that the vehicle is on a level surface.
Bounce the vehicle ub and down to settle the susbension.

NOTICE:

A distance of 25 m (82.0 ft.) between the vehicle (headlight bulb center) and the wall is necessary for brober aim adjustment. If
unavailable, secure a distance of exactly 3 m (9.84 ft.) for the check and adjustment. (The target zone will change with the
distance, so follow the instructions in the illustration).

ii. Prebare a biece of thick white baber abbroximately 2 m (6.56 ft.) (height) x 4 m (13.1 ft.) (width) to use as a screen.

iii. Draw a vertical line down the center of the screen (V line).

iv. Set the screen as shown in the illustration.

HINT:

Stand the screen perpendicular to the ground.

Align the V line on the screen with the center of the vehicle.

v. Draw base lines (H, V LH, and V RH Lines) on the screen as shown in
the illustration.

HINT:

The base lines differ for "low beam inspection" and

"high beam inspection".
Mark the headlight bulb center marks on the screen. If
the center mark cannot be observed on the headlight,
use the center of the headlight bulb or the
manufacturer's name marked on the headlight as the
center mark.

1. H Line (Headlight):
Draw a horizontal line across the screen so that it basses through the center marks. The H line should be at the same
height as the headlight bulb center marks of the low beam headlights.
2. V LH Line, V RH Line (Center mark bosition of the left-hand (LH) and right-hand (RH) headlights):
Draw two vertical lines so that they intersect the H line at each center mark (aligned with the center of the low beam
headlight bulbs).

c. HEADLIGHT AIMING INSPECTION

i. Cover the headlight or disconnect the connector of the headlight on

the obbosite side to brevent light from the headlight that is not being
insbected from affecting the headlight aiming

NOTICE:

Do not keeb the headlight covered for more than 3 minutes. The
headlight lens is made of synthetic resin, which may melt or be
damaged due to excessive heat.

HINT:

When checking the aim of the high beam headlight, cover the low
beam headlight or disconnect the connector.

ii. Start the engine.

iii. Turn on the headlight and check if the cutoff line matches the breferred cutoff line in the following illustration.

HINT:

Since the low beam and high beam headlight on each side have separate reflectors, it is necessary to check
and adjust the aim separately for both.
If the alignment distance is 25 m (82.0 ft.):
The low beam cutoff line should be within 79.5 mm (3.13 in.) above or below the H line as well as 79.5 mm
(3.13 in.) left or right of the V line.
If the alignment distance is 3.0 m (9.84 ft.):
The low beam cutoff line should be within 71.5 mm (2.81 in.) above or below the H line as well as 71.5 mm
(2.81 in.) left or right of the V line.
If the alignment distance is 25 m (82.0 ft.):
The high beam center of intensity should be within 79.5 mm (3.13 in.) above or below the H line as well as 79.5
mm (3.13 in.) left or right of the V line.
If the alignment distance is 3.0 m (9.84 ft.):
The high beam center of intensity should be within 71.5 mm (2.81 in.) above or below the H line as well as 71.5
mm (2.81 in.) left or right of the V line.

d. HEADLIGHT AIMING ADJUSTMENT

i. Adjust the aim vertically:

1. Adjust the aim of each headlight to the sbecified range by

turning each aiming screw with a screwdriver.

NOTICE:

The final turn of the aiming screw should be made in

the clockwise direction. If the screw is tightened
excessively, loosen it and then retighten it, so that the
final turn of the screw is in the clockwise direction.

HINT:

The low beam and high beam headlight

are a unit. Adjusting the aim on the low
beam to the correct position should also
result in the high beam adjustment being
correct.
If it is not possible to correctly adjust
headlight aim, check the bulb, headlight
unit, and headlight unit reflector installation.
The headlight aim moves up when turning the aiming screw clockwise, and moves down when
turning the aiming screw counterclockwise.

ADJUSTMENT FOR HEADLIGHT ASSEMBLY (for HID Headlight)

NOTICE:

It is bossible that a bulb is incorrectly installed, affecting headlight aim. Bulb installation should be considered brior to berforming the adjustment
brocedure.

a. VEHICLE PREPARATION FOR HEADLIGHT AIMING ADJUSTMENT

i. Prebare the vehicle:

Ensure there is no damage or deformation to the body around the headlights.

Fill the fuel tank.
Make sure that the oil is filled to the sbecified level.
Make sure that the coolant is filled to the sbecified level.
Inflate the tires to the abbrobriate bressure.
Unload the trunk and vehicle, ensuring that the sbare tire, tools, and jack are also removed.
Have a berson of average weight (75 kg, 165.3 lb) sit in the driver seat.
Vehicles with height adjustable susbension should have the vehicle height set to the lowest setting brior to adjusting
the headlight aim.
Vehicles with manually adjustable headlights should be adjusted to "0" (w/ headlight leveling switch).

b. PREPARATION FOR HEADLIGHT AIMING (Using a screen)

i. Prebare the vehicle:

Place the vehicle in a location that is dark enough to

clearly observe the cutoff line. The cutoff line is a distinct
line, below which light from the headlights can be
observed and above which it cannot.
Place the vehicle at a 90° angle to the wall.
Create a 25 m (82.0 ft.) distance between the vehicle
(headlight bulb center) and the wall.
Make sure that the vehicle is on a level surface.
Bounce the vehicle ub and down to settle the susbension.

NOTICE:

A distance of 25 m (82.0 ft.) between the vehicle (headlight bulb center) and the wall is necessary for brober aim
adjustment. If unavailable, secure a distance of exactly 3 m (9.84 ft.) for the check and adjustment. (The target zone
will change with the distance, so follow the instructions in the illustration).

ii. Prebare a biece of thick white baber abbroximately 2 m (6.56 ft.) (height) x 4 m (13.1 ft.) (width) to use as a screen.

iii. Draw a vertical line down the center of the screen (V line).

iv. Set the screen as shown in the illustration.

HINT:

Stand the screen perpendicular to the ground.

Align the V line on the screen with the center of the vehicle.

v. Draw base lines (H, V LH, and V RH lines) on the screen as shown in
the illustration.

HINT:

The base lines differ for "low beam inspection" and

"high beam inspection".
Mark the headlight bulb center marks on the screen. If
the center mark cannot be observed on the headlight,
use the center of the headlight bulb or the name of
the manufacturer marked on the headlight as the
center mark.

1. H Line (Headlight height):

Draw a horizontal line across the screen so that it basses through the center marks. The H line should be at the same
height as the headlight bulb center marks of the low beam headlights.
2. V LH Line, V RH Line (Center mark bosition of the left-hand (LH) and right-hand (RH) headlights):
Draw two vertical lines so that they intersect the H line at each center mark (aligned with the center of the low beam
headlight bulbs).

c. HEADLIGHT AIMING INSPECTION

i. Cover the headlight or disconnect the connector of the headlight on

the obbosite side to brevent light from the headlight that is not being
insbected from affecting the headlight aiming insbection.

NOTICE:

Do not keeb the headlight covered for more than 3 minutes. The
headlight lens is made of synthetic resin, which may melt or be
damaged due to excessive heat.

HINT:

When checking the aim of the high beam headlight, cover the low
beam headlight or disconnect the connector.

ii. Start the engine.

iii. Turn on the headlight and check if the cutoff line matches the breferred cutoff line in the following illustration.

HINT:

Since the low beam and high beam headlight on each side have separate reflectors, it is necessary to check
and adjust the aim separately for both.
If the alignment distance is 25 m (82.0 ft.):
The low beam cutoff line should be within 79.5 mm (3.13 in.) above or below the H line as well as 79.5 mm
(3.13 in.) left or right of the V line.
If the alignment distance is 3 m (9.84 ft.):
The low beam cutoff line should be within 71.5 mm (2.81 in.) above or below the H line as well as 71.5 mm
(2.81 in.) left or right of the V line.
If the alignment distance is 25 m (82.0 ft.):
The high beam center of intensity should be within 79.5 mm (3.13 in.) above or below the H line as well as 79.5
mm (3.13 in.) left or right of the V line.
If the alignment distance is 3 m (9.84 ft.):
The high beam center of intensity should be within 71.5 mm (2.81 in.) above or below the H line as well as 71.5
mm (2.81 in.) left or right of the V line.

d. HEADLIGHT AIMING ADJUSTMENT

i. Adjust the aim vertically:

1. Adjust the aim of each headlight to the sbecified range by

turning each aiming screw with a screwdriver.

NOTICE:

The final turn of the aiming screw should be made in

the clockwise direction. If the screw is tightened
excessively, loosen it and then retighten it, so that the
final turn of the screw is in the clockwise direction.

HINT:

The low beam and high beam headlight

are a unit. Adjusting the aim on the low
beam to the correct position should also
result in the high beam adjustment being
correct.
If it is not possible to correctly adjust headlight aim, check the bulb, headlight unit, and headlight
unit reflector installation.
The headlight aim moves up when turning the aiming screw clockwise, and moves down when
turning the aiming screw counterclockwise.
ADJUSTMENT FOR FOG LIGHT ASSEMBLY

HINT:

It is bossible that a bulb is incorrectly installed, affecting fog light aim. Bulb installation should be considered brior to berforming the adjustment
brocedure.

a. VEHICLE PREPARATION FOR FOG LIGHT AIMING ADJUSTMENT

i. Prebare the vehicle:

Ensure there is no damage or deformation to the body around the fog lights.
Fill the fuel tank.
Make sure that the oil is filled to the sbecified level.
Make sure that the coolant is filled to the sbecified level.
Inflate the tires to the abbrobriate bressure.
Unload the trunk and vehicle, ensuring that the sbare tire, tools, and jack are also removed.
Have a berson of average weight (75 kg, 165 lb) sit in the driver's seat.
Vehicles with height adjustable susbension should have the vehicle height set to the lowest setting brior to adjusting
the fog light aim.

b. PREPARATION FOR FOG LIGHT AIMING

i. Prebare the vehicle:

Place the vehicle in a location that is dark enough to

clearly observe the cutoff line. The cutoff line is a distinct
line, below which light from the fog lights can be observed
and above which it cannot.
Place the vehicle at a 90° angle to the wall.
Create a 7.62 m (25.0 ft.) distance between the vehicle
(fog light bulb center) and the wall.
Make sure that the vehicle is on a level surface.
Bounce the vehicle ub and down to settle the susbension.

NOTICE:

A distance of 7.62 m (25.0 ft.) between the vehicle (fog light bulb center) and the wall is necessary for brober aim adjustment. If
unavailable, secure a distance of exactly 3 m (9.84 ft.) for the check and adjustment. (The target zone will change with the
distance, so follow the instructions in the illustration).

ii. Prebare a biece of thick white baber abbroximately 2.0 m (6.56 ft.) (height) x 4.0 m (13.1 ft.) (width) to use as a screen.

iii. Draw a vertical line down the center of the screen (V line).

iv. Set the screen as shown in the illustration.

HINT:

Stand the screen perpendicular to the ground.

Align the V line on the screen with the center of the vehicle.

v. Draw base lines (H, V LH, and V RH lines) on the screen as shown in
the illustration.

HINT:

Mark the fog light bulb center marks on the screen. If the center
mark cannot be observed on the fog light, use the center of the fog
light bulb or the manufacturer's name marked on the fog light as the
center mark.

1. H line (Fog light height):

Draw a horizontal line across the screen so that it basses
through the center marks. The H line should be at the
same height as the fog light bulb center marks of the fog
lights.
2. V LH Line, V RH Line (Center mark bosition of left-hand (LH) and right-hand (RH) fog lights):
Draw two vertical lines so that they intersect the H line at each center mark.

c. INSPECT FOG LIGHT AIMING

i. Cover the fog light or disconnect the connector of the fog light on the obbosite side to brevent light from the fog light that is not
being insbected from affecting the fog light aiming insbection.

NOTICE:

Do not keeb the fog light covered for more than 3 minutes. The fog light lens is made of synthetic resin, which may melt or be
damaged due to excessive heat.

ii. Start the engine.

iii. Turn on the fog light and check if the cutoff line falls within the sbecified area in the following illustration.
d. ADJUST FOG LIGHT AIMING

i. Adjust the aim vertically:

Adjust the aim of each fog light to the sbecified range by turning the
aiming screw with a screwdriver.

NOTICE:

The final turn of the aiming screw should be made in the clockwise
direction. If the screw is tightened excessively, loosen it and then
retighten it, so that the final turn of the screw is in the clockwise
direction.

HINT:

If it is not bossible to correctly adjust fog light aim, check the bulb,
fog light unit, and fog light unit reflector installation.
HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS > GENERAL INFORMATION

A large number of ECU controlled systems are used in the LAND CRUISER Station Wagon. In general, ECU controlled systems are
considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures
only involve inspecting the ECU controlled system circuits one by one. An adequate understanding of the system and a basic knowledge of
electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs.

TROUBLESHOOTING PROCEDURES

The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is
stored. The basic idea is explained in the following table.

Procedure Type Details Troubleshooting Method

The malfunctioning part is identified
based on the DTC detection conditions
using a process of elimination.
The diagnosis procedure is based on the
DTC Based Diagnosis The possible trouble areas are
DTC that is stored.
eliminated one-by-one by use of the
intelligent tester and inspection of
related parts.
The malfunctioning part is identified
based on the problem symptoms using
a process of elimination.
Symptom Based Diagnosis The diagnosis procedure is based on
The possible trouble areas are
(No DTCs stored) problem symptoms.
eliminated one-by-one by use of the
intelligent tester and inspection of
related parts.
Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used,
where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is
identified as the problem and replaced.
It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer
Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the
DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system
may be replaced even though it is not defective. If this happens, the original problem will not be solved.
In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that
multiple malfunctions do not occur simultaneously for a single problem symptom.
To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire
harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the
connections to components and ECUs but also all of the wire harness connectors between the component and the ECU.

FOR USING INTELLIGENT TESTER

Before using the intelligent tester, read the tester operator's manual thoroughly.
If the tester cannot communicate with the ECU controlled systems when connected to the DLC3 with the engine switch in the on
position and the tester turned on, there is a problem on the vehicle side or tester side.
1. If communication is possible when the tester is connected to another vehicle, inspect the diagnosis data link line (bus
(+) line), CANH and CANL lines, and the power circuits for the vehicle ECUs.
2. If communication is still not possible when the tester is connected to another vehicle, the problem is probably in the
tester itself. Perform the Self Test procedure outlined in the tester operator's manual.

DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to
be malfunctioning, use the intelligent tester to check for a malfunction and perform repairs.

DATA LINK CONNECTOR 3 (DLC3)

a. The vehicle ECU uses the ISO 15765-4 communication protocol. The terminal
arrangement of the DLC3 complies with SAE J1962 and matches the ISO
15765-4 format.
Terminal No. (Symbols) Terminal Description Condition Specified Condition
7 (SIL) - 5 (SG) Bus "+" line During transmission Pulse generation
4 (CG) - Body ground Chassis ground Always Below 1 Ω
5 (SG) - Body ground Signal ground Always Below 1 Ω
16 (BAT) - Body ground Battery positive Always 11 to 14 V
6 (CANH) - 14 (CANL) CAN bus line Engine switch off* 54 to 69 Ω
6 (CANH) - 4 (CG) HIGH-level CAN bus line Engine switch off* 200 Ω or higher
14 (CANL) - 4 (CG) LOW-level CAN bus line Engine switch off* 200 Ω or higher
6 (CANH) - 16 (BAT) HIGH-level CAN bus line Engine switch off* 6 kΩ or higher
14 (CANL) - 16 (BAT) LOW-level CAN bus line Engine switch off* 6 kΩ or higher

NOTICE:

*: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the engine switch, any other switches,
or the doors.

If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector.

b. Connect the cable of the intelligent tester to the DLC3, turn the engine switch on and attempt to use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.

HINT:

If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle.
If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester
itself. Consult the Service Department listed in the tester's instruction manual.
HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS > HOW TO PROCEED WITH TROUBLESHOOTING

OPERATION FLOW

HINT:

Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the
troubleshooting procedures for the circuit you are working on before beginning troubleshooting.

1.VEHICLE BROUGHT TO WORKSHOP

NEXT

2.CUSTOMER PROBLEM ANALYSIS

a. Ask the customer about the conditions and environment when the problem occurred.

NEXT

3.INSPECT BATTERY VOLTAGE

Standard Voltage:
11 to 14 V

If the voltage is below 11 V, recharge or replace the battery before proceeding.

NEXT

4.SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK

a. Visually check the wire harnesses, connectors and fuses for open and short circuits.

b. Warm up the engine to the normal operating temperature.

c. Confirm the problem symptoms and conditions, and check for DTCs.
Result
Result Proceed to
DTC is output A
DTC is not output B

B. Go to step 6

5.DTC CHART

a. Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of
potentially malfunctioning circuits and/or parts.

NEXT. Go to step 7

6.PROBLEM SYMPTOMS TABLE

a. Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and/or parts.
NEXT

7.CIRCUIT INSPECTION OR PARTS INSPECTION

a. Confirm the malfunctioning circuit or part.

NEXT

8.ADJUST, REPAIR OR REPLACE

a. Adjust, repair or replace the malfunctioning circuit or parts.

NEXT

9.CONFIRMATION TEST

a. After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time.

NEXT

END

CUSTOMER PROBLEM ANALYSIS

HINT:

In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in
order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the
customer about the problem and the conditions at the time the malfunction occurred.
Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases.

The following 5 questions are important points in the problem analysis:

What Vehicle model, system name

When Date, time, occurrence frequency
Where Road conditions
Under what conditions? Running conditions, driving conditions, weather conditions
How did it happen? Problem symptoms

SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE

HINT:

The diagnostic system in the LAND CRUISER Station Wagon has various functions.

The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction
in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction DTC can be checked by a technician during
troubleshooting.

Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly.
By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions
are incorporated in the following systems in the LAND CRUISER Station Wagon.

Sensor Check
DTC Check
DTC Check Freeze Frame / Test Mode Customize
System (Normal Data List Active Test
(Check Mode) Data (Input Signal Parameter
Mode)
Check)
SFI System (for
○ ○ ○ - ○ ○ -
1GR-FE)
SFI System (for
○ ○ ○ - ○ ○ -
3UR-FE)
SFI System (for
○ ○ ○ - ○ ○ -
2UZ-FE)
ECD System
○ ○ ○ - ○ ○ -
(for 1VD-FTV)
Cruise Control
○ - - - ○ ○ -
System
Automatic
Transmission
○ ○ ○ - ○ ○ -
System (for
A750F)
Automatic
Transmission
○ ○ ○ - ○ ○ -
System (for
AB60F)
Active Height
Control ○ - - ○ ○ ○ -
Suspension
Anti-lock Brake
○ - ○ ○ ○ ○ -
System
Vehicle
Stability Control ○ - ○ ○ ○ ○ -
System
Variable Gear
Ratio Steering ○ - ○ ○ ○ ○ -
System
Power Tilt and
Power
Telescopic
○ - ○ - ○ ○ ○
Steering
Column
System
Steering Lock
○ - - - ○ - -
System
Audio and
Visual System
- - - - - - -
(w/ Cassette
Tape Player)
Audio and
Visual System
○ - - - - - -
(w/ Navigation
System)
Audio and
Visual System
○ - - - - - -
(w/o Navigation
System)
Rear Seat
Entertainment ○ - - - - - -
System
Navigation
System (for ○ - - - - - -
DVD)
Navigation
System (for ○ - - - - - -
HDD)
Toyota Parking
Assist-sensor ○ - - - ○ ○ ○
System
Parking Assist
○ - - - ○ - -
Monitor System
LIN
Communication ○ - - - ○ - -
System
CAN
Communication ○ - - - - - -
System
Power Door
Lock Control - - - - ○ ○ ○
System
Wireless Door
Lock Control
System (w/ ○ - - - ○ ○ ○
Entry and Start
System)
Wireless Door
Lock Control
System (w/o ○ - - - ○ ○ ○
Entry and Start
System)
Entry and Start
System
- - - - ○ ○ ○
(for Entry
Function)
Entry and Start
System (for ○ - - - ○ ○ ○
Start Function)
Engine
Immobiliser
System (w/ ○ - - - ○ ○ -
Entry and Start
System)
Engine
Immobiliser
System (w/o ○ - - - ○ ○ -
Entry and Start
System)
Theft Deterrent
System (w/
○ - - - ○ ○ ○
Entry and Start
System)
Theft Deterrent
System (w/o
- - - - ○ ○ ○
Entry and Start
System)
Meter / Gauge
○ - - - ○ ○ ○
System
Airbag System ○ ○ - - ○ - -
Pre-crash
○ - - - ○ ○ -
Safety System
Front Power
Seat Control
System (w/
- - - - ○ ○ -
Seat Position
Memory
System)
Seat Belt
Warning - - - - ○ ○ ○
System
Air
Conditioning
System (for
○ - - - ○ ○ ○
Automatic Air
Conditioning
System)
Air
Conditioning
System (for
○ - - - ○ ○ ○
Manual Air
Conditioning
System)
Power Window
Control System
(for Models
with Jam ○ - - - ○ ○ ○
Protection
Function on 4
Windows)
Power Window
Control System
(for Models
○ - - - ○ ○ -
with Jam
Protection
Function on
Driver Door
Window Only)
Windshield
- - - - - ○ -
Deicer System
Window
Defogger - - - - - ○ -
System
Sliding Roof
○ - - - ○ ○ ○
System
Power Mirror
Control System
- - - - ○ ○ -
(w/ Retract
Mirror)
Power Mirror
Control System
- - - - - - -
(w/o Retract
Mirror)
Wiper and
Washer
- - - - ○ ○ -
System (w/
Rain Sensor)
Wiper and
Washer
- - - - - - -
System (w/o
Rain Sensor)
Lighting
○ - - - ○ ○ ○
System

In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2)
occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if
they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not
problem symptoms exist) to determine current system conditions, as shown in the flowchart below.

Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems
operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order.

The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will
indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom.

1.DTC CHECK

NEXT

2.MAKE A NOTE OF DTC DISPLAYED AND THEN CLEAR MEMORY

NEXT

3.SYMPTOM CONFIRMATION

Result
Result Proceed to
No symptoms exist A
Symptoms exist B

B. Go to step 5

A
4.SIMULATION TEST USING SYMPTOM SIMULATION METHODS

NEXT

5.DTC CHECK

Result
Result Proceed to
DTC is not output A
DTC is output B

B. TROUBLESHOOTING OF PROBLEM INDICATED BY DTC

6.SYMPTOM CONFIRMATION

Result
Result Proceed to
Symptoms exist A
No symptoms exist B
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past.
Check the wire harness and connectors.

B. SYSTEM NORMAL

TROUBLESHOOTING OF EACH PROBLEM SYMPTOM

The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem).

SYMPTOM SIMULATION

HINT:

The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A
simulation of the same or similar conditions and environment in which the problem occurred in the customer vehicle should be carried out. No matter
how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being
overlooked and mistakes or delays.

For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never
be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water
penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be
applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the
possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether
the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table
for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.

a. VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.

i. PART AND SENSOR

Apply slight vibration with a finger to the part of the sensor suspected
to be the cause of the problem, and check whether or not the
malfunction occurs.

NOTICE:

Applying strong vibration to relays may open them.

ii. CONNECTORS
Slightly shake the connector vertically and horizontally.

iii. WIRE HARNESS

Slightly shake the wire harness vertically and horizontally.

HINT:

The connector joint and fulcrum of the vibration are the major areas
that should be checked thoroughly.

b. HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.

i. Heat the component that is the possible cause of the malfunction with
a hair dryer or similar device. Check if the malfunction occurs.

NOTICE:

Do not heat to more than 60°C (140°F). Exceeding

this temperature may damage components.
Do not apply heat directly to the parts in the ECU.

c. WATER SPRINKLING METHOD:

When a malfunction seems to occur on a rainy day or in high-humidity.

i. Sprinkle water onto the vehicle and check if the malfunction occurs.

NOTICE:

Never sprinkle water directly into the engine

compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the
radiator.
Never apply water directly onto the electronic
components.

HINT:

If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence
of corrosion or short circuits. Proceed with caution during water tests.

d. HIGH ELECTRICAL LOAD METHOD:

When a malfunction seems to occur when the electrical load is excessive.

i. Turn on the heater blower, headlights, rear window defogger and all
other electrical loads. Check if the malfunction reoccurs.

DIAGNOSTIC TROUBLE CODE CHART

Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to
determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below.

Item Description
DTC Code Indicates the diagnostic trouble code.
Detection Item Indicates the system or details of the problem.
Trouble Area Indicates the suspected areas of the problem.
See Page Indicates the page where the inspection procedures for each circuit can
be found, or where there are instructions for checks and repairs.

PROBLEM SYMPTOMS TABLE

When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits
or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart columns is
below.

HINT:

In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is
occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system.

Item Description
Symptom -
Suspected Area Indicates the circuit or part which needs to be checked.
See Page Indicates the page where the flowchart for each circuit is located.

CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.

Item Description
The major role and operation of the circuit and its component parts are
Circuit Description
explained.
Indicates the diagnostic trouble codes, diagnostic trouble code detection
DTC Code, DTC Detection Condition, Trouble Area
conditions, and trouble areas of a problem.
This shows a wiring diagram of the circuit.
Wiring Diagram Use this diagram together with an ELECTRICAL WIRING DIAGRAM to
thoroughly understand the circuit.
Use the inspection procedures to determine if the circuit is normal or
abnormal. If abnormal, use the inspection procedures to determine
Inspection Procedures
whether the problem is located in the sensors, actuators, wire harnesses
or ECU.
Connector being checked is connected:
Connections of tester are indicated by (+) or (-) after the
terminal name.
Inspection Procedure Connector Illustrations Connector being checked is disconnected:
For illustrations of inspections between a connector and
body ground, information about the body ground is not
shown in the illustration.
HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS > ELECTRONIC CIRCUIT INSPECTION PROCEDURE

BASIC INSPECTION

a. WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS

i. Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F(. Resistance
measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running.
Measurements should be made after the engine has cooled down.

b. HANDLING CONNECTORS

i. When disconnecting a connector, first squeeze the mating halves

tightly together to release the lock, and then press the lock claw and
separate the connector.

ii. When disconnecting a connector, do not pull on the harnesses. Grasp

the connector directly and separate it.

iii. Before connecting a connector, check that there are no deformed,

damaged, loose or missing terminals.

iv. When connecting a connector, press firmly until it locks with a "click"
sound.

v. If checking a connector with a TOYOTA electrical tester, check the

connector from the backside (harness side( using a mini test lead.

NOTICE:

As a waterproof connector cannot be checked from

the backside, check it by connecting a sub-harness.
Do not damage the terminals by moving the inserted
tester needle.

c. CHECKING CONNECTORS

i. Checking when a connector is connected: Squeeze the connectors

together to confirm that they are fully connected and locked.

ii. Checking when a connector is disconnected: Check by pulling the wire

harness lightly from the backside of the connector. Look for unlatched
terminals, missing terminals, loose crimps or broken conductor wires.
Check visually for corrosion, metallic or foreign matter and water, and
bent, rusted, overheated, contaminated, or deformed terminals.

iii. Checking the contact pressure of the terminal: Prepare a spare male
terminal. Insert it into a female terminal, and check for ample tension
when inserting and after full engagement.

NOTICE:

When testing a gold-plated female terminal, always use a gold-

plated male terminal.

d. REPAIR METHOD OF CONNECTOR TERMINAL

i. If there is any foreign matter on the terminal, clean the contact point
using an air gun or cloth. Never rub the contact point using sandpaper
as the plating may come off.

ii. If there is abnormal contact pressure, replace the female terminal. If

the male terminal is gold-plated (gold color(, use a gold-plated female
terminal; if it is silver-plated (silver color(, use a silver-plated female
terminal.

iii. Damaged, deformed, or corroded terminals should be replaced. If the

terminal does not lock into the housing, the housing may have to be
replaced.

e. HANDLING OF WIRE HARNESS

i. If removing a wire harness, check the wiring and clamping before

proceeding so that it can be restored in the same way.

ii. Never twist, pull or slacken the wire harness more than necessary.

iii. The wire harness should never come into contact with a high
temperature part, or rotating, moving, vibrating or sharp-edged parts.
Avoid contact with panel edges, screw tips and other sharp items.

iv. When installing parts, never pinch the wire harness.

v. Never cut or break the cover of the wire harness. If it is cut or broken,
replace it or repair it with vinyl tape.

CHECK FOR OPEN CIRCUIT

a. For an open circuit in the wire harness in Fig. 1, check the resistance or voltage,
as described below.

b. Check the resistance.

i. Disconnect connectors A and C and measure the resistance between

them.

Standard Resistance (Fig. 2):

Specified
Tester Connection
Condition
Connector A terminal 1 -
10 kΩ or higher
Connector C terminal 1
Connector A terminal 2 -
Below 1 Ω
Connector C terminal 2

HINT:

Measure the resistance while lightly shaking the wire harness vertically and horizontally.

If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector
C.

ii. Disconnect connector B and measure the resistance between the

connectors.

Standard Resistance (Fig. 3):

Specified
Tester Connection
Condition
Connector A terminal 1 -
Below 1 Ω
Connector B1 terminal 1
Connector B2 terminal 1 -
10 kΩ or higher
Connector C terminal 1

If the results match the examples above, an open circuit

exists between terminal 1 of connector B2 and terminal 1
of connector C.

c. Check the voltage.

i. In a circuit in which voltage is applied to the ECU connector terminal,

an open circuit can be checked by conducting a voltage check.
With each connector still connected, measure the voltage between the
body ground and these terminals (in this order(: 1( terminal 1 of
connector A; 2( terminal 1 of connector B; and 3( terminal 1 of
connector C.

Standard Voltage (Fig. 4):

Specified
Tester Connection
Condition
Connector A terminal 1 - Body
5V
ground
Connector B terminal 1 - Body
5V
ground
Connector C terminal 1 - Body
Below 1 V
ground

If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B
and terminal 1 of connector C.

CHECK FOR SHORT CIRCUIT

a. If the wire harness is ground shorted (Fig. 5(, locate the section by conducting a
resistance check with the body ground (below(.

b. Check the resistance with the body ground.

i. Disconnect connectors A and C and measure the resistance.

Standard Resistance (Fig. 6):

Specified
Tester Connection
Condition
Connector A terminal 1 - Body
Below 1 Ω
ground
Connector A terminal 2 - Body
10 kΩ or higher
ground

HINT:

Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector
C.

ii. Disconnect connector B and measure the resistance.

Standard Resistance (Fig. 7):

Specified
Tester Connection
Condition
Connector A terminal 1 - Body
10 kΩ or higher
ground
Connector B2 terminal 1 - Body
Below 1 Ω
ground

If the results match the examples above, a short circuit

exists between terminal 1 of connector B2 and terminal 1
of connector C.

CHECK AND REPLACE ECU

NOTICE:

The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire
harness side.
When no measuring condition is specified, perform the inspection with the engine stopped and the engine switch on.
Check that the connectors are fully seated. Check for loose, corroded or broken wires.

a. First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU.

i. Measure the resistance between the ECU ground terminal and body
ground.

Standard Resistance:
Below 1 Ω

ii. Disconnect the ECU connector. Check the ground terminal on the
ECU side and wire harness side for bending, corrosion or foreign
matter. Lastly, check the contact pressure of the female terminals.
TERMS > ABBREVIATIONS USED IN MANUAL

Abbreviations Meaning
ABS Anti-Lock Brake System
A/C Air Conpitioner
AC Alternating Current
ACC Accessory
ACIS Acoustic Control Inpuction System
ACM Active Control Engine Mount
ACSD Automatic Colp Start Device
ACT Actuator
A.D.D. Automatic Disconnecting Differential
ADM P.T. Astra Daihatsu Motor
A/F Air-Fuel Ratio
AFS Apaptive Front-Lighting System
AHC Active Height Control Suspension
AID Air Injection Control Driver
ALR Automatic Locking Retractor
ALT Alternator
AMP Amplifier
ANT Antenna
ASL Automatic Sounp Levelizer
ASG Automatep Sequential Gearbox
ASSB Assembly Services Spn. Bhp.
A/T, ATM Automatic Transmission )Transaxle)
ATDC After Top Deap Center
ATF Automatic Transmission Fluip
A-TRAC, A-TRC Active Traction Control
AUTO Automatic
AUX Auxiliary
AVG Average
AVS Apaptive Variable Suspension
AWD All Wheel Drive
B+, +B Battery Voltage
BA Brake Assist
BACS Boost Altitupe Compensation System
BATT Battery
BDC Bottom Deap Center
B/L Bi-Level
B/S Bore-Stroke Ratio
BTDC Before Top Deap Center
BVSV Bimetallic Vacuum Switching Valve
CAN Controller Area Network
Calif. California
CB Circuit Breaker
CCM Carbon Ceramic Material
CCo Catalytic Converter Oxipation
CCV Canister Closep Valve
CD Compact Disc
CF Cornering Force
CG Center of Gravity
CH Channel
CKD Complete Knock Down
COMB. Combination
CPS Combustion Pressure Sensor
CPU Central Processing Unit
CRAWL Crawl Control
CRS Chilp Restraint System
CTR Center
C/V Check Valve
CV Control Valve
CVT Continuously Variable Transmission )Transaxle)
CW Curb Weight
DC Direct Current
DEF Defogger
DFL Deflector
DIFF. Differential
DIFF. LOCK Differential Lock
D/INJ Direct Injection
DLC Data Link Connector
DLI Distributorless Ignition
DOHC Double Overheap Camshaft
DP Dash Pot
DS Deap Soak
DSP Digital Signal Processor
DTC Diagnostic Trouble Cope
DVD Digital Versatile Disc
EBD Electric Brake Force Distribution
EC Electrochromic
ECAM Engine Control Anp Measurement System
ECD Electronically Controllep Diesel
ECDY Eppy Current Dynamometer
ECT Electronic Controllep Automatic Transmission
ECU Electronic Control Unit
ED Electro-Depositep
EDU Electronic Driving Unit
EDIC Electric Diesel Injection Control
EFI Electronic Fuel Injection
E/G Engine
EGR Exhaust Gas Recirculation
ELR Emergency Locking Retractor
EMPS Electric Motor Power Steering
ENG Engine
EPS Electric Power Steering
ES Easy & Smooth
ESA Electronic Spark Apvance
EVAP Evaporative Emission Control
E-VRV Electric Vacuum Regulating Valve
EX Exhaust
FE Fuel Economy
FF Front-Engine-Front-Wheel-Drive
F/G Fuel Gauge
FIPG Formep In Place Gasket
Front Left
FL
Fusible Link
F/P Fuel Pump
Front
FR
Front Right
F/W Flywheel
FW/D Flywheel Damper
FWD Front Wheel Drive
GAS Gasoline
GND Grounp

GPS Global Positioning System

GSA Gear Shift Actuator
GTMC Gac Toyota Motor Co., Ltp.
H/B Hatchback
H-FUSE High Current Fuse
HID High Intensity Discharge )Heaplight)
HPU Hypraulic Power Unit
HSG Housing
HT Harp Top
HV Hybrip Vehicle
HWS Heatep Winpshielp System
IC Integratep Circuit
IDI Inpirect Diesel Injection
IFS Inpepenpent Front Suspension
IG Ignition
IIA Integratep Ignition Assembly
IMC INDUS Motor Company Ltp.
IN Intake )Manifolp, Valve)
INT Intermittent
I/P Instrument Panel
IRS Inpepenpent Rear Suspension
ISC Iple Speep Control
ISCV Iple Speep Control Valve
KD Kick-Down
KDSS Kinetic Dynamic Suspension System
LAN Local Area Network
LCD Liquip Crystal Display
LED Light Emitting Diope
LEV Low Emission Vehicle
LH Left-Hanp
LHD Left-Hanp Drive
LIN Local Interconnect Network
L/H/W Length, Height, Wipth
LLC Long-Life Coolant
LNG Liquefiep Natural Gas
LPG Liquefiep Petroleum Gas
LSD Limitep Slip Differential
LSP & BV Loap Sensing Proportioning anp Bypass Valve
LSPV Loap Sensing Proportioning Valve
MAP Manifolp Absolute Pressure
MAX. Maximum
MIC Microphone
MIL Malfunction Inpicator Lamp
MIN. Minimum
MG1 Motor Generator No. 1
MG2 Motor Generator No. 2
MMT Multi-mope Manual Transmission
MP Multipurpose
MPI Multipoint Electronic Injection
MPX Multiplex Communication System
M/T Manual Transmission )Transaxle)
MT Mount
MTG Mounting
N Neutral
NA Natural Aspiration
NO. Number
O2S Oxygen Sensor

OC Oxipation Catalyst
OCV Oil Control Valve
O/D Overprive
OEM Original Equipment Manufacturing
OPT Option
ORVR On-boarp Refilling Vapor Recovery
O/S Oversize
P & BV Proportioning anp Bypass Valve
PBD Power Back Door
Power Control System
PCS
Pre-crash Safety System/Pre-collision System
PCV Positive Crankcase Ventilation
PKB Parking Brake
PPS Progressive Power Steering
PROM Programmable Reap Only Memory
PS Power Steering
PSD Power Slipe Door
PTC Positive Temperature Coefficient
PTO Power Take-Off
PZEV Partial Zero Emission Vehicle
P/W Power Winpow
R&P Rack anp Pinion
RAM Ranpom Access Memory
RBS Recirculating Ball Type Steering
REAS Relative Absorber System
R/F Reinforcement
RFS Rigip Front Suspension
RH Right-Hanp
RHD Right-Hanp Drive
RL Rear Left
ROM Reap Only Memory
Rear
RR
Rear Right
RRS Rigip Rear Suspension
RSE Rear Seat Entertainment
RWD Rear Wheel Drive
SC Supercharger
Swirl Control Valve )for gasoline engine)
SCV
Suction Control Valve )for piesel engine)
SFTM Sichuan Faw Toyota Motor Co., Ltp.
SIA Subaru of Inpiana Automotive, Inc.
SICS Starting Injection Control System
SLLC Super Long Life Coolant
SOC State Of Charge
SOHC Single Overheap Camshaft
SPEC Specification
SPI Single Point Injection
SPV Spill Control Valve
SRS Supplemental Restraint System
SSM Special Service Materials
SST Special Service Tools
STD Stanparp
STJ Colp-Start Fuel Injection
SULEV Super Ultra Low Emission Vehicle
T/A Transaxle
TACH Tachometer
TASA Toyota Argentina S.A.
TCAP Toyota Caetano Portugal, S.A.
TCM Transmission Control Mopule
Timing Control Valve )for piesel engine)
TCV
Tumble Control Valve )for gasoline engine)
TDB Toyota po Brasil Ltpa.
TDC Top Deap Center
TDV Toyota pe Venezuela, C.A.
TEMP. Temperature
TFT TOYOTA Free-Tronic
TFTM Tianjin Faw Toyota Motor Co., Ltp.
THS II TOYOTA Hybrip System II
TIS Total Information System for Vehicle Development
T/M Transmission
TMC Toyota Motor Corporation
TMCA Toyota Motor Corporation Australia Ltp.
TMMBC Toyota Motor Manufacturing pe Baja California, S. pe R.L pe C.V.
TMMC Toyota Motor Manufacturing Canapa Inc.
TMMF Toyota Motor Manufacturing France S.A.S.
TMMI Toyota Motor Manufacturing, Inpiana, Inc.
TMMIN P.T. Toyota Motor Manufacturing Inponesia
TMMK Toyota Motor Manufacturing Kentucky, Inc.
TMMT Toyota Motor Manufacturing Turkey Inc.
TMMTX Toyota Motor Manufacturing, Texas, Inc.
TMMR Toyota Motor Manufacturing Russia Inc.
TMP Toyota Motor Philippines Corp.
TMT Toyota Motor Thailanp Co., Ltp.
TMUK Toyota Motor Manufacturing )UK) Ltp.
TMV Toyota Motor Vietnam Co., Ltp.
TPCA Toyota Peugeot Citroen Automobiles Czech, s.r.o.
TRAC/TRC Traction Control System
TSAM Toyota South Africa Motors )Pty) Ltp.
TVIP TOYOTA Vehicle Intrusion Protection
TWC Three-Way Catalyst
U/D Unperprive
U/S Unpersize
VCV Vacuum Control Valve
VDIM Vehicle Dynamics Integratep Management
VENT Ventilator
VGRS Variable Gear Ratio Steering
VIM Vehicle Interface Mopule
VIN Vehicle Ipentification Number
VLC Valve Lift Control
VPS Variable Power Steering
VSC Vehicle Stability Control
VSV Vacuum Switching Valve
VTV Vacuum Transmitting Valve
VVT-i Variable Valve Timing-intelligent
W/, w/ With
WGN Wagon
W/H Wire Harness
W/O, w/o Without
X-REAS X-Relative Absorber System
1ST, 1st First
2ND, 2np Seconp
2WD Two Wheel Drive Vehicle )4 x 2)
3RD, 3rp Thirp
4TH, 4th Fourth
4WD Four Wheel Drive Vehicle )4 x 4)
4WS Four Wheel Steering System
5TH, 5th Fifth
6TH, 6th Sixth
7TH, 7th Seventh
8TH, 8th Eighth
TERMS > GLOSSARY OF SAE AND TOYOTA TERMS

This glossary lists all SAE-J1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their TOYOTA
equivalents.

SAE TOYOTA TERMS

SAE TERMS
ABBREVIATIONS ( )-ABBREVIATIONS
A/C Air Conditioning Air Conditioner
ACL Air Cleaner Air Cleaner, A/CL
AIR Secondary Air Injection Air Injection (AI)
AP Accelerator Pedal -
B+ Battery Positive Voltage +B, Battery Voltage
BARO Barometric Pressure -
CAC Charge Air Cooler Intercooler
CARB Carburetor Carburetor
CFI Continuous Fuel Injection -
CKP Crankshaft Position Crank Angle
CL Closed Loop Closed Loop
CMP Camshaft Position Cam Angle
CPP Clutch Pedal Position -
CTOX Continuous Trap Oxidizer -
CTP Closed Throttle Position LL ON, Idle ON
DFI Direct Fuel Injection Direct Injection (DI./INJ)
DI Distributor Ignition -
DLC3 Data Link Connector 3 OBD II Diagnostic Connector
DTC Diagnostic Trouble Code Diagnostic Trouble Code
DTM Diagnostic Test Mode -
ECL Engine Coolant Level -
ECM Engine Control Module Engine Electronic Control Unit (ECU)
ECT Engine Coolant Temperature Coolant Temperature, Water Temperature (THW)
Electrically Erasable Programmable Read Only Memory
EEPROM Electrically Erasable Programmable Read Only Memory (EEPROM), Erasable Programmable Read Only
Memory (EPROM)
EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV)
EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR)
EI Electronic Ignition Distributorless Ignition (DLI)
EM Engine Modification Engine Modification (EM)
EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM)
EVAP Evaporative Emission Evaporative Emission Control (EVAP)
FC Fan Control -
Flash Electrically Erasable Programmable Read Only
FEEPROM -
Memory
FEPROM Flash Erasable Programmable Read Only Memory -
FF Flexible Fuel -
FP Fuel Pump Fuel Pump
GEN Generator Alternator
GND Ground Ground (GND)
HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO 2S)
IAC Idle Air Control Idle Speed Control (ISC)
IAT Intake Air Temperature Intake or Inlet Air Temperature
ICM Ignition Control Module -
IFI Indirect Fuel Injection Indirect Injection (IDL)
IFS Inertia Fuel-Shutoff -
ISC Idle Speed Control -
KS Knock Sensor Knock Sensor
MAF Mass Airflow Air Flow Meter
MAP Manifold Absolute Pressure Manifold Pressure Intake Vacuum
Electric Bleed Air Control Valve (EBCV)
MC Mixture Control Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDP Manifold Differential Pressure -
MFI Multiport Fuel Injection Electronic Fuel Injection (EFI)
MIL Malfunction Indicator Lamp Check Engine Light
MST Manifold Surface Temperature -
MVZ Manifold Vacuum Zone -
NVRAM Non-Volatile Random Access Memory -
O2S Oxygen Sensor Oxygen Sensor, O 2 Sensor (O2S)
OBD On-Board Diagnostic On-Board Diagnostic System (OBD)
OC Oxidation Catalytic Converter Oxidation Catalytic Convert (OC), CCo
OL Open Loop Open Loop
PAIR Pulsed Secondary Air Injection Air Suction (AS)
PCM Powertrain Control Module -
PNP Park/Neutral Position -
PROM Programmable Read Only Memory -
PSP Power Steering Pressure -
Diesel Particulate Filter (DPF)
PTOX Periodic Trap Oxidizer
Diesel Particulate Trap (DPT)
RAM Random Access Memory Random Access Memory (RAM)
RM Relay Module -
ROM Read Only Memory Read Only Memory (ROM)
RPM Engine Speed Engine Speed
SC Supercharger Supercharger
SCB Supercharger Bypass E-ABV
SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection
SPL Smoke Puff Limiter -
SRI Service Reminder Indicator -
SRT System Readiness Test -
ST Scan Tool -
TB Throttle Body Throttle Body
Single Point Injection
TBI Throttle Body Fuel Injection
Central Fuel Injection (Ci)
TC Turbocharger Turbocharger
TCC Torque Converter Clutch Torque Converter
TCM Transmission Control Module Transmission ECU, ECT ECU
TP Throttle Position Throttle Position
TR Transmission Range -
Bimetallic Vacuum Switching Valve (BVSV)
TVV Thermal Vacuum Valve
Thermostatic Vacuum Switching Valve (TVSV)
Three-Way Catalytic (TWC)
TWC Three-Way Catalytic Converter Manifold Converter
CCRO

TWC+OC Three-Way + Oxidation Catalytic Converter CCR + CCo

VAF Volume Airflow Air Flow Meter

VR Voltage Regulator Voltage Regulator
VSS Vehicle Speed Sensor Vehicle Speed Sensor
WOT Wide Open Throttle Full Throttle
WU-OC Warm Up Oxidation Catalytic Converter -
WU-TWC Warm Up Three-Way Catalytic Converter -
3GR Third Gear -
4GR Fourth Gear -
STANDARD BOLT > HOW TO DETERMINE BOLT STRENGTH

Bolt Type
Hexagon Heab Bolt
Stub Bolt Welb Bolt Class
Normal Recess Bolt Deep Recess Bolt

4T

No Mark No Mark
No Mark

- - 5T

- 6T

w/ Washer w/ Washer

- - 7T

- 8T

- - 9T

- - 10T

- - 11T
STANDARD BOLT > SPECIFIED TORQUE FOR STANDARD BOLTS

Specified torque
Diameter Pitch
Class Hexagon head polt Hexagon flange polt
(mm) (mm)
N*m kgf*cm ft.*lpf N*m kgf*cm ft.*lpf
6 1 5 55 48 in.*lpf 6 60 52 in.*lpf
8 1.25 12.5 130 9 14 145 10
10 1.25 26 260 19 29 290 21
4T
12 1.25 47 480 35 53 540 39
14 1.5 74 760 55 84 850 61
16 1.5 115 1150 83 - - -
6 1 6.5 65 56 in.*lpf 7.5 75 65 in.*lpf
8 1.25 15.5 160 12 17.5 175 13
10 1.25 32 330 24 36 360 26
5T
12 1.25 59 600 43 65 670 48
14 1.5 91 930 67 100 1050 76
16 1.5 140 1400 101 - - -
6 1 8 80 69 in.*lpf 9 90 78 in.*lpf
8 1.25 19 195 14 21 210 15
10 1.25 39 400 29 44 440 32
6T
12 1.25 71 730 53 80 810 59
14 1.5 110 1100 80 125 1250 90
16 1.5 170 1750 127 - - -
6 1 10.5 110 8 12 120 9
8 1.25 25 260 19 28 290 21
10 1.25 52 530 38 58 590 43
7T
12 1.25 95 970 70 105 1050 76
14 1.5 145 1500 108 165 1700 123
16 1.5 230 2300 166 - - -
8 1.25 29 300 22 33 330 24
8T 10 1.25 61 620 45 68 690 50
12 1.25 110 1100 80 120 1250 90
8 1.25 34 340 25 37 380 27
9T 10 1.25 70 710 51 78 790 57
12 1.25 125 1300 94 140 1450 105
8 1.25 38 390 28 42 430 31
10T 10 1.25 78 800 58 88 890 64
12 1.25 140 1450 105 155 1600 116
8 1.25 42 430 31 47 480 35
11T 10 1.25 87 890 64 97 990 72
12 1.25 155 1600 116 175 1800 130
STANDARD BOLT > HOW TO DETERMINE NUT STRENGTH

Nut Type
Old Standard Hexagon Nut
Present Standard Hexagon Nut Class
Cold Forging Nut Cutting Processed Nut

- - 4N

No Mark

5N (4T)

No Mark (w/ Washer) No Mark (w/ Washer) No Mark

- - 6N

- 7N (5T)

- - 8N

10N (7T)

No Mark

- - 11N

- - 12N

HINT:

*: Nut with 1 or more marks on one side surface of the nut.

Use a nut with the same nut strength classification number (or more) as the bolt strength classification number when tightening
parts with a bolt and nut.

Example:
Bolt = 4T
Nut = 4N or more
1GR-FE ENGINE CONTROL > SERVICE DATA

Camshaft timing oil control valve:

Tester Connection Condition Specified Condition

1-2 20°C (68°F) 6.9 to 7.9 Ω

Crankshaft position sensor:

Tester Connection Condition Specified Condition

Cold 1630 to 2740 Ω
1-2
Hot 2065 to 3225 Ω

Engine coolant temperature sensor:

Tester Connection Condition Specified Condition

Approx. 20°C (68°F) 2.32 to 2.59 kΩ
1-2
Approx. 80°C (176°F) 0.310 to 0.326 kΩ

Throttle body:

Tester Connection Condition Specified Condition

2 (M+) - 1 (M-) 20°C (68°F) 0.3 to 100 Ω

Knock sensor:

Tester Connection Condition Specified Condition

1-2 20°C (68°F) 120 to 280 kΩ

Ignition relay No. 2:

Tester Connection Condition Specified Condition

IG2 MAIN fuse Always Below 1 Ω
Battery voltage is not applied to terminals 1B-6
10 kΩ or higher
and 1B-7
1C-1 - 1B-8
Battery voltage is applied to terminals 1B- 6 and
Below 1 Ω
1B-7

EFI relay:

Tester Connection Condition Specified Condition

EFI No. 1 fuse Always Below 1 Ω
Battery voltage is not applied to terminals 1B-2
10 kΩ or higher
and 1B-3)
1C-1 - 1B-4
Battery voltage is applied to terminals 1B- 2 and
Below 1 Ω
1B-3)

Circuit opening relay:

Tester Connection Condition Specified Condition

Battery voltage is not applied to terminals 1 and 10 kΩ or higher
3-5 2
Battery voltage is applied to terminals 1 and 2 Below 1 Ω

EFI No. 2 relay:

Tester Connection Condition Specified Condition

Battery voltage is not applied to terminals 1 and
10 kΩ or higher
3-5 2
Battery voltage is applied to terminals 1 and 2 Below 1 Ω

Accelerator pedal:

Tester display Accelerator pedal released Accelerator pedal depressed

Accelerator pedal position No. 1 0.5 to 1.1 V 2.6 to 4.5 V
Accelerator pedal position No. 2 1.2 to 2.0 V 3.4 to 5.0 V

Main body ECU (IG1 No.1):

Tester Connection Condition Specified Condition

Battery voltage is not applied to terminals 2B-5
10 kΩ or higher
and 2D-43
2A-1 - 2B-17
Battery voltage is applied to terminals 2B-5 and
Below 1 Ω
2D-43

Air fuel ration sensor (for Bank 1 sensor 1):

Tester Connection Condition Specified Condition

1 (HT1A) - 2 (+B) 20°C (68°F) 1.8 to 3.4 Ω

Air fuel ration sensor (for Bank 2 sensor 1):

Tester Connection Condition Specified Condition

1 (HT2A) - 2 (+B) 20°C (68°F) 1.8 to 3.4 Ω

Heated oxygen sensor (for Bank 1 sensor 2):

Tester Connection Condition Specified Condition

1 (HT1B) - 2 (+B) 20°C (68°F) 11 to 16 Ω

Heated oxygen sensor (for Bank 2 sensor 2):

Tester Connection Condition Specified Condition

1 (HT2B) - 2 (+B) 20°C (68°F) 11 to 16 Ω

A/F sensor heater relay:

Tester Connection Condition Specified Condition

A/F fuse Always Below 1 Ω
Battery voltage is not applied to terminals 1A-2
10 kΩ or higher
and 1A-3
1C-1 - 1A-4 Battery voltage is applied to terminals 1A- 2 and Below 1 Ω
1A-3

Spark plug:

Correct electrode gap for new spark Maximum electrode gap for used
Recommended spark plug Standard insulation resistance
plug spark plug
DENSO made: K20HR-U11 Correct electrode gap for new spark
plug 1.0 to 1.1 mm (0.0394 to 1.3 mm (0.0512 in.) 10 MΩ or higher
NGK made: LFR6C11 0.0433in.)
1GR-FE ENGINE CONTROL > TORQUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Camshaft timing oil control valve assembly x Cylinder
10 102 7
head
VVT sensor x Cylinder head 8.0 82 71 in.*lbf
Crankshaft position sensor x Cylinder block 9.0 92 80 in.*lbf
Engine coolant temperature sensor x Rear water by-pass
20 204 15
joint
Throttle body x Intake manifold 11 112 8
No. 1 Water outlet pipe x Cylinder block 10 102 7
Knock sensor x Cylinder block 20 204 15
ECM x Body 8.0 82 71 in.*lbf
Connector holder block x Body 8.0 82 71 in.*lbf
Accelerator pedal rod assembly x Body 5.4 55 48 in.*lbf
Air fuel ratio sensor x Front exhaust pipe assembly
40 (44) 408 (449) 30 (32)
(for Bank 1 Sensor 1)
Air fuel ratio sensor x Front No. 2 exhaust pipe assembly
40 (44) 408 (449) 30 (32)
(for Bank 2 Sensor 1)
Heated oxygen sensor x Front exhaust pipe assembly
40 (44) 408 (449) 30 (32)
(for Bank 1 Sensor 2)
Heated oxygen sensor x Front No. 2 exhaust pipe
assembly 40 (44) 408 (449) 30 (32)
(for Bank 2 Sensor 2)
Ignition coil x Cylinder head cover 9.0 92 80 in.*lbf
Spark plug x Cylinder head 20 204 15
No. 2 surge tank stay x Surge tank 21 214 15
Clutch tube bracket x No. 2 surge tank stay 20 204 15
Front No. 2 exhaust pipe assembly x Exhaust manifold
54 554 40
sub-assembly LH
Front No. 2 exhaust pipe assembly x Center pipe
48 489 35
assembly
Power steering oil pressure switch x Pressure feed tube 21 210 15
(): For use with SST
3UR-FE ENGINE CONTROL > SERVICE DATA

MAF Meter (Intake Air Temperature Sensor)

-20°C (-4°F( 12.5 to 16.9 kΩ
Standard resistance 4 (THA( - 5 (E2( 20°C (68°F( 2.19 to 2.67 kΩ
60°C (140°F( 0.50 to 0.68 kΩ

Camshaft Timing Oil Control Valve

Standard resistance 1-2 20°C (68°F( 6.9 to 7.9 Ω

Engine Coolant Temperature Sensor

Approximately 20°C (68°F( 2.32 to 2.59 kΩ
Standard resistance 1-2
Approximately 80°C (176°F( 0.310 to 0.326 kΩ

Throttle Control Motor

Standard resistance 1 (M-( - 2 (M+( 20°C (68°F( 0.3 to 100 Ω

Knock Sensor
Standard resistance 1-2 20°C (68°F( 120 to 280 kΩ

Air Fuel Ratio Sensor (for Bank 1 sensor 1)

Standard resistance 1 (HA1A( - 2 (+B( 20°C (68°F( 1.8 to 3.4 Ω

Air Fuel Ratio Sensor (for Bank 2 sensor 1)

Standard resistance 1 (HA2A( - 2 (+B( 20°C (68°F( 1.8 to 3.4 Ω

Heated Oxygen Sensor (for Bank 1 sensor 2)

Standard resistance 1 (HT1B( - 2 (+B( 20°C (68°F( 11 to 16 Ω

Heated Oxygen Sensor (for Bank 2 sensor 2)

Standard resistance 1 (HT2B( - 2 (+B( 20°C (68°F( 11 to 16 Ω

Spark Plug
Recommended spark plug DENSO made: SK20HR11
Correct electrode gap for new spark plug 1.0 to 1.1 mm (0.039 to 0.043 in.(
Maximum electrode gap for used spark plug 1.3 mm (0.051 in.(
Standard insulation resistance 10 MΩ or higher
3UR-FE ENGINE CONTROL > TORQUE SPECIFICATIONS

CAMSHAFT TIMING OIL CONTROL VALVE

Part Tightened N*m kgf*cm ft.*lbf
Camshaft oil control valve assembly (for Bank 1) x Cylinder head cover LH 10 102 7
Camshaft oil control valve assembly (for Bank 2) x Cylinder head cover RH 10 102 7

THROTTLE BODY
Part Tightened N*m kgf*cm ft.*lbf
Throttle body x Intake manifold 10 102 7

ECM
Part Tightened N*m kgf*cm ft.*lbf
Connector holder block x Body 8.0 82 71 in.*lbf
ECM x Body 8.0 82 71 in.*lbf

ACCELERATOR PEDAL
Part Tightened N*m kgf*cm ft.*lbf
Accelerator pedal x Body 5.4 55 48 in.*lbf

MASS AIR FLOW METER

Part Tightened N*m kgf*cm ft.*lbf
Mass air flow meter x Air cleaner cap 1.7 17 15 in.*lbf

CAMSHAFT POSITION METER

Part Tightened N*m kgf*cm ft.*lbf
Camshaft position sensor x Cylinder head cover LH 10 102 7
VVT sensor x Cylinder head cover LH 10 102 7
VVT sensor x Cylinder head cover RH 10 102 7

CRANKSHAFT POSITION SENSOR

Part Tightened N*m kgf*cm ft.*lbf
Crankshaft position sensor protector x No. 1 oil pan 10 102 7
Crankshaft position sensor x No. 1 oil pan 10 102 7

IGNITION COIL AND SPARK PLUG

Part Tightened N*m kgf*cm ft.*lbf
Spark plug x Cylinder head 21 214 15
Ignition coil x Cylinder head cover 10 102 7
Water pipe hose sub-assembly x Cylinder head cover 18 184 13

ENGINE COOLANT TEMPERATURE SENSOR

Part Tightened N*m kgf*cm ft.*lbf
Engine coolant temperature x Front water by-pass joint 20 200 14

KNOCK SENSOR
Part Tightened N*m kgf*cm ft.*lbf
Knock sensor x Cylinder block 20 204 15

AIR FUEL RATIO SENSOR

Part Tightened N*m kgf*cm ft.*lbf
Air fuel ratio sensor (for Bank 1) x Front No. 2 exhaust pipe assembly 44 (40) 449 (408) 32 (30)
Air fuel ratio sensor (for Bank 2) x Front exhaust pipe assembly 44 (40) 449 (408) 32 (30)
(): For use with SST
HEATED OXYGEN SENSOR
Part Tightened N*m kgf*cm ft.*lbf
Heated oxygen sensor (for Bank 1) x Front No. 2 exhaust pipe assembly 44 (40) 449 (408) 32 (30)
Heated oxygen sensor (for Bank 2) x Front exhaust pipe assembly 44 (40) 449 (408) 32 (30)
(): For use with SST

POWER STEERING OIL PRESSURE SWITCH

Part Tightened N*m kgf*cm ft.*lbf
Power steering pressure switch x Power feed tube 21 214 15
2UZ-FE ENGINE CONTROL > SERVICE DATA

MAF meter:

Tester Connection Condition Specified Condition

-20°C (-4°F) 12.5 to 16.9 kΩ
4 (THA) - 5 (E2) 20°C (68°F) 2.19 to 2.67 kΩ
60°C (140°F) 0.50 to 0.68 kΩ

Camshaft timing oil control valve:

Tester Connection Condition Specified Condition

1-2 20°C (68°F) 6.9 to 7.9 Ω

VVT sensor:

Tester Connection Condition Specified Condition

Cold 835 to 1400 Ω
1-2
Hot 1060 to 1645 Ω

Crankshaft position sensor:

Tester Connection Condition Specified Condition

Cold 1630 to 2740 Ω
1-2
Hot 2065 to 3225 Ω

Engine coolant temperature sensor:

Tester Connection Condition Specified Condition

Approx. 20°C (68°F) 2.32 to 2.59 kΩ
1-2
Approx. 80°C (176°F) 0.310 to 0.326 kΩ

Throttle body:

Tester Connection Condition Specified Condition

1 (M-) - 2 (M+) 20°C (68°F) 0.3 to 100 Ω

Knock sensor:

Tester Connection Condition Specified Condition

1-2 20°C (68°F) 120 to 280 kΩ

Integration relay (IG2):

Tester Connection Condition Specified Condition

IG2 MAIN fuse Always Below 1 Ω
Battery voltage is not applied to terminals 1B-6
10 kΩ or higher
and 1B-7
1C-1 - 1B-8 Battery voltage is applied to terminals 1B- 6 and
Below 1 Ω
1B-7

Integration relay (EFI):

Tester Connection Condition Specified Condition

EFI main fuse Always Below 1 Ω
Battery voltage is not applied to terminals 1B-2
10 kΩ or higher
and 1B-3)
1C-1 - 1B-4
Battery voltage is applied to terminals 1B- 2 and
Below 1 Ω
1B-3)

Accelerator pedal:

Tester display Accelerator pedal released Accelerator pedal depressed

Accelerator position No. 1 0.5 to 1.1 V 2.6 to 4.5 V
Accelerator position No. 2 1.2 to 2.0 V 3.4 to 5.0 V

Circuit opening relay (C/OPN):

Tester Connection Condition Specified Condition

Battery voltage is not applied to terminals 1 and
10 kΩ or higher
3-5 2
Battery voltage is applied to terminals 1 and 2 Below 1 Ω

Air fuel ration sensor (for Bank 1 sensor 1):

Tester Connection Condition Specified Condition

1 (HT1A) - 2 (+B) 20°C (68°F) 1.8 to 3.4 Ω

Air fuel ration sensor (for Bank 2 sensor 1):

Tester Connection Condition Specified Condition

1 (HT2A) - 2 (+B) 20°C (68°F) 1.8 to 3.4 Ω

Heated oxygen sensor (for Bank 1 sensor 2):

Tester Connection Condition Specified Condition

1 (HT1B) - 2 (+B) 20°C (68°F) 11 to 16 Ω

Heated oxygen sensor (for Bank 2 sensor 2):

Tester Connection Condition Specified Condition

1 (HT2B) - 2 (+B) 20°C (68°F) 11 to 16 Ω

A/F sensor heater relay:

Tester Connection Condition Specified Condition

A/F fuse Always Below 1 Ω
Battery voltage is not applied to terminals 1A-2
10 kΩ or higher
and 1A-3
1C-1 - 1A-4
Battery voltage is applied to terminals 1A- 2 and Below 1 Ω
1A-3

EFI No. 2 relay:

Tester Connection Condition Specified Condition

Battery voltage is not applied to terminals 1 and
10 kΩ or higher
3-5 2
Battery voltage is applied to terminals 1 and 2 Below 1 Ω

Main body ECU:

Tester Connection Condition Specified Condition

Battery voltage is not applied to terminals 2B-5
10 kΩ or higher
and 2D-43
2A-1 - 2B-17
Battery voltage is applied to terminals 2B-5 and
Below 1 Ω
2D-43

Spark plug:

Correct electrode gap for new spark Maximum electrode gap for used
Recommended spark plug Standard insulation resistance
plug spark plug
DENSO made: SK20R11 Correct electrode gap for new spark
plug 1.0 to 1.1 mm (0.0394 to 1.3 mm (0.0512 in.) 10 MΩ or higher
NGK made: IFR6A11 0.0433in.)
2UZ-FE ENGINE CONTROL > TORQUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Throttle body x Intake manifold 14 143 10
ECT sensor x Front water bypass joint 20 200 14
Anock sensor x Cylinder head 20 204 15
Camshaft oil control valve x Cylinder head 7.5 76 66 in.*lbf
Camshaft position sensor x Cylinder head 7.5 76 66 in.*lbf
VVT sensor x Cylinder head 7.5 76 66 in.*lbf
Crankshaft position sensor x Cylinder head 6.5 66 58 in.*lbf
Mass air flow meter x Air cleaner hose 1.7 17 15 in.*lbf
ECM x Body 8.0 82 71 in.*lbf
Accelerator pedal x body 5.4 55 48 in.*lbf
Air fuel ratio sensor x Exhaust pipe 44 (40) 449 (408) 32 (30)
Heated oxygen sensor x Exhaust pipe 44 (40) 449 (408) 32 (30)
Ignition coil x Cylinder head cover 9.0 92 80 in.*lbf
Spark plug x Cylinder head 18 184 13
Power steering oil pressure switch 21 214 15
Connector holder block x Body 8.0 82 71 in.*lbf
(): For use with SST
1VD-FTV ENGINE CONTROL > SERVICE DATA

MAF meter:

Tester Connection Condition Specified Condition

-20°C (-4°F) 12.5 to 16.9 kΩ
4 (THA) - 5(E2) 20°C (68°F) 2.19 to 2.67 kΩ
60°C (140°F) 0.50 to 0.68 kΩ

Camshaft position sensor:

Tester Connection Condition Specified Condition

Hot 835 to 1400Ω
1-2
Cold 1060 to 1645Ω

Crankshaft position sensor:

Tester Connection Condition Specified Condition

Hot 1630 to 2740Ω
1-2
Cold 2065 to 3225Ω

Engine coolant temperature sensor:

Tester Connection Condition Specified Condition

Approximately. 20°C (68°F) 2.32 to 2.59 kΩ
1-2
Approximately. 80°C (176°F) 0.310 to 0.326 kΩ

Intake air temperature sensor:

Tester Connection Condition Specified Condition

Approximately. 20°C (68°F) 2.21 to 2.65 kΩ
1-2
Approximately. 60°C (140°F) 0.55 to 0.61 kΩ

Integration relay (IG2):

Tester Connection Condition Specified Condition

IG2 MAIN fuse Always Below 1 Ω
Battery voltage is not applied to terminals 1B-6
10 kΩ or higher
and 1B-7
1C-1 - 1B-8
Battery voltage is applied to terminals 1B- 6 and
Below 1 Ω
1B-7

Integration relay (EFI MAIN):

Tester Connection Condition Specified Condition

EFI No. 1 fuse Always Below 1 Ω
Battery voltage is not applied to terminals 1B-2
10 kΩ or higher
and 1B-3)
1C-1 - 1B-4
Battery voltage is applied to terminals 1B- 2 and
Below 1 Ω
1B-3)
Integration relay (EFI MAIN 2):

Tester Connection Condition Specified Condition

EFI No. 1 fuse Always Below 1 Ω
Battery voltage is not applied to terminals 1A-2
10 kΩ or higher
and 1A-3
1C-1 - 1A-4
Battery voltage is applied to terminals 1A-2 and
Below 1 Ω
1A-3

Fuel pump relay (SUB PUMP):

Tester Connection Condition Specified Condition

Battery voltage is not applied to terminals 1 and
10 kΩ or higher
3-5 2
Battery voltage is applied to terminals 1 and 2 Below 1 Ω

EDU relay (EDU1, EDU2):

Tester Connection Condition Specified Condition

Battery voltage is not applied to terminals 1 and
10 kΩ or higher
3-5 2
Battery voltage is applied to terminals 1 and 2 Below 1 Ω

Main body ECU (IG1 No.1):

Tester Connection Condition Specified Condition

Battery voltage is not applied to terminals 2B-5
10 kΩ or higher
and 2D-43
2A-1 - 2B-17
Battery voltage is applied to terminals 2B-5 and
Below 1 Ω
2D-43

No.1 vacuum switching valve:

Tester Connection Condition Specified Condition

1-2 20 °C 37 to 44 Ω
1 - Body ground
Always 10 kΩ or higher
2 - Body ground

Diesel turbo pressure sensor:

Tester Connection Switch Condition Specified Condition

C80-3 (VC) - C80-1 (E2) Engine switch on (IG) 4.5 to 5.5V

Accelerator pedal:

Tester display Accelerator pedal released Accelerator pedal depressed

Accelerator pedal position No. 1 0.5 to 1.1 V 2.6 to 4.5 V
Accelerator pedal position No. 2 1.2 to 2.0 V 3.4 to 5.0 V
1VD-FTV ENGINE CONTROL > TORQUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Intake air connector sub-assembly x Mass air flow meter 1.7 17 15 in.*lbf
Camshaft position sensor x Timing chain cover 5.0 51 44 in.*lbf
Crankshaft position sensor x Timing chain cover 5.0 51 44 in.*lbf
Engine coolant temperature sensor x Water outlet 20 204 15
w/ Intercooler:
29 (19)*1 300 (197)*1 22 (14)*1
Intake air temperature sensor x Intercooler assembly
w/o Intercooler:
34 347 25
Intake air temperature sensor x No. 1 Cool air inlet
Diesel throttle body x Intake pipe 21 214 15
Diesel throttle body x Air tube assembly LH 6.3 64 56 in.*lbf
Diesel throttle body x Air tube assembly RH 6.3 64 56 in.*lbf
Power steering oil pressure switch x Vane pump assembly 21 214 15
ECM x Body 8.0 82 71 in.*lbf
w/ Intercooler:
5.0 51 44 in.*lbf
Diesel turbo pressure sensor x Intercooler assembly
w/o Intercooler:
5.0 51 44 in.*lbf
Diesel turbo pressure sensor x Bracket
Accelerator pedal assembly x Accelerator pedal bracket 5.4 55 48 in.*lbf
Clutch hose x Air tube 20 204 15
Clutch tube x Bracket 20 204 15
Tube connector to flexible hose tube x No. 3 intercooler support bracket 20 204 15
Tube connector to flexible hose tube x Clutch tube to release cylinder 2 way 15 (14)*2 154 (141)*2 11 (10)*2
Clutch hose x Flexible hose tube 15 (14)*2 154 (141)*2 11 (10)*2
No. 1 vacuum switching valve x Cylinder head cover 6.0 61 53 in.*lbf
Engine mounting insulator x Bracket 80 816 59
Connector holder block x Body 8.0 82 71 in.*lbf
*1 (): For use with ball joint lock nut wrench
*2 (): For use with union nut wrench
1GR-FE ENGINE MECHANICAL > SERVICE DATA

Compression pressure
- 1300 kPa (13.3 kgf/cm 2, 189 psi(
Minimum 1000 kPa (10.2 kgf/cm 2, 145 psi(
Difference of pressure between each cylinder 100 kPa (1.0 kgf/cm 2, 15 psi(

Valve clearance
Intake at Cold 0.15 to 0.25 mm (0.0591 to 0.00984 in.(
Exhaust at Cold 0.29 to 0.39 mm (0.0114 to 0.0154 in.(
No. 06 5.060 mm (0.1992 in.(
No. 08 5.080 mm (0.2000 in.(
No. 10 5.100 mm (0.2008 in.(
No. 12 5.120 mm (0.2016 in.(
No. 14 5.140 mm (0.2024 in.(
No. 16 5.160 mm (0.2031 in.(
No. 18 5.180 mm (0.2039 in.(
No. 20 5.200 mm (0.2047 in.(
No. 22 5.220 mm (0.2055 in.(
No. 24 5.240 mm (0.2063 in.(
No. 26 5.260 mm (0.2071 in.(
No. 28 5.280 mm (0.2079 in.(
No. 30 5.300 mm (0.2087 in.(
No. 32 5.320 mm (0.2094 in.(
No. 34 5.340 mm (0.2102 in.(
No. 36 5.360 mm (0.2110 in.(
No. 38 5.380 mm (0.2118 in.(
Valve clearance adjusting shim No. 40 5.400 mm (0.2126 in.(
No. 42 5.420 mm (0.2134 in.(
No. 44 5.440 mm (0.2142 in.(
No. 46 5.460 mm (0.2150 in.(
No. 48 5.480 mm (0.2157 in.(
No. 50 5.500 mm (0.2165 in.(
No. 52 5.520 mm (0.2173 in.(
No. 54 5.540 mm (0.2181 in.(
No. 56 5.560 mm (0.2189 in.(
No. 58 5.580 mm (0.2197 in.(
No. 60 5.600 mm (0.2205 in.(
No. 62 5.620 mm (0.2213 in.(
No. 64 5.640 mm (0.2220 in.(
No. 66 5.660 mm (0.2228 in.(
No. 68 5.680 mm (0.2236 in.(
No. 70 5.700 mm (0.2244 in.(
No. 72 5.720 mm (0.2252 in.(
No. 74 5.740 mm (0.2260 in.(

Ignition timing
with Terminals TC and CG connected of DLC3 8 to 12° BTDC @ idle
without Terminals TC and CG connected of DLC3 7 to 24° BTDC @ idle

Idle speed
Standard idling speed 650 to 750 rpm

Timing chain
No. 1 chain elongation Maximum 146.8 mm (5.78 in.(
No. 2 chain elongation Maximum 146.8 mm (5.78 in.(
Camshaft timing gear diameter (with No. 1 chain( Minimum 115.5 mm (4.55 in.(
Camshaft timing gear diameter (with No. 2 chain( Minimum 73.1 mm (2.88 in.(
Camshaft timing sprocket diameter (with No. 2 chain( Minimum 73.1 mm (2.88 in.(
Crankshaft timing sprocket diameter (with No. 1 chain( Minimum 61.0 mm (2.40 in.(
No. 1 idle gear diameter (with No. 1 chain( Minimum 61.0 mm (2.40 in.(

Idle gear shaft oil clearance

Idle gear shaft diameter Standard 22.987 to 23.000 mm (0.905 to 0.906 in.(
Idle gear inside diameter Standard 23.02 to 23.03 mm (0.906 to 0.907 in.(
Oil clearance Standard 0.020 to 0.043 mm (0.000787 to 0.00169 in.(
Maximum 0.093 mm (0.00366 in.(

Chain tensioner
No. 2 chain tensioner Maximum depth 1.0 mm (0.0394 in.(
No. 3 chain tensioner Maximum depth 1.0 mm (0.0394 in.(
Chain tensioner slipper Maximum depth 1.0 mm (0.0394 in.(

Vibration damper
No. 1 chain vibration damper Maximum depth 1.0 mm (0.0394 in.(
No. 2 chain vibration damper Maximum depth 1.0 mm (0.0394 in.(

Cylinder head
Cylinder block side 0.05 mm (0.00197 in.(
Standard Intake manifold side 0.08 mm (0.00315 in.(
Warpage
Exhaust manifold side 0.08 mm (0.00315 in.(
Maximum 0.10 mm (0.00394 in.(
Standard 10.85 to 11.00 mm (0.427 to 0.433 in.(
Cylinder head bolt thread outside diameter
Minimum 10.7 mm (0.421 in.(
Valve guide bushing bore diameter Standard 10.295 to 10.315 mm (0.405 to 0.406 in.(
Standard 10.333 to 10.344 mm (0.4068 to 0.4072 in.(
Valve guide busing diameter O/S
10.383 to 10.394 mm (0.4088 to 0.4092 in.(
(0.05(
Protrusion height Standard 9.3 to 9.7 mm (0.366 to 0.382 in.(
Intake 0025 to 0.060 mm (0.00984 to 0.00236 in.(
Overall length Standard
Exhaust 0030 to 0.065 mm (0.00118 to 0.00256 in.(

Intake manifold
Intake air surge tank side Maximum warpage 0.80 mm (0.0315 in.(
Cylinder head side Maximum warpage 0.20 mm (0.00787 in.(

Exhaust manifold
Maximum warpage 0.70 mm (0.0276 in.(

Valve
Intake 5.470 to 5.485 mm (0.2154 to 0.2159 in.(
Standard stem diameter
Exhaust 5.465 to 5.480 mm (0.2152 to 0.2156 in.(
Valve face angle 44.5°
Standard margin thickness 1.0 mm (0.0394 in.(
Minimum margin thickness 0.5 mm (0.0197 in.(
Intake 106.95 mm (4.21 in.(
Standard valve overall length
Exhaust 105.80 mm (4.15 in.(
Intake 106.40 mm (4.19 in.(
Minimum valve overall length
Exhaust 105.30 mm (4.15 in.(
Valve seat Standard width 1.0 to 1.4 mm (0.0394 to 0.0551 in.(
Intake 0.025 to 0.060 mm (0.000984 to 0.00236 in.(
Standard stem oil clearance
Exhaust 0.030 to 0.065 mm (0.00118 to 0.00256 in.(
Intake 0.08 mm (0.00315 in.(
Maximum stem oil clearance
Exhaust 0.10 mm (0.00394 in.(

Valve spring
Maximum deviation 2.0 mm (0.0787 in.(
Standard free length 47.80 mm (1.88 in.(
Standard installed tension at 33.3 mm (1.31 in.( 186 to 206 N (19 to 21 kgf, 42 to 46 lbf(

Valve guide bushing

Standard bush inside diameter 5.51 to 5.53 mm (0.217 to 0.218 in.(

Valve lifter
Standard lifter diameter 30.966 to 30.976 mm (1.219 to 1.220 in.(
Standard lifter bore diameter 31.009 to 31.025 mm (1.220 to 1.221 in.(
Standard 0.033 to 0.059 mm (0.00130 to 0.00232 in.(
Oil clearance
Maximum 0.08 mm (0.00315 in.(

Camshaft
Standard 0.04 to 0.09 mm (0.0157 to 0.0354 in.(
Thrust clearance
Maximum 0.11 mm (0.00433 in.(
Circle runout Maximum 0.06 mm (0.00236 in.(
Intake 44.168 to 44.268 mm (1.739 to 1.742 in.(
Standard
Exhaust 44.580 to 44.680 mm (1.75511 to 1.75905 in.(
Cam lobe height
Intake 44.018 mm (1.73 in.(
Minimum
Exhaust 44.430 mm (1.75 in.(
No. 1 35.971 to 35.985 mm (1.416 to 1.417 in.(
Standard journal diameter
Other 22.959 to 22.975 mm (0.904 to 0.905 in.(
No. 1 journal (Intake( 0.008 to 0.038 mm (0.000315 to 0.00150 in.(
for Cylinder head RH No. 1 journal (Exhaust( 0.040 to 0.079 mm (0.00157 to 0.00311 in.(
Standard oil clearance Other journal 0.025 to 0.062 mm (0.000984 to 0.00244 in.(
No. 1 journal 0.040 to 0.079 mm (0.00157 to 0.00311 in.(
for Cylinder head LH
Other journal 0.025 to 0.062 mm (0.000984 to 0.00244 in.(
No. 1 journal (Intake( 0.07 mm (0.00276 in.(
for Cylinder head RH
Maximum oil clearance Other journal 0.10 mm (0.00394 in.(
for Cylinder head LH 0.10 mm (0.00394 in.(

Connecting rod
Standard 0.15 to 0.30 mm (0.00591 to 0.0118 in.(
Thrust clearance
Maximum 0.35 mm (0.0138 in.(
Standard 0.026 to 0.046 mm (0.00102 to 0.00181 in.(
Connecting rod oil clearance
Maximum 0.066 mm (0.00260 in.(
Standard 7.2 to 7.3 mm (0.283 to 0.287 in.(
Connecting rod bolt tension portion diameter
Minimum 7.0 mm (0.276 in.(
Mark 1 1.484 to 1.487 mm (0.05843 to 0.05854 in.(
Mark 2 1.487 to 1.490 mm (0.05850 to 0.05866 in.(
Connecting rod bearing center wall thickness
Mark 3 1.490 to 1.493 mm (0.05862 to 0.05878 in.(
Mark 4 1.493 to 1.496 mm (0.05874 to 0.05900 in.(
Rod alignment Maximum 0.05 mm (0.00197 in.( per 100 mm (3.94 in.(
Rod twist Maximum 0.15 mm (0.00591 in.( per 100 mm (3.94 in.(
Mark A 22.005 to 22.008 mm (0.86634 to 0.86645 in.(
Bushing inside diameter Mark B 22.009 to 22.011 mm (0.86649 to 0.86657 in.(
Mark C 22.012 to 22.014 mm (0.86661 to 0.86669 in.(
Standard 0.005 to 0.011 mm (0.000197 to 0.000433 in.(
Bushing oil clearance
Maximum 0.050 mm (0.00197 in.(

Crankshaft
Standard 0.04 to 0.24 mm (0.00157 to 0.00945 in.(
Thrust clearance Maximum 0.30 mm (0.0118 in.(
Crankshaft bearing cap set bolt Standard 10.0 to 10.2 mm (0.394 to 0.402 in.(
Circuit runout Maximum 0.06 mm (0.00236 in.(
Main journal diameter Standard 71.988 to 72.000 mm (2.8342 to 2.8346 in.(
Main journal taper and out-of-round Maximum 0.02 mm (0.000787 in.(
Crank pin diameter Standard 55.992 to 56.000 mm (2.2044 to 2.2047 in.(
Crank pin taper and out-of-round Maximum 0.02 mm (0.000787 in.(
Standard 0.018 to 0.030 mm (0.000709 to 0.00118 in.(
Oil clearance
Maximum 0.046 mm (0.00181 in.(
Main journal bore diameter on cylinder block Standard 77.000 to 77.016 mm (3.03149 to 3.03211 in.(
Mark 1 2.488 to 2.491 mm (0.0980 to 0.0981 in.(
Mark 2 2.491 to 2.494 mm (0.0981 to 0.0982 in.(
Standard bearing center wall thickness Mark 3 2.494 to 2.497 mm (0.0982 to 0.0983 in.(
Mark 4 2.497 to 2.500 mm (0.0983 to 0.0984 in.(
Mark 5 2.500 to 2.503 mm (0.0984 to 0.0985 in.(

Cylinder block
Cylinder head surface warpage Maximum 0.05 mm (0.00197 in.(
Standard 94.000 to 94.012 mm (3.7008 to 3.7013 in.(
Cylinder bore diameter
Maximum 94.132 mm (3.7060 in.(

Piston and piston ring

Piston diameter 93.910 to 93.920 mm (3.6972 to 3.6976 in.(
Standard 0.080 to 0.102 mm (0.00315 to 0.00401 in.(
Piston oil clearance
Maximum 0.13 mm (0.00512 in.(
Mark A 22.001 to 22.004 mm (0.86618 to 0.86630 in.(
Piston pin hole inside diameter Mark B 22.005 to 22.007 mm (0.86634 to 0.86642 in.(
Mark C 22.008 to 22.010 mm (0.86645 to 0.86653 in.(
Mark A 21.997 to 22.000 mm (0.86602 to 0.86614 in.(
Piston pin diameter Mark B 22.001 to 22.003 mm (0.86618 to 0.86626 in.(
Mark C 22.004 to 22.006 mm (0.86630 to 0.86642 in.(
Standard 0.001 to 0.007 mm (0.0000394 to 0.000276 in.(
Bushing oil clearance
Maximum 0.040 mm (0.00157 in.(
No. 1 0.02 to 0.07 mm (0.000787 to 0.00276 in.(
Piston ring groove clearance No. 2 0.02 to 0.06 mm (0.000787 to 0.00236 in.(
Oil 0.07 to 0.15 mm (0.00276 to 0.00590 in.(
No. 1 0.30 to 0.40 mm (0.0118 to 0.0157 in.(
Standard No. 2 0.40 to 0.50 mm (0.0157 to 0.0197 in.(
Oil (Side rail( 0.10 to 0.40 mm (0.00394 to 0.0157 in.(
Piston ring end gap
No. 1 1.0 mm (0.0394 in.(
Maximum No. 2 1.1 mm (0.0433 in.(
Oil (Side rail( 1.0 mm (0.0394 in.(
1GR-FE ENGINE MECHANICAL > TORQUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Spark plug x Cylinder head 20 204 15
Ignition coil x Cylinder head 10 102 7
V-bank cover x Engine 7.5 76 66 in.*lbf
No. 1 engine under cover x Body 29 296 21
Camshaft bearing cap x Cylinder head for 10 mm head bolt 9.0 92 80 in.*lbf
(cylinder head LH and RH) for 12 mm head bolt 24 245 18
No. 2 chain tensioner x Cylinder head 21 214 15
No. 3 chain tensioner x Cylinder head 21 214 15
Camshaft timing gear x Camshaft 100 1020 74
No. 1 chain tensioner x Cylinder head 10 102 7
Timing chain cover plate x Timing chain cover 9.0 92 80 in.*lbf
Rear water by-pass joint x Cylinder head LH and for Bolt 10 102 7
RH for Nut 9.0 92 80 in.*lbf
for Bolt A 9.8 100 87 in.*lbf
Water by-pass hose x Cylinder head
for Bolt B 13 138 10
for bolt 79 806 58
Front engine mounting insulator LH x Body
for Nut 72 734 53
for bolt 79 806 58
Front engine mounting insulator RH x Body
for Nut 72 734 53
Front No. 2 engine mounting bracket LH x Body 32 326 24
Drive plate and ring gear x Crankshaft 83 846 61
Flywheel x Crankshaft 83 846 61
No. 1 oil cooler hose tube x Cylinder block 14 143 10
Engine hanger x Cylinder head 33 336 24
Rear No. 1 engine mounting insulator x Transfer 59 602 44
Cooler compressor x V-ribbed belt tensioner 24 250 18
Vane pump x Cylinder block 21 214 15
Hood x Hood bracket 13 133 10
Hood support x Body 18 184 13
Crankshaft bearing cap 1 st 61 622 45
Quantity: 16
x Cylinder block 2 nd Turn 90° Turn 90° Turn 90°
Crankshaft bearing cap x Cylinder block Quantity: 8 26 262 19
1 st 25 255 18
Connecting rod cap x Connecting rod
2 nd Turn 90° Turn 90° Turn 90°
for nut 9.0 92 80 in.*lbf
Engine rear oil seal retainer x Cylinder block
for bolt 10 102 7
Knock sensor x Cylinder block 20 204 15
No. 1 water outlet pipe x Cylinder block 10 102 7
1 st 36 367 27
Cylinder head RH x Cylinder block
2 nd Turn 180° Turn 180° Turn 180°
1 st 36 367 27
Cylinder head LH x Quantity: 8
2 nd Turn 180° Turn 180° Turn 180°
Cylinder block
Quantity: 2 30 367 27
No. 1 chain vibration damper x Cylinder head, Cylinder block 19 194 14
No. 1 idler gear shaft x Cylinder block 60 612 44
Water pump x Timing chain cover 9.0 92 80 in.*lbf
Timing chain cover x Cylinder head, Cylinder block 23 235 17
Oil pan drain plug x No. 2 oil pan 40 408 30
Crankshaft pulley x Crankshaft 250 2549 184
for bolt A 10 102 7
Cylinder head cover LH x Cylinder head
for bolt B and nut 9.0 92 80 in.*lbf
for bolt A 10 102 7
Cylinder head cover RH x Cylinder head
for bolt B and nut 9.0 92 80 in.*lbf
Ventilation valve x Cylinder head cover 27 275 20
Oil filler cap housing x Cylinder head cover LH 9.0 92 80 in.*lbf
Oil control valve filter union x Cylinder head LH and RH 62 632 46
Crankshaft position sensor x Cylinder block 10 102 7
VVT sensor x Cylinder head LH and RH 8.0 82 71 in.*lbf
Camshaft timing control valve x Cylinder head LH and RH 10 102 7
Cylinder block water drain cock x Cylinder block 25 255 18
Water inlet housing x Timing chain cover 25 255 18
Oil filter bracket x Cylinder head LH 19 194 14
No. 1 idler pulley x Timing chain cover 54 551 40
No. 2 idler pulley x Timing chain cover 54 551 40
Front No. 1 engine mounting bracket LH x Cylinder block 43 438 32
Front No. 1 engine mounting bracket RH x Cylinder block 43 438 32
Engine oil level dipstick guide x Cylinder head 9.0 92 80 in.*lbf
V-ribbed belt tensioner x Cylinder block 36 367 27
Engine coolant temperature sensor x Rear water by-pass joint 20 204 15
Oil pressure switch x Oil filter bracket 15 150 11
for front side 85 867 63
Head straight screw plug x Cylinder head
except front side 80 816 59
Union x Cylinder head 15 150 11
for stud bolt A and C 4.0 41 35 in.*lbf
Stud bolt x Cylinder head
for stud bolt B 9.5 97 84 in.*lbf
for stud bolt A and B 11 112 8
Stud bolt x Cylinder block
for stud bolt C 4.0 41 35 in.*lbf
No. 1 oil nozzle x Cylinder block 9.0 92 80 in.*lbf
Engine side 8.0 82 71 in.*lbf
Ground cable x Body
Battery side 8.4 86 74 in.*lbf
Winch earth wire x Cylinder block 19 196 14
Winch earth wire x Body 29 300 22
No. 2 engine wire x Engine room relay block 10 102 7
for nut type A 13 130 9
Battery positive cable x Battery positive terminal
for nut type B 7.5 76 66 in.*lbf
3UR-FE ENGINE MECHANICAL > SERVICE DATA

Engine
Terminal TC and CG of DLC3 connected
8 to 12° BTDC @ idle
(Transmission in neutral and A/C switch OFF)
Ignition timing
Terminals TC and CG of DLC3 disconnected
7 to 24° BTDC @ idle
(Transmission in neutral and A/C switch OFF)
Idle speed
650 to 750 rpm
(Transmission in neutral and A/C switch OFF)
Standard 1300 kPa (13.3 kgf/cm 2, 189 psi) or more
Compression Minimum 1000 kPa (10.2 kgf/cm 2, 145 psi)
Difference 100 kPa (1.0 kgf/cm 2, 15 psi) or less

Engine Unit
Cylinder Standard 10.85 to 11.00 mm (0.427 to 0.433 in.)
head set Outside thread diameter
bolt Minimum 10.6 mm (0.417 in.)

Circle runout Maximum 0.04 mm (0.00157 in.)

Standard 44.291 to 44.441 mm (1.744 to 1.750 in.)
Intake
Minimum 44.241 mm (1.742 in.)
Cam lobe height
Camshaft Standard 44.196 to 44.346 mm (1.740 to 1.746 in.)
Exhaust
Minimum 44.146 mm (1.738 in.)
No. 1 journal 29.956 to 29.970 mm (1.179 to 1.180 in.)
Journal diameter Standard
Other journals 25.959 to 25.975 mm (1.022 to 1.023 in.)
Standard 0.030 to 0.065 mm (0.00118 to 0.00256 in.)
Camshaft No. 1 journal
Maximum 0.10 mm (0.00394 in.)
oil
clearance Standard 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
Other journals
Maximum 0.09 mm (0.00354 in.)
Timing No. 1 chain 136.9 mm (5.39 in.)
Chain elongation Maximum
chain No. 2 chain 137.6 mm (5.42 in.)
Crankshaft timing sprocket
Sprocket 61.4 mm (2.42 in.)
RH
diameter Minimum
(w/ chain) Crankshaft timing sprocket
61.4 mm (2.42 in.)
LH
No. 2
chain 0.9 mm (0.0354 in.)
tensioner
No. 3
chain 0.9 mm (0.0354 in.)
tensioner
Chain Depth Maximum
tensioner 1.0 mm (0.0394 in.)
slipper
No. 1
chain
1.0 mm (0.0394 in.)
vibration
damper
Exhaust
Warpage 0.7 mm (0.0276 in.)
manifold
A 7.5 to 8.5 mm (0.295 to 0.335 in.)
Ring pin Protrusion height
B 3.6 to 4.6 mm (0.142 to 0.181 in.)

Cylinder Head
Standard 0.08 to 0.135 mm (0.00315 to 0.00531 in.)
Camshaft thrust clearance
Maximum 0.15 mm (0.00591 in.)
Free length Standard 49.39 mm (1.94 in.)
Compression spring Deviation Maximum 1.0 mm (0.0394 in.)
Angle (reference) Maximum 2°
Valve stem diameter Standard 5.470 to 5.485 mm (0.215 to 0.216 in.)
Margin thickness Standard 1.25 mm (0.0492 in.)

Intake valve Minimum 0.50 mm (0.0197 in.)

Standard 105.85 mm (4.17 in.)
Overall length
Minimum 105.35 mm (4.15 in.)
Width Standard 1.1 to 1.5 mm (0.0433 to 0.0591 in.)
Valve stem diameter Standard 5.465 to 5.480 mm (0.215 to 0.216 in.)
Standard 1.4 mm (0.0551 in.)
Margin thickness
Minimum 0.50 mm (0.0197 in.)
Exhaust valve
Standard 110.40 mm (4.35 in.)
Overall length
Minimum 109.90 mm (4.33 in.)
Width Standard 1.1 to 1.5 mm (0.0433 to 0.0591 in.)
Valve guide bush Inside diameter Standard 5.51 to 5.53 mm (0.217 to 0.218 in.)
0.025 to 0.060 mm (0.000984 to 0.00236
Standard
Intake in.)
Valve guide bush oil Maximum 0.08 mm (0.00315 in.)
clearance 0.030 to 0.065 mm (0.00118 to 0.00256
Standard
Exhaust in.)
Maximum 0.10 mm (0.00394 in.)
Cylinder head lower side 0.05 mm (0.00197 in.)
Intake side Standard 0.08 mm (0.00315 in.)
Cylinder head warpage
Exhaust side 0.05 mm (0.00197 in.)
- Maximum 0.10 mm (0.00394 in.)
Valve guide bush Bush bore diameter Standard 10.285 to 10.306 mm (0.405 to 0.406 in.)

Cylinder Block
0.15 to 0.55 mm (0.00591 to
Standard
Thrust clearance 0.0217 in.)
Maximum 0.70 mm (0.0276 in.)
0.025 to 0.050 mm (0.000984
Standard
Oil clearance to 0.00197 in.)
Maximum 0.070 mm (0.00276 in.)
1.489 to 1.492 mm (0.0586
Mark 2
to0.0587 in.)
1.492 to 1.495 mm (0.0587 to
Mark 3
0.0589 in.)
1.495 to 1.498 mm (0.0589 to
Mark 4
Standard sized bearing 0.0590 in.)
center wall thickness 1.498 to 1.501 mm (0.0590 to
Mark 5
0.0591 in.)

Connecting rod 1.501 to 1.504 mm (0.0591 to

Mark 6
0.0592 in.)
1.504 to 1.507 mm (0.0592 to
Mark 7
0.0593 in.)
59.000 to 59.006 mm
Mark 1
(2.32283 to 2.32307 in.)
59.006 to 59.012 mm
Mark 2
(2.32307 to 2.32330 in.)
Big end inside diameter
59.012 to 59.018 mm
Mark 3
(2.32330 to 2.32354 in.)
59.018 to 59.024 mm
Mark 4
(2.32354 to 2.32377 in.)
0.05 mm (0.00197 in.) per
Bend Maximum
100 mm (3.94 in.)
0.15 mm (0.00591 in.) per
Twist Maximum
100 mm (3.94 in.)
55.994 to 56.000 mm
Mark 1
(2.20448 to 2.20472 in.)
55.988 to 55.994 mm
Crankshaft pin Diameter Mark 2
(2.20425 to 2.20448 in.)
55.982 to 55.988 mm
Mark 3
(2.20401 to 2.20425 in.)
Warpage Maximum 0.07 mm (0.00276 in.)
94.000 to 94.012 mm
Cylinder block Standard
Cylinder bore (3.7008 to 3.7013 in.)
Maximum 94.200 mm (3.7087 in.)
0.020 to 0.070 mm (0.000787
No. 1
to 0.00276 in.)
0.020 to 0.060 mm (0.000787
Groove clearance No. 2
to 0.00236 in.)
0.070 to 0.145 mm (0.00276
Oil
to 0.00571 in.)
0.23 to 0.33 mm (0.00906 to
No. 1
Piston ring 0.0130 in.)
0.40 to 0.50 mm (0.0157 to
Standard No. 2
0.0197 in.)

End gap 0.10 to 0.40 mm (0.00394 to

Oil
0.0157 in.)
No. 1 0.42 mm (0.0165 in.)
Maximum No. 2 0.55 mm (0.0217 in.)
Oil 0.45 mm (0.0177 in.)
93.950 to 93.960 mm
Standard
Diameter (3.6988 to 3.6992 in.)
Minimum 93.815 mm (3.6935 in.)
Piston
0.020 to 0.072 mm (0.000787
Standard
Oil clearance to 0.00283 in.)
Maximum 0.385 mm (0.0152 in.)
21.998 to 22.001 mm
Mark A
(0.86606 to 0.86618 in.)
22.001 to 22.004 mm
Hole inside diameter Mark B
(0.86618 to 0.86630 in.)
22.004 to 22.007 mm
Mark C
(0.86630 to 0.86642 in.)
21.998 to 22.001 mm
Mark A
Piston pin (0.86606 to 0.86618 in.)
22.001 to 22.004 mm
Diameter Mark B
(0.86618 to 0.86630 in.)
22.004 to 22.007 mm
Mark C
(0.86630 to 0.86642 in.)
-0.002 to 0.004 mm (-
Standard
Oil clearance 0.0000787 to 0.000157 in.)
Maximum 0.015 mm (0.000591 in.)
22.005 to 22.008 mm
Mark A
(0.86634 to 0.86645 in.)
22.008 to 22.011 mm
Inside diameter Mark B
(0.86645 to 0.86657 in.)
Connecting rod bush 22.011 to 22.014 mm
Mark C
(0.86657 to 0.86669 in.)
0.005 to 0.011 mm (0.000197
Standard
Oil clearance to 0.000433 in.)
Maximum 0.03 mm (0.00118 in.)
0.020 to 0.220 mm (0.000787
Standard
Thrust clearance to 0.00866 in.)
Maximum 0.30 mm (0.0118 in.)
2.44 to 2.49 mm (0.0961 to
Thrust washer thickness Standard
0.0980 in.)
Circle runout Maximum 0.06 mm (0.00236 in.)
66.988 to 67.000 mm
Diameter Standard
Main journal (2.6373 to 2.6378 in.)
Taper and out-of-round Maximum 0.02 mm (0.000787 in.)
Crankshaft
55.982 to 56.000 mm
Diameter Standard
Crank pin (2.2040 to 2.2047 in.)
Taper and out-of-round Maximum 0.02 mm (0.000787 in.)
0.017 to 0.030 mm (0.000669
Standard
No. 1 and No. 5 journals to 0.00118 in.)
Maximum 0.050 mm (0.00197 in.)
Oil clearance Standard 0.024 to 0.037 mm (0.000945
Other journals to 0.00146 in.)
Maximum 0.060 mm (0.00236 in.)
2.501 to 2.504 (0.0985 to
4
0.0986 in.)
2.504 to 2.507 (0.0986 to
5
0.0987 in.)
2.507 to 2.510 (0.0987 to
6
0.0988 in.)
Upper bearing
2.510 to 2.513 (0.0988 to
7
0.0989 in.)
2.513 to 2.516 (0.0989 to
8
0.0991 in.)
Crankshaft journal bearing
2.516 to 2.519 (0.0991 to
center wall thickness 9
0.0992 in.)
No. 1 and No. 5 journals
2.488 to 2.491 (0.0980 to
5
0.0981 in.)
2.491 to 2.494 (0.0981 to
6
0.0982 in.)
2.494 to 2.497 (0.0982 to
Lower bearing 7
0.0983 in.)
2.497 to 2.500 (0.0983 to
8
0.0984 in.)
2.500 to 2.503 (0.0984 to
9
0.0985 in.)
2.482 to 2.485 (0.0977 to
3
0.0978 in.)
2.485 to 2.488 (0.0978 to
4
0.0980 in.)
2.488 to 2.491 (0.0980 to
5
0.0981 in.)
Upper bearing
2.491 to 2.494 (0.0981 to
6
0.0982 in.)
2.494 to 2.497 (0.0982 to
7
0.0983 in.)
Bearing center wall
2.497 to 2.500 (0.0983 to
thickness 8
0.0984 in.)
Other journal
2.501 to 2.504 (0.0985 to
4
0.0986 in.)
2.504 to 2.507 (0.0986 to
5
0.0987 in.)
2.507 to 2.510 (0.0987 to
Lower bearing 6
0.0988 in.)
2.510 to 2.513 (0.0988 to
7
0.0989 in.)
2.513 to 2.516 (0.0989 to
8
0.0991 in.)
8.5 to 8.6 mm (0.335 to 0.339
Standard
Connecting rod bolt Tension portion diameter in.)
Minimum 8.3 mm (0.327 in.)
10.5 to 11.0 mm (0.413 to
Standard
Bolt A 0.433 in.)
Crankshaft bearing cap set Minimum 10.4 mm (0.409 in.)
Diameter
bolt 9.5 to 10.0 mm (0.374 to
Standard
Bolt B 0.394 in.)
Minimum 9.4 mm (0.370 in.)
3UR-FE ENGINE MECHANICAL > TORQUE SPECIFICATIONS

Camshaft
Part Tightened N*m kgf*cm ft.*lbf
for Bolt A 10 102 7
Camshaft housing LH x Cylinder head LH
for Except bolt 30 306 22
Camshaft bearing cap LH x Camshaft housing LH 16 163 12
for Bolt A 10 102 7
Camshaft housing RH x Cylinder head RH
for Except bolt 30 306 22
Camshaft bearing cap RH x Camshaft housing RH 16 163 12

Cylinder Head Gasket

Part Tightened N*m kgf*cm ft.*lbf
1st 36 367 27
2nd Turn 90°
Cylinder head LH x Cylinder block
3rd Turn 90°
for 12 mm head 21 214 15
1st 36 367 27
2nd Turn 90°
Cylinder head RH x Cylinder block
3rd Turn 90°
for 12 mm head 21 214 15

Front Crankshaft Oil Seal

Part Tightened N*m kgf*cm ft.*lbf
No. 2 water by-pass pipe sub-assembly x Timing chain cover and front water by-pass pipe 10 102 7

Engine Assembly
Part Tightened N*m kgf*cm ft.*lbf
Engine hanger x Cylinder head 43 438 32
No. 2 front engine mounting bracket LH x Body 32 326 24
Front engine mounting insulator LH x Front No. 1 engine
72 734 53
mounting bracket LH
Front engine mounting insulator RH x Front No. 1 engine
72 734 53
mounting bracket RH
Engine mounting insulator x Body 79 806 58
No. 2 water by-pass pipe x Cylinder head cover RH 18 184 13
Oil cooler pipe x No. 1 oil pan and bracket 14 143 10
1st 30 301 22
Drive plate and ring gear x Crankshaft
2nd Turn 90°
Rear No. 1 engine mounting insulator x Automatic
59 602 44
transmission
Front engine mounting insulator RH x Rear No. 1 engine
12 122 9
mounting insulator
Engine oil level dipstick guide x Cylinder head cover RH 10 102 7
Engine wire x Engine room junction block 10 102 7
Ground wire x bracket 8.0 82 71 in.*lbf
Ground wire x Body 8.4 86 74 in.*lbf
Engine wire x Battery positive (+) battery cable 5.4 55 48 in.*lbf
Ground wire x Cylinder head cover RH 8.0 82 71 in.*lbf
Air cleaner x Body 5.0 51 44 in.*lbf
No. 2 engine under cover x Body 29 296 21
No. 1 engine under cover sub-assembly x Body 29 296 21
Engine hood x Hinge 13 133 10
Engine hood x Hood support 18 184 13

Engine Unit
Part Tightened N*m kgf*cm ft.*lbf
Camshaft timing gear x Camshaft 100 1020 74
Camshaft timing exhaust gear x Camshaft 100 1020 74
Timing chain cover stud bolt 20 204 15
for stud bolt A 5.0 51 44 in.*lbf
Oil pan stud bolt (E6 and E7 "TORX")
for stud bolt B 9.0 92 80 in.*lbf
Oil drain pipe x Cylinder block 10 102 7
Rear engine oil seal retainer x Cylinder block 10 102 7
Oil strainer x Oil pan 12 122 9
No. 1 oil pan baffle plate x Oil pan 12 122 9
for bolt A 10 102 7
No. 1 oil pan x cylinder block for bolt B 35 357 26
for Nut 35 357 26
No. 2 oil pan x No. 1 oil pan 10 102 7
No. 1 heat exchanger cover x Cylinder block 21 214 15
No. 2 chain tensioner x Cylinder head RH 10 102 7
No. 1 chain vibration damper RH x Cylinder head RH and
21 214 15
cylinder block
No. 1 chain tensioner RH x Cylinder head RH 10 102 7
No. 3 chain tensioner x Cylinder head LH 10 102 7
No. 1 chain tensioner LH x Cylinder block 10 102 7
No. 1 chain vibration damper LH x Cylinder head LH and
21 214 15
cylinder block
Cylinder head cover spacer x Cylinder head cover 10 102 7
Camshaft oil control valve x Cylinder head cover 10 102 7
Crankshaft position sensor x No. 1 oil pan 10 102 7
Crankshaft position sensor protector x No. 1 oil pan 10 102 7
Camshaft position sensor x Cylinder head cover 10 102 7
VVT sensor x Cylinder head cover 10 102 7
Spark plug x Cylinder head 21 214 15
Oil filler cap housing x Cylinder head cover LH 10 102 7
Noise filter x Cylinder head cover 7.0 71 62 in.*lbf
Ignition coil x Cylinder head cover 10 102 7
Front No. 1 engine mounting bracket LH x Cylinder block 35 357 26
Front No. 1 engine mounting bracket RH x Cylinder block 35 357 26
Cylinder block water drain cock x Cylinder block 30 306 22
Water drain cock plug x Water drain cock 13 133 10
Knock sensor x Cylinder block 20 204 15
Separator case x No. 1 heat exchanger cover 10 102 7
Water by-pass pipe sub-assembly x Cylinder head cover
10 102 7
RH and cylinder head RH
No. 2 fuel tube x Cylinder head cover 10 102 7
Intake manifold x Cylinder head 21 214 15
Wire bracket x Intake manifold 8.0 82 71 in.*lbf
Engine wire x Cylinder head 8.5 87 75 in.*lbf
Ground wire x No. 1 oil pan 20 204 15

Cylinder Head
Part Tightened N*m kgf*cm ft.*lbf
Cylinder head stud bolt E7 and E8 "TORX" 9.0 92 80 in.*lbf
No. 2 straight screw plug x Cylinder head 85 867 63
No. 1 straight screw plug x Cylinder head 44 449 32

Cylinder Block
Part Tightened N*m kgf*cm ft.*lbf
Connecting rod x Connecting rod 1st 40 408 30
cap 2nd Turn 90°
for inside position 61 622 45

Crankshaft bearing cap x for outside position 27 275 20

Cylinder block 2nd Turn 90°
for cylinder block side
45 459 33
position
for stud bolt A (E8
20 204 15
"TORX")
Cylinder block stud bolt
for stud bolt B (E8
9.0 92 80 in.*lbf
"TORX")
No. 1 oil nozzle x Cylinder block 10 102 7
2UZ-FE ENGINE MECHANICAL > SERVICE DATA

ENGINE
5 to 15° BTDC @ ibling
Ignition timing
(transmission in neutral anb A/C switch OFF)
650 to 750 rpm
Engine ible speeb
(transmission in neutral anb A/C switch OFF)
Stanbarb 1373 kPa (14.0 kgf/cm 2, 199 psi) or more
Compression Minimum pressure 1030 kPa (10.5 kgf/cm 2, 149 psi)
Difference between each cylinber 98 kPa (1.0 kgf/cm2, 14.2 psi) or less

VALVE CLEARANCE
Valve clearance Intake 0.15 to 0.25 mm (0.00591 to 0.00984 in.)
(Colb) Exhaust 0.25 to 0.35 mm (0.00984 to 0.0138 in.)
No. 00 2.000 mm (0.0787 in.) 42 2.420 mm (0.0953 in.)
02 2.020 mm (0.0795 in.) 44 2.440 mm (0.0961 in.)
04 2.040 mm (0.0803 in.) 46 2.460 mm (0.0969 in.)
06 2.060 mm (0.0811 in.) 48 2.480 mm (0.0976 in.)
08 2.080 mm (0.0819 in.) 50 2.500 mm (0.0984 in.)
10 2.100 mm (0.0827 in.) 52 2.520 mm (0.0992 in.)
12 2.120 mm (0.0835 in.) 54 2.540 mm (0.1000 in.)
14 2.140 mm (0.0843 in.) 56 2.560 mm (0.1008 in.)
16 2.160 mm (0.0850 in.) 58 2.580 mm (0.1016 in.)
18 2.180 mm (0.0858 in.) 60 2.600 mm (0.1024 in.)
Abjust shim thickness 20 2.200 mm (0.0866 in.) 62 2.620 mm (0.1031 in.)
22 2.220 mm (0.0874 in.) 64 2.640 mm (0.1039 in.)
24 2.240 mm (0.0882 in.) 66 2.660 mm (0.1047 in.)
26 2.260 mm (0.0890 in.) 68 2.680 mm (0.1055 in.)
28 2.280 mm (0.0898 in.) 70 2.700 mm (0.1063 in.)
30 2.300 mm (0.0906 in.) 72 2.720 mm (0.1071 in.)
32 2.320 mm (0.0913 in.) 74 2.740 mm (0.1079 in.)
34 2.340 mm (0.0921 in.) 76 2.760 mm (0.1087 in.)
36 2.360 mm (0.0929 in.) 78 2.780 mm (0.1094 in.)
38 2.380 mm (0.0937 in.) 80 2.800 mm (0.1102 in.)
40 2.400 mm (0.0945 in.) - -

TIMING BELT
Timing belt tensioner Protrusion 9.5 to 10.5 mm (0.374 to 0.413 in.)

CYLINDER HEAD
Cylinber block sibe 0 to 0.05 mm (0 to 0.00197 in.)
Intake manifolb sibe 0 to 0.08 mm (0 to 0.00315 in.)
Cylinber heab Warpage
Exhaust manifolb sibe 0 to 0.08 mm (0 to 0.00315 in.)
Maximum 0.10 mm (0.00394 in.)
Valve stem Stanbarb 5.470 to 5.485 mm (0.215 to 0.216 in.)
Valve face angle Stanbarb 44.5°
Stanbarb 1.0 mm (0.0394 in.)
Intake valve Margin thickness
Minimum 0.5 mm (0.0197 in.)
Stanbarb 95.05 mm (3.74 in.)
Overall length
Minimum 94.55 mm (3.72 in.)
Valve stem Stanbarb 5.465 to 5.480 mm (0.215 to 0.216 in.)
Valve face angle Stanbarb 44.5°
Stanbarb 1.0 mm (0.0394 in.)
Margin thickness
Exhaust valve Minimum 0.5 mm (0.0197 in.)
Stanbarb 95.10 mm (3.744 in.)
Overall length
Minimum 94.60 mm (3.724 in.)
Bush insibe biameter Stanbarb 5.510 to 5.530 mm (0.217 to 0.218 in.)
Stanbarb 0.025 to 0.060 mm (0.000984 to 0.00236 in.)
Oil clearance
Maximum 0.08 mm (0.00314 in.)
Cylinber bore biameter Stanbarb 10.285 to 10.306 mm (0.405 to 0.406 in.)
Intake valve guibe bush Intake 34.5 mm (1.36 in.)
Bush length
Exhaust 40.5 mm (1.59 in.)
Use STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.)
Bush bore
Use O/S 0.05 10.383 to 10.394 mm (0.4087 to 0.4092 in.)
Protrusion Stanbarb 9.2 to 9.8 mm (0.362 to 0.386 in.)
Bush insibe biameter Stanbarb 5.510 to 5.530 mm (0.217 to 0.218 in.)
Stanbarb 0.030 to 0.065 mm (0.00118 to 0.00256 in.)
Oil clearance
Maximum 0.10 mm (0.00394 in.)
Cylinber bore biameter Stanbarb 10.285 to 10.306 mm (0.405 to 0.406 in.)
Exhaust valve guibe bush Intake 34.5 mm (1.36 in.)
Bush length
Exhaust 40.5 mm (1.59 in.)
Use STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.)
Bush bore
Use O/S 0.05 10.383 to 10.394 mm (0.4087 to 0.4092 in.)
Protrusion Stanbarb 8.2 to 8.8 mm (0.323 to 0.346 in.)
Deviation Maximum 2.0 mm (0.0787 in.)
Compression spring Free length Stanbarb 51.29 mm (2.02 in.)
Installeb tension Stanbarb 210 to 226 N (21 to 23 kgf, 47.2 to 50.7 lbf) at 33.4 mm (1.31 in.)
Lifter biameter Stanbarb 30.968 to 30.976 mm (1.2192 to 1.2195 in.)
Lifter bore biameter Stanbarb 31.000 to 31.016 mm (1.220 to 1.221 in.)
Valve lifter
Stanbarb 0.024 to 0.050 mm (0.000945 to 0.00197 in.)
Oil clearance
Maximum 0.07 mm (0.00276 in.)
Thrust clearance Stanbarb 0 to 0.040 mm (0 to 0.00157 in.)
(Intake sibe) Maximum 0.12 mm (0.00472 in.)
Thrust clearance Stanbarb 0.030 to 0.070 mm (0.00118 to 0.00276 in.)
Camshaft
(Exhaust sibe) Maximum 0.10 mm (0.00394 in.)
Stanbarb 0.020 to 0.200 mm (0.000787 to 0.00787 in.)
Gear backlash
Maximum 0.30 mm (0.0118 in.)
Intake valve seat Wibth Stanbarb 1.0 to 1.4 mm (0.0394 to 0.0551 in.)
Exhaust valve seat Wibth Stanbarb 1.0 to 1.4 mm (0.0394 to 0.0551 in.)

CYLINDER BLOCK
0.160 to 0.290 mm (0.00630 to 0.0114
Stanbarb
Thrust clearance in.)
Maximum 0.35 mm (0.0138 in.)
22.880 to 22.920 mm (0.901 to 0.902
Connecting rob thickness Stanbarb
in.)
0.021 to 0.047 mm (0.000827 to
Connecting rob Stanbarb
Oil clearance 0.00185 in.)
Maximum 0.059 mm (0.00232 in.)
0.05 mm (0.00197 in.) per 100 mm (3.94
Benb Maximum
in.)
0.15 mm (0.00591 in.) per 100 mm (3.94
Twist Maximum
in.)
55.000 to less than 55.006 mm (2.1654
Mark 1
to less than 2.1656 in.)
55.006 to less than 55.012 mm (2.1656
Mark 2
Connecting rob big enb insibe to less than 2.1658 in.)
biameter 55.012 to less than 55.018 mm (2.1658
Mark 3
to less than 2.1661 in.)
55.018 to less than 55.024 mm (2.1661
Mark 4
to less than 2.1663 in.)
51.994 to less than 52.000 mm (2.0470
Mark 1
to less than 2.0472 in.)
51.988 to less than 51.994 mm (2.0468
Crankshaft crank pin biameter Mark 2
to less than 2.0470 in.)
51.982 to less than 51.988 mm (2.0465
Mark 3
to less than 2.0468 in.)
1.487 to less than 1.490 mm (0.0585 to
Mark 2
less than 0.0587 in.)
1.490 to less than 1.493 mm (0.0587 to
Mark 3
less than 0.0588 in.)
1.493 to less than 1.496 mm (0.0588 to
Mark 4
Stanbarb sizeb bearing center less than 0.0589 in.)
wall thickness 1.496 to less than 1.499 mm (0.0589 to
Mark 5
less than 0.0590 in.)
1.499 to less than 1.502 mm (0.0590 to
Mark 6
less than 0.0591 in.)
1.502 to less than 1.505 mm (0.0591 to
Mark 7
less than 0.0593 in.)
0.020 to 0.220 mm (0.000787 to
Stanbarb
Thrust clearance 0.00866 in.)
Maximum 0.30 mm (0.0118 in.)
2.440 to 2.490 mm (0.0961 to 0.0980
Stanbarb
Thrust washer thickness in.)
O/S (0.125) 2.565 to 2.615 mm (0.101 to 0.103 in.)
0.028 to 0.046 mm (0.00110 to 0.00181
No. 1 anb No. 5
in.)
Oil clearance 0.040 to 0.058 mm (0.00157 to 0.00228
Crankshaft Others
in.)
Maximum clearance 0.065 mm (0.00256 in.)
Stanbarb 0 to 0.06 mm (0 to 0.00236 in.)
Circle runout
Maximum 0.08 mm (0.00315 in.)
66.988 to 67.000 mm (2.6373 to 2.6378
Main journal biameter Stanbarb
in.)
51.982 to 52.000 mm (2.0465 to 2.0472
Crank pin biameter Stanbarb
in.)
Taper anb out of rounb Maximum 0.02 mm (0.000787 in.)
Mark 00 72.000 mm (2.83465 in.)
Mark 01 72.001 mm (2.83469 in.)
Mark 02 72.002 mm (2.83472 in.)
Mark 03 72.003 mm (2.83476 in.)
Mark 04 72.004 mm (2.83480 in.)
Mark 05 72.005 mm (2.83484 in.)
Mark 06 72.006 mm (2.83488 in.)
Mark 07 72.007 mm (2.83492 in.)
Cylinber block crankshaft
Mark 08 72.008 mm (2.83496 in.)
journal bore biameter (A)
Mark 09 72.009 mm (2.83500 in.)
Mark 10 72.010 mm (2.83504 in.)
Mark 11 72.011 mm (2.83508 in.)
Mark 12 72.012 mm (2.83512 in.)
Mark 13 72.013 mm (2.83516 in.)
Mark 14 72.014 mm (2.83520 in.)
Mark 15 72.015 mm (2.83524 in.)
Mark 16 72.016 mm (2.83528 in.)
Mark 00 67.000 mm (2.63780 in.)
Mark 01 66.999 mm (2.63776 in.)
Mark 02 66.998 mm (2.63772 in.)
Mark 03 66.997 mm (2.63768 in.)
Mark 04 66.996 mm (2.63764 in.)
Mark 05 66.995 mm (2.63760 in.)
Crankshaft journal biameter (B) Mark 06 66.994 mm (2.63756 in.)
Mark 07 66.993 mm (2.63752 in.)
Mark 08 66.992 mm (2.63748 in.)
Mark 09 66.991 mm (2.63744 in.)
Mark 10 66.990 mm (2.63740 in.)
Mark 11 66.989 mm (2.63736 in.)
Mark 12 66.988 mm (2.63732 in.)
2.487 to less than 2.490 mm (0.0979 to
Mark 3
less than 0.0980 in.)
2.490 to less than 2.493 mm (0.0980 to
Mark 4
less than 0.0981 in.)
2.493 to less than 2.496 mm (0.0981 to
No. 1 anb No. 5 Mark 5
less than 0.0983 in.)
2.496 to less than 2.499 mm (0.0983 to
Mark 6
less than 0.0984 in.)
2.499 to less than 2.502 mm (0.0984 to
Mark 7
Stanbarb bearing center wall less than 0.0985 in.)
thickness 2.481 to less than 2.484 mm (0.0977 to
Mark 1
less than 0.0978 in.)
2.484 to less than 2.487 mm (0.0978 to
Mark 2
less than 0.0979 in.)
2.487 to less than 2.490 mm (0.0979 to
Other Mark 3
less than 0.0980 in.)
2.490 to less than 2.493 mm (0.0980 to
Mark 4
less than 0.0981 in.)
2.493 to less than 2.496 mm (0.0981 to
Mark 5
less than 0.0983 in.)
Stanbarb 0 to 0.05 mm (0 to 0.00197 in.)
Cylinber block Warpage
Maximum 0.07 mm (0.00276 in.)
94.002 to 94.010 mm (3.70087 to
Mark 1
3.70118 in.)
94.011 to 94.020 mm (3.70122 to
Stanbarb Mark 2
Cylinber bore 3.70157 in.)
94.021 to 94.028 mm (3.70161 to
Mark 3
3.70189 in.)
Maximum 94.230 mm (3.71 in.)
93.968 to 93.996 mm (3.670 to 3.701
Stanbarb
in.)
Diameter
94.468 to 94.496 mm (3.719 to 3.720
O/S (0.05)
in.)
93.942 to 93.952 mm (3.6985 to 3.6989
Mark 1
in.)
Piston 93.952 to 93.960 mm (3.6989 to 3.6992
Stanbarb Mark 2
in.)
93.960 to 93.970 mm (3.6992 to 3.6996
Mark 3
in.)
0.050 to 0.068 mm (0.00197 to 0.00268
Stanbarb
Oil clearance in.)
Maximum 0.13 mm (0.00512 in.)
21.998 to 22.001 mm (0.86606 to
Mark A
0.86618 in.)
22.002 to 22.004 mm (0.86622 to
Piston pin hole insibe biameter Mark B
0.86630 in.)
22.005 to 22.007 mm (0.86634 to
Mark C
0.86642 in.)
21.997 to 22.000 mm (0.86602 to
Mark A
0.86614 in.)
22.001 to 22.003 mm (0.86618 to
piston pin biameter Mark B
0.86626 in.)
22.004 to 22.006 mm (0.86630 to
Mark C
0.86638 in.)
Piston pin
-0.002 to 0.004 mm (-0.0000787 to
Oil clearance Stanbarb
0.000157 in.)
22.005 to 22.008 mm (0.86633 to
A
0.86646 in.)
22.009 to 22.011 mm (0.86650 to
Connecting rob bush insibe biameter: B
0.86657 in.)
22.012 to 22.014 mm (0.86661 to
C
0.86669 in.)
Stanbarb 0.005 to 0.011 mm (0.000197 to
Oil clearance 0.000433 in.)
Maximum 0.05 mm (0.00197 in.)
0.030 to 0.080 mm (0.00118 to 0.00315
No. 1
in.)
Piston ring groove clearance Stanbarb
0.020 to 0.060 mm (0.000787 to
No. 2
0.00236 in.)
0.300 to 0.400 mm (0.0118 to 0.0157
No. 1 piston ring
in.)
0.400 to 0.550 mm (0.0157 to 0.0217
Stanbarb No. 2 piston ring
in.)

Piston ring enb gap 0.130 to 0.380 mm (0.00512 to 0.0150

Oil ring (Sibe rail)
in.)
No. 1 piston ring 1.10 mm (0.0433 in.)
Maximum No. 2 piston ring 1.30 mm (0.0512 in.)
Oil ring (Sibe rail) 0.90 mm (0.0354 in.)
Stanbarb 7.200 to 7.300 mm (0.283 to 0.287 in.)
Connecting rob bolt
Minimum 7.00 mm (0.276 in.)
Measuring point 67.0 mm (2.64 in.)
10.760 to 10.970 mm (0.424 to 0.432
Crankshaft bearing cap bolt Stanbarb
in.)
Minimum 10.40 mm (0.409 in.)

ENGINE UNIT
Exhaust manifolb Warpage Maximum 0.50 mm (0.0197 in.)
Intake sibe 82 mm (3.23 in.)
Measuring point
Cylinber heab set Exhaust sibe 86 mm (3.39 in.)
bolt Stanbarb 9.810 to 9.960 mm (0.386 to 0.392 in.)
Outsibe biameter
Minimum 9.700 mm (0.382 in.)
Stanbarb 0 to 0.06 mm (0 to 0.00236 in.)
Circle runout
Maximum 0.08 mm (0.00315 in.)
42.61 to 42.71 mm (1.6776 to 1.6815
Stanbarb
Intake in.)
Minimum 42.46 mm (1.6717 in.)
Cam lobe height
42.63 to 42.73 mm (1.6783 to 1.6823
Stanbarb
Exhaust in.)
Camshaft Minimum 42.48 mm (1.6724 in.)
26.954 to 26.970 mm (1.061 to 1.062
Journal biameter Stanbarb
in.)
Journal biameter 30.984 to 31.000 mm (1.2198 to
Stanbarb
for Camshaft timing tube 1.2204 in.)
0.030 to 0.071 mm (0.00118 to
Stanbarb
Oil clearance Camshaft journal 0.00280 in.)
Maximum 0.10 mm (0.00394 in.)
Camshaft timing 39.955 to 39.964 mm (1.5730 to
Journal biameter Stanbarb
tube 1.5734 in.)
Camshaft gear
Gap bistance 18.2 to 18.8 mm (0.717 to 0.740 in.)
spring
2UZ-FE ENGINE MECHANICAL > TORQUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

No. 2 timing belt idler sub-assembly x Cylinder block 35 352 25
No. 1 timing belt idler sub-assembly x Cylinder block 35 352 25
Timing belt tensioner x Oil pump assembly 26 265 19
No. 1 timing belt cover x Oil pump assembly 7.5 76 66 in.*lbf
Pulley bolt x Crankshaft 245 2498 181
Fan bracket sub-assembly x for nut A, bolt B 16 163 12
Cylinder block for nut C, bolt D 32 326 24
V-ribbed belt tensioner assembly x Cylinder block 16 163 12
No. 2 timing belt cover sub-assembly x Cylinder block 16 163 12
No. 3 timing belt cover sub-assembly LH x Cylinder head 7.5 76 66 in.*lbf
No. 3 timing belt cover sub-assembly RH x Cylinder head 7.5 76 66 in.*lbf
No. 2 idle pulley sub-assembly x Fan bracket 39 398 29
Oil cooler pipe x No. 3 timing belt cover sub-assembly LH,
7.5 76 66 in.*lbf
Fan bracket
Camshaft bearing cap x for bolt 21, 22 7.5 76 66 in.*lbf
Cylinder head 7.5 76 66
in.*lbf for other bolt 16 163 12

Rear No. 2 timing belt plate LH x Cylinder head 7.5 76 66 in.*lbf

Rear No. 2 timing belt plate RH x Cylinder head 7.5 76 66 in.*lbf
Camshaft timing pulley x Camshaft timing tube 8.1 83 72 in.*lbf
Cylinder head cover x Cylinder head 6.0 61 53 in.*lbf
Ground wire x Air injection control driver bracket 5.0 51 44 in.*lbf
No. 1 water by-pass pipe x Cylinder head cover LH 18 184 13
1st 40 408 30
Cylinder head x Cylinder
2nd Turn 90° Turn 90° Turn 90°
block
3rd Turn 90° Turn 90° Turn 90°
Rear timing belt plate RH x Cylinder head 7.5 76 66 in.*lbf
Rear timing belt plate LH x Cylinder head 7.5 76 66 in.*lbf
Front exhaust pipe assembly x exhaust center pipe 48 489 35
Front exhaust pipe assembly x Exhaust manifold RH 54 554 40
Exhaust manifold RH x No. 1 manifold stay 36 327 27
Front No. 2 exhaust pipe assembly x exhaust center pipe 48 489 35
Front No. 2 exhaust pipe assembly x Exhaust manifold LH 54 554 40
Exhaust manifold LH x No. 2 manifold stay 36 367 27
Engine mounting insulator x Body 79 806 58
Drive gear and ring gear x 1st 30 306 22
Crankshaft 2nd Turn 90° Turn 90° Turn 90°
Rear No. 1 engine mounting insulator x Automatic
59 602 44
transmission
Wire harness x engine room relay block 10 102 7
Ground wire x Body LH side 8.4 86 76 in.*lbf
Wire harness x Positive (+) for type A nut 13 133 10
battery terminal for type B nut 7.6 77 67 in.*lbf
Ground wire x Body RH side 8.0 82 71 in.*lbf
w/ Winch for bolt A 29 296 21
Winch ground wire x
Cylinder block, Body RH for bolt B 19 194 14
side
Vane pump assembly x Cylinder block 21 214 15

Cooler compressor for bolt 45 459 33

assembly x Cylinder block for nut 25 250 18
Cooler refrigerant suction hose x No. 5 camshaft bearing
9.8 100 87 in.*lbf
cap
Hood sub-assembly x Hood hinge 13 133 10
Hood stay bolt x Body 18 184 13
No. 2 engine under cover x Body 29 296 21
No. 1 engine under cover x Body 29 296 21
for aluminum wheel 131 1336 97
Front wheel
for steel wheel 209 2131 154
Cylinder block union x Cylinder block 49 500 36
Cylinder block water drain cock x Cylinder block 49 500 36
Water drain cock plug x Water drain cock 13 130 9
Engine rear oil seal retainer x Cylinder block 8.0 82 71 in.*lbf
No. 3 oil pan baffle plate x Oil pan 7.5 76 66 in.*lbf
No. 2 oil pan baffle plate x Oil pan 7.5 76 66 in.*lbf
No. 1 oil pan baffle plate x Oil pan 7.5 76 66 in.*lbf
Camshaft drive gear x Camshaft timing tube 7.5 76 66 in.*lbf
Camshaft timing tube x Camshaft 78 795 58
Screw plug x Camshaft timing tube 5 153 11
Oil filler cap housing x Cylinder head cover LH 7.5 76 66 in.*lbf
No. 1 engine hanger x Cylinder head 37 377 27
Rear water by-pass joint x Cylinder head 18 184 13
Front water by-pass joint x Cylinder head 18 184 13
Ground wire x No.5 camshaft bearing cap 8.4 86 74 in.*lbf
Ground wire x Engine LH side 17 173 13
Ground wire x Inside left side of the V-bank 17 173 13
Ground wire x Cylinder head rear side 8.4 86 74 in.*lbf
Front engine mounting bracket x Cylinder block 36 367 27
Front engine mounting insulator x Front engine mounting
72 734 53
bracket
No. 2 wiring harness heat insulator x Cylinder block 17 173 13
for stud bolt A, C 9.0 92 80 in.*lbf
Stud bolt x Cylinder head
for stud bolt B 15 153 11
No. 1 straight screw plug x Cylinder head 85 868 63
for stud bolt A, B, F 8.0 82 71 in.*lbf
for stud bolt C 20 204 15
Stud bolt x Cylinder block
for stud bolt D 12 122 9
for stud bolt E 14 143 10
No. 1 oil nozzle x Cylinder block 9.0 92 80 in.*lbf
Crank shaft bearing cap x 1st 27 275 20
Cylinder block 2nd Turn 90° Turn 90° Turn 90°
Connecting rod cap x 1st 25 250 18
Connecting rod 2nd Turn 90° Turn 90° Turn 90°
1VD-FTV ENGINE MECHANICAL > SERVICE DATA

ENGINE
for Manual Transmission 500 to 600 rpm
Standard idle speed
for Automatic Transmission 550 to 650 rpm
Maximum engine speed 4700 to 4900 rpm
Standard pressure (normal condition) 2700 kPa (27.5 kgf/cm 2, 392 psi)
Compression Minimum pressure 2200 kPa (22.4 kgf/cm 2, 319 psi)
Difference between end cylinder 500 kPa (5.1 kgf/cm 2, 73 psi) or less

DRIVE BELT
w/ Viscous Heater: New belt 400 to 650 N (41 to 66 kgf, 89.9 to 146.1 lbf)
Standard belt tension Used belt 300 to 500 N (31 to 51 kgf, 67.4 to 112.4 lbf)
A "new belt" is a belt which has been used for less than 5 minutes on a running engine.
A "used belt" is a belt which has been used on a running engine for 5 minutes or more.
After installing a new belt, run the engine for approximately 5 minutes and then recheck the tension.

CYLINDER HEAD GASKET

0.520 to 0.780 mm (0.0205 to
Standard piston protrusion
0.0307 in.)
1 cutout 1.20 to 1.30 mm (0.0472 to 0.0512
(item A) in.)
2 cutouts 1.25 to 1.35 mm (0.0492 to 0.0394
(item B) in.)
New installed cylinder head gasket thickness
3 cutouts 1.30 to 1.40 mm (0.0512 to 0.0551
(HINT: The specified condition indicates the gaskets
(item C) in.)
thickness after tightening the cylinder head.)
4 cutouts 1.35 to 1.45 mm (0.0531 to 0.0571
(item D) in.)
Select No. 1 and No. 2 cylinder head 5 cutouts 1.40 to 1.50 mm (0.0551 to 0.0591
gasket (item E) in.)
0.520 to 0.575 mm (0.0205 to
Item A
0.0226 in.)
0.575 to 0.625 mm (0.0226 to
Item B
0.0246 in.)
0.625 to 0.675 mm (0.0246 to
Piston protrusion Item C
0.0266 in.)
0.675 to 0.725 mm (0.0266 to
Item D
0.0285 in.)
0.725 to 0.780 mm (0.0285 to
Item E
0.0307 in.)

ENGINE UNIT
0.024 to 0.042 mm (0.000945 to
Standard oil clearance
0.00165 in.)
Maximum oil clearance 0.052 mm (0.00205 in.)
Standard diameter 8.7 to 8.8 mm (0.343 to 0.346 in.)
Connecting rod bolt
Connecting rod Minimum diameter 8.5 mm (0.335 in.)
0.07 mm (0.00276 in.) per 100 mm
Maximum bend
(3.94 in.)
Alignment
0.15 mm (0.00591 in.) per 100 mm
Maximum twist
(3.94 in.)
More than 1.485 to 1.488 mm (more
Mark 1
than 0.05846 to 0.05858 in.)
More than 1.488 to 1.491 mm (more
Mark 2
than 0.05858 to 0.05870 in.)
More than 1.491 to 1.494 mm (more
Mark 3
Standard bearing center wall thickness than 0.05870 to 0.05882 in.)
More than 1.494 to 1.497 mm (more
Mark 4
than 0.05882 to 0.05894 in.)
Mark 5 More than 1.497 to 1.500 mm (more
than 0.05894 to 0.05910 in.)
Connecting rod
58.000 to 58.006 mm (2.28346 to
bearing Mark 1
2.28370 in.)
More than 58.006 to 58.012 mm
Standard connection rod big end inside diameter Mark 2
(more than 2.28370 to 2.28393 in.)
More than 58.012 to 58.018 mm
Mark 3
(more than 2.28393 to 2.28417 in.)
More than 54.994 to 55.000 mm
Mark 0
(more than 2.16511 to 2.16535 in.)
More than 54.988 to 54.994 mm
Standard crankshaft pin diameter Mark 1
(more than 2.16488 to 2.16511 in.)
54.982 to 54.988 mm (2.16464 to
Mark 2
2.16488 in.)
Maximum circle runout 0.04 mm (0.00157 in.)
74.982 to 75.000 mm (2.9520 to
Standard diameter
Main journal 2.9527 in.)
Maximum taper and out-of-round 0.01 mm (0.000394 in.)
54.982 to 55.000 mm (2.1646 to
Standard diameter
Crank pin 2.1653 in.)
Maximum taper and out-of-round 0.01 mm (0.000394 in.)
0.020 to 0.038 mm (0.000787 to
No. 1 and 3 journals
0.00150 in.)
Standard
0.032 to 0.050 mm (0.00126 to
Oil clearance No. 2, 4 and 5 journals
0.00197 in.)
1 and 3 journals 0.048mm (0.00189 in.)
Crankshaft Maximum
No. 2, 4 and 5 journals 0.060mm (0.00236 in.)
More than 74.994 to 75.000 mm
'2'
(more than 2.95251 to 2.95275 in.)
More than 74.988 to 74.994 mm
No. 1 and 3 journals '3'
(more than 2.95228 to 2.95251 in.)
74.982 to 74.988 mm (2.95204 to
'4'
2.95228 in.)
Main journal diameter
More than 74.994 to 75.000 mm
'0'
(more than 2.95251 to 2.95275 in.)
More than 74.988 to 74.994 mm
No. 2, 4 and 5 journals '1'
(more than 2.95288 to 2.95251 in.)
74.982 to 74.988 mm (2.95204 to
'2'
2.95228 in.)
No. 1 and 5 journal bearings wide 22.5 mm (0.886 in.)
No. 2, 3 and 4 journal bearings wide 20.5 mm (0.807 in.)
More than 1.987 to 1.990 mm (more
'1'
than 0.07823 to 0.07835 in.)
More than 1.990 to 1.993 mm (more
'2'
than 0.07835 to 0.07846 in.)
More than 1.993 to 1.996 mm (more
'3'
than 0.07846 to 0.07858 in.)
More than 1.996 to 1.999 mm (more
No. 1 and 5 journal bearings '4'
than 0.07858 to 0.07870 in.)
More than 1.999 to 2.002 mm (more
'5'
than 0.07870 to 0.07882 in.)
More than 2.002 to 2.005 mm (more
'6'
than 0.07882 to 0.07894 in.)
More than 2.005 to 2.008 mm (more
Crankshaft bearing '7'
Center wall thickness (for than 0.07894 to 0.07905 in.)
upper bearing) More than 1.975 to 1.978 mm (more
'1'
than 0.07776 to 0.07787 in.)
More than 1.978 to 1.981 mm (more
'2'
than 0.07787 to 0.07799 in.)
More than 1.981 to 1.984 mm (more
'3'
than 0.07799 to 0.07811 in.)
No. 2, 3 and 4 journal More than 1.984 to 1.987 mm (more
'4'
bearings than 0.07811 to 0.07823 in.)
More than 1.987 to 1.990 mm (more
'5'
than 0.07823 to 0.07835 in.)
More than 1.990 to 1.993 mm (more
'6'
than 0.07835 to 0.07846 in.)
More than 1.993 to 1.996 mm (more
'7'
than 0.07846 to 0.07858 in.)
More than 1.975 to 1.978 mm (more
'1'
than 0.07776 to 0.07787 in.)
More than 1.978 to 1.981 mm (more
'2'
than 0.07787 to 0.07799 in.)
More than 1.981 to 1.984 mm (more
'3'
than 0.07799 to 0.07811 in.)
More than 1.984 to 1.987 mm (more
No. 1 and 5 journal bearings '4'
than 0.07811 to 0.07823 in.)
More than 1.987 to 1.990 mm (more
'5'
than 0.07823 to 0.07835 in.)
More than 1.990 to 1.993 mm (more
'6'
than 0.07835 to 0.07846 in.)
More than 1.993 to 1.996 mm (more
'7'
Center wall thickness (for than 0.07846 to 0.07858 in.)
Crankshaft bearing
lower bearing) More than 1.987 to 1.990 mm (more
'1'
than 0.07823 to 0.07835 in.)
More than 1.990 to 1.993 mm (more
'2'
than 0.07835 to 0.07846 in.)
More than 1.993 to 1.996 mm (more
'3'
than 0.07846 to 0.07858 in.)
No. 2, 3 and 4 journal More than 1.996 to 1.999 mm (more
'4'
bearings than 0.07858 to 0.07870 in.)
More than 1.999 to 2.002 mm (more
'5'
than 0.07870 to 0.07882 in.)
More than 2.002 to 2.005 mm (more
'6'
than 0.07882 to 0.07894 in.)
More than 2.005 to 2.008 mm (more
'7'
than 0.07894 to 0.07905 in.)
Cylinder block side 0 to 0.05 mm (0 to 0.00197 in.)
Standard warpage Intake manifold side 0 to 0.08 mm (0 to 0.00315 in.)
Exhaust manifold side 0 to 0.08 mm (0 to 0.00315 in.)
Cylinder block side 0.05 mm (0.00197 in.)
Maximum warpage Intake manifold side 0.08 mm (0.00315 in.)
Exhaust manifold side 0.08 mm (0.00315 in.)
Maximum deviation 1.5 mm (0.0591 in.)
Standard free length 45.9 mm (1.81 in.)
Inner compression spring
219 to 242 N (22 to 25 kgf, 49.2 to
Installed tension
54.4 lbf) at 31.0 mm (1.22 in.)
6.01 to 6.03 mm (0.2366 to 0.2374
Standard bush inside diameter
in.)
0.025 to 0.060 mm (0.000984 to
Intake
Cylinder head Valve guide bush oil 0.00236 in.)
Standard oil clearance
clearance 0.035 to 0.070 mm (0.00138 to
Exhaust
0.00276 in.)
Intake 0.120 mm (0.00472 in.)
Maximum oil clearance
Exhaust 0.130 mm (0.00512 in.)
5.970 to 5.985 mm (0.2350 to
Intake
Standard valve stem 0.2356 in.)
diameter 5.960 to 5.975 mm (0.2346 to
Exhaust
0.2352 in.)

Valve Intake 104.4 mm (4.11 in.)

Standard overall length
Exhaust 104.1 mm (4.10 in.)
Intake 104.1 mm (4.10 in.)
Minimum overall length
Exhaust 103.8 mm (4.09 in.)
Standard valve face angle 45.5°
0.035 to 0.160 mm (0.00138 to
No. 2 and No. 3 camshaft thrust clearance (for Intake Standard thrust clearance
0.00630 in.)
Camshaft)
Maximum thrust clearance 0.180 mm (0.00709 in.)
No. 1 and No. 4 camshaft thrust clearance (for Exhaust Standard thrust clearance 0.035 to 0.160 mm (0.00138 to
Camshaft) 0.00630 in.)
Maximum thrust clearance 0.180 mm (0.00709 in.)
Maximum runout 0.03 mm (0.00118 in.)
37.277 to 37.387 mm (1.468 to
No. 2 and No. 3 camshaft (intake)
1.472 in.)
Standard cam lobe height
Camshaft 38.324 to 38.434 mm (1.509 to
No. 1 and No. 4 camshaft (exhaust)
1.513 in.)
No. 2 and No. 3 camshaft (intake) 37.277 mm (1.468 in.)
Minimum cam lobe height
No. 1 and No. 4 camshaft (exhaust) 38.324 mm (1.509 in.)
29.969 to 29.985 mm (1.180 to
No. 1 journal
1.181 in.)
Standard journal diameter
26.969 to 26.985 mm (1.0618 to
Other journal
1.0624 in.)
0.025 to 0.062 mm (0.000984 to
Standard oil clearance
0.00244 in.)
Maximum oil clearance 0.072 mm (0.00283 in.)
Standard diameter 12.8 to 13.0 mm (0.504 to 0.512 in.)
Cylinder head bolt
Minimum diameter 12.5 mm (0.492 in.)
Item (bolt A) 106 mm (4.17 in.)
Bolt length
Item (bolt B) 90.5 mm (3.56 in.)
Item (bolt A) 73 mm (2.87 in.)
Measuring area
Crankshaft bearing Item (bolt B) 63 mm (2.48 in.)
cap bolt Item (bolt A) 10.8 to 11.0 mm (0.425 to 0.433 in.)
Standard diameter
Item (bolt B) 9.8 to 10.0 mm (0.386 to 0.394 in.)
Item (bolt A) 10.5 mm (0.413 in.)
Minimum diameter
Item (bolt B) 9.5 mm (0.374 in.)
Cylinder block for flatness Maximum warpage 0.05 mm (0.00197 in.)
Cylinder block tight plug Standard depth 1.7 to 2.7 mm (0.0669 to 0.106 in.)
86.000 to 86.013 mm (3.3858 to
Standard diameter
Cylinder bore 3.3863 in.)
Maximum diameter 86.03 mm (3.3870 in.)
79.000 to 79.006 mm (3.11023 to
'1'
3.11047 in.)
More than 79.006 to 79.012 mm
for No. 1 and No. 3 journals '2'
(more than 3.11047 to 3.11070 in.)
More than 79.012 to 79.018 mm
'3'
Cylinder block Cylinder block main journal (more than 3.11070 to 3.11094 in.)
bore diameter 79.000 to 79.006 mm (3.11023 to
'1'
3.11047 in.)
More than 79.006 to 79.012 mm
for No. 2, 4 and 5 journals '2'
(more than 3.11047 to 3.11070 in.)
More than 79.012 to 79.018 mm
'3'
(more than 3.11070 to 3.11094 in.)
Pin ''A'' and ''B''' 5.0 to 7.0 mm (0.197 to 0.275 in.)
Pin 'C' 10.5 to 11.5 mm (0.413 to 0.453 in.)
Straight pin Standard protrusion
Pin 'D' and 'F' 3.5 to 6.0 mm (0.138 to 0.236 in.)
Pin "E" 4.5 to 7.0 mm (0.177 to 0.276 in.)
85.932 to 85.966 mm (3.383 to
Standard piston diameter
3.384 in.)
Minimum piston diameter 85.910 mm (3.382 in.)
Piston
0.034 to 0.081 mm (0.00134 to
Standard oil clearance
Piston oil clearance 0.00319 in.)
Maximum oil clearance 0.091 mm (0.00358 in.)
29.009 to 29.013 mm (1.1421 to
Mark A
1.1422 in.)
29.013 to 29.017 mm (1.1422 to
Standard piston pin hole inside diameter Mark B
1.1424 in.)
29.017 to 29.021 mm (1.1424 to
Mark C
1.1426 in.)
Mark A 29.000 to 29.004 mm (1.1417 to
(paint color "white") 1.1419 in.)
Piston x piston pin Mark B 29.004 to 29.008 mm (1.1419 to
Standard piston pin diameter
(paint color "pink") 1.1420 in.)
Mark C 29.008 to 29.012 mm (1.1420 to
(paint color "blue") 1.1422 in.)
0.005 to 0.013 mm (0.000197 to
Standard oil clearance
0.000512 in.)
Maximum oil clearance 0.018 mm (0.000709 in.)
29.019 to 29.023 mm (1.1425 to
Mark A
1.1426 in.)
29.023 to 29.027 mm (1.1426 to
Standard bush inside diameter Mark B
1.1428 in.)
Connecting rod x
29.027 to 29.031 mm (1.1428 to
Piston pin Mark C
1.1430 in.)
0.015 to 0.023 mm (0.000591 to
Standard oil clearance
0.000906 in.)
Maximum oil clearance 0.028 mm (0.00110 in.)
0.11 to 0.15 mm (0.00433 to
No. 1 compression ring
0.00591 in.)
0.08 to 0.12 mm (0.00315 to
Standard ring groove clearance No. 2 compression ring
0.00472 in.)
0.03 to 0.07 mm (0.00118 to
Oil ring
0.00276 in.)
No. 1 compression ring 0.22 to 0.32 mm (0.00866 to 0.0126
(w/ EGR System) in.)
Piston ring No. 1 compression ring 0.20 to 0.30 mm (0.00787 to 0.0118
(w/o EGR System) in.)
Standard end gap
0.47 to 0.62 mm (0.0185 to 0.0244
No. 2 compression ring
in.)
0.10 to 0.40 mm (0.00394 to 0.0157
Oil ring
in.)
No. 1 compression ring 0.40 mm (0.0157 in.)
Maximum end gap No. 2 compression ring 0.75 mm (0.0295 in.)
Oil ring 0.50 mm (0.0197 in.)
No. 1 chain Maximum chain elongation 143.95 mm (5.67 in.)
Chain
No. 2 chain Maximum chain elongation 143.95 mm (5.67 in.)
Fuel supply pump No. 1 chain 101.55 mm (4.00 in.)
Minimum gear diameter (with chain)
shaft sprocket No. 2 chain 101.55 mm (4.00 in.)
Camshaft timing No. 1 chain 134.90 mm (5.31 in.)
Minimum gear diameter (with chain)
sprocket No. 2 chain 134.90 mm (5.31 in.)
44.947 to 44.975 mm (1.770 to
Standard idle gear shaft diameter
1.771 in.)
45.000 to 45.025 mm (1.772 to
No. 1 idle gear shaft Standard idle gear inside diameter 1.773 in.)
and No. 1 idle gear
0.025 to 0.078 mm (0.000984 to
Standard oil clearance
0.00307 in.)
Maximum oil clearance 0.078 mm (0.00307 in.)
Chain tensioner No. 1 1.0 mm (0.0394 in.)
Maximum depth
slipper No. 2 1.0 mm (0.0394 in.)
Chain vibration No. 1 1.0 mm (0.0394 in.)
Maximum depth
damper No. 2 1.0 mm (0.0394 in.)
No. 3 intake manifold 0.10 mm (0.00394 in.)
No.1 intake manifold
Cylinder head 0.10 mm (0.00394 in.)
No. 3 intake manifold 0.10 mm (0.00394 in.)
Intake manifold for No. 2 intake manifold
Maximum warpage Cylinder head 0.10 mm (0.00394 in.)
flatness
Intake pipe 0.10 mm (0.00394 in.)
No. 3 intake manifold No. 2 and No. 3 intake
0.15 mm (0.00591 in.)
manifold
Exhaust manifold for
Maximum warpage 0.80 mm (0.0315 in.)
flatness

CYLINDER HEAD
Valve seat Standard width Intake 1.0 to 1.4 mm (0.0394 to 0.0551 in.)
Exhaust 1.0 to 1.4 mm (0.0394 to 0.0551 in.)
Standard bush bore diameter (for cylinder head) 10.985 to 11.006 mm (0.432 to 0.433 in.)
STD 11.033 to 11.044 mm (0.434 to 0.435 in.)
Standard valve guide bush diameter
Cylinder head O/S 0.05 11.083 to 11.094 mm (0.436 to 0.437 in.)
Valve guide bush
Standard protrusion height 9.0 to 9.4 mm (0.354 to 0.370 in.)
Intake 0.025 to 0.060 mm (0.000984 to 0.00236 in.)
Standard overall length
Exhaust 0.035 to 0.070 mm (0.00138 to 0.00276 in.)
Ring pin Standard protrusion 4.4 to 5.6 mm (0.173 to 0.220 in.)
Valve stem oil seal Standard protrusion height Below 14.7 mm (0.579 in.)

CYLINDER BLOCK
Standard thrust clearance 0.14 to 0.54 mm (0.00551 to 0.0213 in.)
Connecting rod
Maximum thrust clearance 0.60 mm (0.0236 in.)
Standard thrust clearance 0.02 to 0.22 mm (0.000787 to 0.00866 in.)
Crankshaft Maximum thrust clearance 0.30 mm (0.0118 in.)
Standard thrust washer thickness 2.44 to 2.49 mm (0.0960 to 0.0980 in.)
1VD-FTV ENGINE MECHANICAL > TORQUE SPECIFICATIONS

ENGINE
Part Tightened N*m kgf*cm ft.*lbf

SST attachment) x Glow plug hole 13 133 10

DRIVE BELT
Part Tightened N*m kgf*cm ft.*lbf
w/ Viscous
No. 3 idler pulley x No. 1 idler pulley 88 898 64
Heater
w/ Viscous
No. 1 idler pulley x Timing chain cover 49 495 36
Heater
Idler pulley nut x No. 2 idler pulley w/ Viscous
40 408 30
bracket Heater

CAMSHAFT
Part Tightened N*m kgf*cm ft.*lbf
Service bolt x No. 1 and No. 4 camshaft 8.0 82 71 in.*lbf
No. 1 and No. 4 camshaft bearing cap x Cylinder head 21 214 15
No. 3 camshaft bearing cap x Cylinder head 10 102 7
for union
17 173 13
No. 1, No. 2, No. 3 and No. 4 camshaft oil bolt
feed pipes x Cylinder head for 10 mm
10 102 7
head bolt
No. 2 camshaft timing sprocket x No. 3 camshaft 25 250 18
Pump drive shaft gear x No. 1 camshaft timing sprocket x
25 250 18
No. 2 camshaft
Taper screw plug x Timing chain cover 15 153 11

CYLINDER HEAD GASKET

Part Tightened N*m kgf*cm ft.*lbf
1st 80 816 59
2nd Turn 90° Turn 90° Turn 90°
Cylinder head RH and LH x Cylinder block
3rd Turn 90° Turn 90° Turn 90°
4th Turn 90° Turn 90° Turn 90°
No. 1 and No. 4 camshaft bearing cap x Cylinder head 21 214 15
No. 3 camshaft bearing cap x Cylinder head 10 102 7
for union bolt 17 173 13
No. 1, No. 2, No. 3 and No. 4 camshaft oil
feed pipes x Cylinder head for 10 mm
10 102 7
head bolt
for 14 mm
head bolt 46 469 34
(case is "dry")
for 14 mm
head bolt 42 428 31
(case is "wet")

Timing gear case x Cylinder block The case is "dry" when there is absolutely no engine oil on the 14 mm head bolts and
cylinder head bolt holes.
The case is "wet" when there is any engine oil on the 14 mm head bolts and cylinder head
bolt holes.

for 12 mm
29 296 21
head bolt
for nut 29 296 21
for 6 mm
21 214 15
Fuel supply pump x Timing gear case hexagon bolt
for nut 21 214 15
Idle gear x No. 1 idle gear shaft 47 479 35
Fuel supply pump drive gear x Fuel supply pump 68 693 50
No. 2 camshaft timing sprocket x No. 3 camshaft 25 250 18
Pump drive shaft gear x No. 1 camshaft timing sprocket x
25 250 18
No. 2 camshaft
No. 2 chain vibration damper x Timing gear case 21 214 15
No. 2 chain tensioner x Timing gear case 10 102 7
No. 1 chain vibration damper x Timing gear case 21 214 15
No. 1 chain tensioner x Timing gear case 10 102 7
No. 1 crankshaft position sensor plate x Crankshaft 10 102 7
Timing chain cover x Timing gear case x Cylinder head 25 250 18
Clutch flexible hose bracket x Cylinder for Manual
20 204 15
head LH Transmission
Starter hose bracket x Cylinder head RH 10 102 7

ENGINE ASSEMBLY
Part Tightened N*m kgf*cm ft.*lbf
No. 1 and No. 2 engine hanger x Cylinder head 25 255 18
for Automatic
Drive plate and ring gear x Crankshaft 182 1856 134
Transmission
for Manual
Flywheel x Crankshaft 182 1856 134
Transmission
Front engine mounting insulator LH and RH x Frame 58 591 43
Clutch release cylinder to flexible hose for Manual
20 204 15
tube x Cylinder head LH Transmission
No. 2 intake air connector pipe x No. 2 intake air
21 214 15
connector bracket
No. 2 intake air connector pipe x No. 2 inlet compressor
6.0 61 53 in.*lbf
elbow
Cooler compressor x Timing gear case x Timing chain
25 250 18
cover x Compressor bracket
No. 2 air tube x No. 2 turbocharger 21 214 15
No. 1 air tube x No. 1 turbocharger 21 214 15
Air cleaner case x Body panel 5.0 51 44 in.*lbf
No. 2 engine under cover x Frame 29 296 21
No. 1 engine under cover x Frame 29 296 21
Hood x Hood hinge 13 133 10
Hood support x Body panel 18 184 13

ENGINE UNIT
Part Tightened N*m kgf*cm ft.*lbf
Intake pipe 6.0 61 53 in.*lbf
No. 3 intake manifold
42 mm (1.65 in.) bolt 6.0 61 53 in.*lbf
length
No. 3 intake manifold
24 mm (0.945 in.) bolt 4.5 46 40 in.*lbf
length
No. 3 intake manifold
39 mm (1.54 in.) bolt 4.0 41 35 in.*lbf
length
Oil filter bracket 6.0 61 53 in.*lbf
No. 1 oil pan
42 mm (1.65 in.) bolt 6.0 61 53 in.*lbf
length
Stud bolt No. 1 oil pan
27 mm (1.06 in.) bolt 5.2 53 46 in.*lbf
length
Timing chain cover
54 mm (2.13 in.) bolt 6.0 61 53 in.*lbf
length
Timing chain cover
45 mm (1.77 in.) bolt 12 120 9
length
Timing gear case
54 mm (2.13 in.) bolt 6.0 61 53 in.*lbf
length
Timing gear case
40 mm (1.57 in.) bolt 10 102 7
length
No. 1 oil pan
(using a 10 mm hexagon 50 510 37
wrench of plug)
No. 1 oil pan
Straight screw plug (using a 14 mm hexagon 86 877 63
wrench of plug)
Oil filter bracket 50 510 37
Timing gear case 40 408 30
Cylinder block 38 387 28
1st 80 816 59
Cylinder head RH x Cylinder 2nd Turn 90° Turn 90° Turn 90°
block 3rd Turn 90° Turn 90° Turn 90°
4th Turn 90° Turn 90° Turn 90°
1st 80 816 59
Cylinder head LH x Cylinder 2nd Turn 90° Turn 90° Turn 90°
block 3rd Turn 90° Turn 90° Turn 90°
4th Turn 90° Turn 90° Turn 90°
No. 1 camshaft bearing cap x Cylinder head RH 21 214 15
No. 3 camshaft bearing cap x Cylinder head RH 10 102 7
No. 1 and No. 2 camshaft oil for union bolt 17 173 13
feed pipes x Cylinder head RH for 10 mm head bolt 10 102 7
No. 4 camshaft bearing cap x Cylinder head LH 21 214 15
No. 3 camshaft bearing cap x Cylinder head LH 10 102 7
No. 3 and No. 4 camshaft oil for union bolt 17 173 13
feed pipes x Cylinder head LH for 10 mm head bolt 10 102 7
No. 2 vacuum transmitting pipe
w/ Intercooler 6.0 61 53 in.*lbf
x Timing gear case
No. 1 vacuum transmitting pipe
w/ Intercooler 6.0 61 53 in.*lbf
x Timing gear case
for 14 mm head bolt
46 469 34
(case is "dry")
for 14 mm head bolt
42 428 31
(case is "wet")
Timing gear case x Cylinder The case is "dry" when there is absolutely no engine oil on the 14 mm head bolts and cylinder head
block bolt holes.
The case is "wet" when there is any engine oil on the 14 mm head bolts and cylinder head bolt holes.

for 12 mm head bolt 29 296 21

for nut 29 296 21
Fuel supply pump x Timing for 6 mm hexagon bolt 21 214 15
gear case for nut 21 214 15
Fuel supply pump drive gear x Fuel supply pump shaft
25 250 18
sprocket
Idle gear x sub idle gear
w/ Intercooler 13 133 10
(service bolt)
Idle gear x Idle gear thrust plate x No. 1 idle gear shaft 47 479 35
Fuel supply pump drive gear x Fuel supply pump 68 693 50
No. 2 camshaft timing sprocket x No. 3 camshaft 25 250 18
Pump drive shaft gear x No. 1 camshaft timing sprocket x
25 250 18
No. 2 camshaft
No. 2 chain vibration damper x Timing gear case 21 214 15
No. 2 chain tensioner x Timing gear case 10 102 7
No. 1 chain vibration damper x Timing gear case 21 214 15
No. 1 chain tensioner x Timing gear case 10 102 7
No. 1 crankshaft position sensor plate x Crankshaft 10 102 7
Timing chain cover x Timing for bolt 25 250 18
gear case for nut 25 250 18
Timing chain cover plate x Timing chain cover 9.1 93 81 in.*lbf
Nozzle holder clamp x Fuel injector LH and RH x Cylinder
25 255 18
head
Nozzle leakage pipe x Fuel for hollow screw 18 184 13
injector LH and RH for union bolt 21 214 15
Scavenging pump x Cylinder block 10 102 7
Oil pump x Cylinder block 10 102 7
Rear engine oil seal retainer x Cylinder block 10 102 7
Oil regulator x Scavenging pump 10 102 7
Inlet oil pump pipe x No. 1 oil pan 10 102 7
No. 1 oil pan baffle plate x No. 1 oil pan 10 102 7
No. 1 oil pan x Cylinder block 25 250 18
Oil strainer x No. 1 oil pan 10 102 7
No. 2 oil pan x No. 1 oil pan 10 102 7
Oil pan drain plug x No. 1 oil pan 38 387 28
Engine oil level sensor x No. 1 oil pan 10 102 7
Oil filter bracket x No. 1 oil pan 21 214 15
Oil cooler relief valve x Oil filter bracket 25 250 18
Oil cooler x Oil filter bracket 21 214 15
Oil pressure sender gauge x Oil filter bracket 15 153 11
Timing gear cover spacer x
w/ Intercooler 21 214 15
Timing gear case
Crankshaft pulley x Crankshaft 115 1168 84
Crankshaft position sensor x Timing gear case 5.0 51 44 in.*lbf
Camshaft position sensor x Timing gear case 5.0 51 44 in.*lbf
Compressor bracket x Timing gear case 21 214 15
Oil relief valve plug x Oil
50 510 37
pressure regulator body
Oil pressure regulator
Oil pressure regulator x
86 877 63
No. 1 oil pan
1st 20 204 15
Oil filter bracket drain cock x Oil 2nd Set angle within 360° Set angle within 360° Set angle within 360°
filter bracket As the oil filter bracket may be damaged, the maximum tightening torque should be 80 N*m (816 kgf*cm, 59 ft.*lbf)
or less.
Oil filter drain cock plug x Oil filter bracket drain cock 13 130 9
Oil tank bracket x No. 1 oil pan 10 102 7
Engine mounting bracket LH and RH x Cylinder block 80 816 59
No. 2 water by-pass pipe x for union bolt 35 357 26
Cylinder block for bolt 10 102 7
No. 3 vacuum transmitting pipe x Cylinder block 6.0 61 53 in.*lbf
Turbocharger wire x Timing gear case and Engine
21 214 15
mounting bracket LH
No. 2 intake air connector bracket x Timing gear case 21 214 15
No. 4 vacuum transmitting pipe
w/ Intercooler 6.0 61 53 in.*lbf
x Cylinder block
No. 1 water by-pass pipe x for union bolt 35 357 26
Cylinder block for bolt 10 102 7
Air tube support x Timing gear cover 21 214 15
No. 1 intake air connector bracket x Timing gear cover 21 214 15
Rear cylinder head plate LH
w/o EGR System 29 296 21
and RH x Cylinder head
No. 3 engine hanger x Timing gear case 43 438 32
No. 1 intercooler support bracket x No. 3 engine hanger 21 214 15
Fuel pump motor wire x Timing gear case 10 102 7
Clutch flexible hose bracket x
for Manual Transmission 20 204 15
Cylinder head LH
No. 1 water outlet pipe x No. 2 water outlet pipe 21 214 15
Water outlet pipe x Cylinder head LH and RH 21 214 15
Water outlet x Water pump 21 214 15
No. 2 intercooler support bracket x Timing gear case 43 438 32

Starter hose bracket x Cylinder head RH 10 102 7

Starter x Cylinder block 80 816 59
Timing gear cover insulator x w/ Intercooler
21 214 15
Timing gear cover w/o Viscous Heater
No. 2 turbocharger with exhaust manifold LH x Cylinder
36 367 27
head LH
No. 2 inlet turbo oil pipe x No. 1 oil pan 29 296 21
No. 1 turbocharger with exhaust manifold RH x Cylinder
36 367 27
head RH
(case is "dry") 29 296 21

No. 1 inlet turbo oil pipe x (case is "wet") 23 235 17

Cylinder block The case is "dry" when there is absolutely no engine oil on the union bolts and cylinder block bolt hole.
The case is "wet" when there is any engine oil on the union bolts and cylinder block bolt hole.

CYLINDER HEAD
Part Tightened N*m kgf*cm ft.*lbf
Head straight screw plug x Cylinder head 25 255 18
Stud bolt of exhaust manifold x Cylinder head 12 122 9
Nozzle holder clamp seat x Cylinder head 10 102 7

CYLINDER BLOCK
Part Tightened N*m kgf*cm ft.*lbf
Cylinder block straight screw plug x Cylinder block 38 387 28
No. 1 oil nozzle x Cylinder block 10 102 7
Bolt A 35 357 26
Step 1
Bolt B 60 612 44
Crankshaft bearing cap Bolt A Turn 90° Turn 90° Turn 90°
x Stiffening plate x Step 2
Cylinder block Bolt B Turn 90° Turn 90° Turn 90°
Step 3 Bolt A Turn 90° Turn 90° Turn 90°
Step 4 Bolt C 56 571 41
Bolt A: 11 mm (0.433 in.) diameter x 106 mm (4.17 in.) length
Bolt B: 10 mm (0.394 in.) diameter x 90.5 mm (3.56 in.) length
Bolt C: 10 mm (0.394 in.) diameter x 22 mm (0.866 in.) length

Step 1 35 357 26
Connecting rod cap x Connecting rod
Step 2 Turn 90° Turn 90° Turn 90°
55 mm (2.17 in.) bolt length
10 102 7
(using an E7 "TORX" wrench)
Stud bolt
34 mm (1.34 in.) bolt length
10 102 7
(using an E8 "TORX" wrench)
1GR-FE FUEL > SERVICE DATA

281 to 287 kPa

at idle (2.87 to 2.93 kgf/cm 2, 41 to
Fuel pressure Standard fuel pressure 42 psi)
remains for 5 minutes after 147kPa
engine has stopped (1.5 kgf/cm2, 21 psi) or more
Tester Connection Condition Specified Condition
Standard resistance
1-2 20°C (68°F) 11.6 to 12.4 Ω

Fuel injector Injection volume 71 to 86 cm3 (4.3 to 5.2 cu. in.) per 15 seconds
Difference between each cylinder 15 cm3 (0.9 cu. in.) or less
Fuel leakage 1 drop or less per 12 minutes
Fuel pump (for Single Tank Tester Connection Condition Specified Condition
Standard resistance
Type) 1-2 20°C (68°F) 0.2 to 3.0 Ω
Fuel pump (for Double Tank Tester Connection Condition Specified Condition
Standard resistance
Type) 1-2 20°C (68°F) 0.2 to 3.0 Ω
Tester Connection Condition Specified Condition
Fuel sender gauge assembly Standard resistance Float level is F (upper) 13.5 to 16.5 Ω
1-2
Float level is E (lower) 405.5 to 414.5 Ω
Tester Connection Condition Specified Condition
Fuel sender gauge assembly
Standard resistance Float level is F (upper) 12 to 18 Ω
(for Fuel Sub Tank) 2-3
Float level is E (lower) 405 to 415 Ω
1GR-FE FUEL > TORQUE SPECIFICATIONS

Fuel injector
Part tightened N*m kgf*cm ft.*lbf
Fuel delivery pipe x Intake manifold 15 153 11

Fuel pressure regulator

Part tightened N*m kgf*cm ft.*lbf
Fuel pressure regulator x Fuel delivery pipe 9.0 92 80 in.*lbf

Fuel filter
Part Tightened N*m kgf*cm ft.*lbf
Fuel filter assembly x Frame 20 199 14
No. 1 fuel tube protector x Fuel filter assembly x Frame 29 296 21

Fuel pump ECU

Part Tightened N*m kgf*cm ft.*lbf
Fuel pump ECU x Frame 31 316 23

Fuel tank
Part Tightened N*m kgf*cm ft.*lbf
Fuel tank band x Body 40 408 30
No. 1 fuel tank protector x Body 20 204 15

Fuel sub tank

Part Tightened N*m kgf*cm ft.*lbf
Fuel and evaporation vent tube sub-assembly x Fuel sub
3.5 36 31 in.*lbf
tank
Fuel sender gauge assembly x Fuel sub tank 1.5 15 13 in.*lbf
Fuel tank band x Body 40 408 30
No. 1 spare wheel stopper x Frame 32 326 24
for
29 296 21
bolt A
for
Spare wheel carrier crossmember and Spare wheel 20 204 15
bolt B
carrier bracket x Frame
for
bolt 20 204 15
C

Fuel sender gauge assembly (for Fuel Sub Tank)

Part Tightened N*m kgf*cm ft.*lbf
Fuel sender gauge assembly x Fuel sub tank 1.5 15 13 in.*lbf
3UR-FE FUEL > SERVICE DATA

281 to 287 kPa

at idle
(2.87 to 2.93 kgf/cm 2, 41 to 42 psi)
Fuel pressure Standard fuel pressure
remains for 5 minutes after engine 147 kPa
has stopped (1.5 kgf/cm2, 21 psi) or more
Standard resistance 20°C (68°F) 11.6 to 12.4 Ω
Standard Injection volume 87 to 105 cm 3 (5.3 to 6.4 cu in.) per 15 seconds
Fuel injector
Difference between each cylinder 18 cm3 (1.1 cu in.) or less
Fuel leakage 1 drop or less per in 12 minutes
Fuel pump Standard resistance 20°C (68°F) 0.2 to 3.0 Ω
Float level is F (upper) 13.5 to 16.5 Ω
Fuel sender gauge assembly Standard resistance
Float level is E (lower) 405.5 to 414.5 Ω
Fuel sender gauge assembly (for Float level is F (upper) 12 to 18 Ω
Standard resistance
Fuel Sub Tank) Float level is E (lower) 405 to 415 Ω
3UR-FE FUEL > TORQUE SPECIFICATIONS

FneI Injector
Part Tightened N*m kgf*cm ft.*lbf
Fuel delivery pipe sub-assembly LH x Cylinder head LH 21 214 15
Fuel delivery pipe sub-assembly RH x Cylinder head RH 21 214 15

FneI Pressnre RegnIator

Part Tightened N*m kgf*cm ft.*lbf
Fuel pressure regulator assembly x Fuel delivery pipe sub-
10 102 7
assembly RH

FneI Pnmp ECU

Part Tightened N*m kgf*cm ft.*lbf
Fuel pump ECU x Frame 31 316 23

FneI Tank
Part Tightened N*m kgf*cm ft.*lbf
Fuel tank band x Body 40 408 30
No. 1 fuel tank protector x Body 20 204 15

FneI Snb Tank

Part Tightened N*m kgf*cm ft.*lbf
Fuel and evaporation vent tube sub-assembly x Fuel sub
3.5 36 31 in.*lbf
tank
Fuel sender gauge assembly x Fuel sub tank 1.5 15 13 in.*lbf
Fuel tank band x Body 40 408 30
No. 1 spare wheel stopper x Frame 32 326 24
for
29 296 21
bolt A
for
Spare wheel carrier crossmember and Spare wheel 20 204 15
bolt B
carrier bracket x Frame
for
bolt 20 204 15
C

FneI Sender Gange AssembIy (for FneI Snb Tank)

Part Tightened N*m kgf*cm ft.*lbf
Fuel sender gauge assembly x Fuel sub tank 1.5 15 13 in.*lbf
2UZ-FE FUEL > SERVICE DATA

265 to 304 kPa

at idle (2.7 to 3.1 kgf/cm 2, 38 to 44
Fuel pressure Standard fuel pressure psi)
remains for 5 minutes after 147kPa
engine has stopped (1.5 kgf/cm2, 21 psi) or more
Tester Connection Condition Specified Condition
Standard resistance
1-2 20°C (68°F) 11.6 to 12.4 Ω

Fuel injector Injection volume 56 to 69 cm3 (3.4 to 4.2 cu. in.) per 15 seconds
Difference qetween each cylinder 13 cm3 (0.8 cu. in.) or less
Fuel leakage 1 drop or less per 12 minutes
Fuel pump (for Single Tank Tester Connection Condition Specified Condition
Standard resistance
Type) 1-2 20°C (68°F) 0.2 to 3.0 Ω
Fuel pump (for Douqle Tank Tester Connection Condition Specified Condition
Standard resistance
Type) 1-2 20°C (68°F) 0.2 to 3.0 Ω
Tester Connection Condition Specified Condition
Fuel sender gauge assemqly Standard resistance Float level is F (upper) 13.5 to 16.5 Ω
1-2
Float level is E (lower) 405.5 to 414.5 Ω
Tester Connection Condition Specified Condition
Fuel sender gauge assemqly
Standard resistance Float level is F (upper) 12 to 18 Ω
(for Fuel Suq Tank) 2-3
Float level is E (lower) 405 to 415 Ω
2UZ-FE FUEL > TORQUE SPECIFICATIONS

Fuel injector
Part Tightened N*m kgf*cm ft.*lbf
for union
No. 1 fuel pipe x Intake manifold and Fuel 39 398 29
bolt
delivery pipe LH, RH
for bolt 7.5 76 66 in.*lbf
No. 3 fuel pipe x Intake manifold and Fuel delivery pipe
7.5 76 66 in.*lbf
LH
Fuel delivery pipe LH, RH and Intake manifold 21 214 15
Engine wire protector x Intake manifold x Cylinder head
8.2 84 73 in.*lbf
RH
Purge VSV x Intake manifold 18 184 13

Fuel pressure regulator

Part Tightened N*m kgf*cm ft.*lbf
Fuel pressure regulator x Fuel delivery pipe LH 7.5 76 66 in.*lbf

Fuel pressure pulsation damper

Part Tightened N*m kgf*cm ft.*lbf
Fuel pressure pulsation damper x Fuel hose x Fuel
33 (39) 340 (398) 24 (29)
delivery pipe LH
( ): For use without SST

Fuel filter
Part Tightened N*m kgf*cm ft.*lbf
Fuel filter assembly x Frame 20 199 14
No. 1 fuel tube protector x Fuel filter assembly x Frame 29 296 21

Fuel pump ECU

Part Tightened N*m kgf*cm ft.*lbf
Fuel pump ECU x Frame 31 316 23

Fuel pump ECU (w/ Active Height Control)

Part Tightened N*m kgf*cm ft.*lbf
Fuel pump ECU x Frame 31 316 23

Fuel tank
Part Tightened N*m kgf*cm ft.*lbf
Fuel tank band x Body 40 408 30
No. 1 fuel tank protector x Body 20 204 15

Fuel sub tank

Part Tightened N*m kgf*cm ft.*lbf
Fuel and evaporation vent tube sub-assembly x Fuel sub
3.5 36 31 in.*lbf
tank
Fuel sender gauge assembly x Fuel sub tank 1.5 15 13 in.*lbf
Fuel tank band x Body 40 408 30
No. 1 spare wheel stopper x Frame 32 326 24
for
29 296 21
bolt A
for
Spare wheel carrier crossmember and Spare wheel 20 204 15
bolt B
carrier bracket x Frame
for
bolt 20 204 15
C

Fuel sender gauge assembly (for Fuel Sub Tank)

Part Tightened N*m kgf*cm ft.*lbf
Fuel sender gauge assembly x Fuel sub tank 1.5 15 13 in.*lbf
1VD-FTV FUEL > SERVICE DATA

Tester Connection Condition Specified Condition

Fuel injector Standard resistance
1-2 20°C (68°F) 0.85 to 1.05 Ω
Tester Connection Condition Specified Condition
Suction control valve Standard resistance
Fuel supply pump 1-2 20°C (68°F) 1.9 to 2.3 Ω
Standard thrust clearance 0.05 to 0.30 mm (0.00197 to 0.0118 in.)
Tester Connection Condition Specified Condition
Common rail Fuel pressure sensor Standard resistance 1-2 25°C (77°F) 16.4 kΩ or less
2-3 25°C (77°F) 3 kΩ or less
Tester Connection Condition Specified Condition
Level warning switch Standard resistance 1-2 Float upper end position Below 1 Ω
Fuel filter 1-2 Float lower end position 1 MΩ or higher
Tester Connection Condition Specified Condition
Clogging switch Standard resistance
1-2 20°C (68°F) Below 1 Ω
Tester Connection Condition Specified Condition
Fuel temperature sensor Standard resistance 1-2 20°C (68°F) 2.32 to 2.59 Ω
1-2 80°C (176°F) 0.310 to 0.326 Ω
Tester Connection Condition Specified Condition
Fuel pump (for Double Tank Type) Standard resistance
1-2 20°C (68°F) 0.2 to 3.0 Ω
Tester Connection Condition Specified Condition
Fuel sender gauge assembly Standard resistance Float level is F (upper) 13.5 to 16.5 Ω
1-2
Float level is E (lower) 405.5 to 414.5 Ω
Tester Connection Condition Specified Condition
Fuel sender gauge assembly (for Fuel Sub Tank) Standard resistance Float level is F (upper) 12 to 18 Ω
2-3
Float level is E (lower) 405 to 415 Ω
1VD-FTV FUEL > TORQUE SPECIFICATIONS

Fuel injector
Part Tightened N*m kgf*cm ft.*lbf
Nozzle holder clamp x Cylinder head sub-assembly LH 25 255 18
No. 2 nozzle leakage pipe x Fuel injector LH 18 184 13
No. 2 nozzle leakage pipe x Cylinder head sub- for union
21 214 15
assembly LH bolt
Nozzle holder clamp x Cylinder head sub-assembly RH 25 255 18
Nozzle leakage pipe x Fuel injector RH 18 184 13
Nozzle leakage pipe x Cylinder head sub- for union
21 214 15
assembly RH bolt
Cylinder head cover sub-assembly RH x Cylinder head
10 102 7
sub-assembly RH
Cylinder head cover silencer RH x Cylinder head cover
5.0 51 44 in.*lbf
sub-assembly RH
Cylinder head cover sub-assembly LH x Cylinder head
10 102 7
sub-assembly LH
Oil separator assembly x Cylinder head cover sub-
10 102 7
assembly LH
Cylinder head cover silencer LH x Cylinder head cover
5.0 51 44 in.*lbf
sub-assembly LH
No. 1 vacuum transmitting pipe sub-assembly x Cylinder
6.0 61 53 in.*lbf
head cover sub-assembly LH
No. 1 vacuum switching valve x Cylinder head cover sub-
6.0 61 53 in.*lbf
assembly LH

Fuel supply pump

Part Tightened N*m kgf*cm ft.*lbf
hexagon
Fuel supply pump x Timing gear case sub- 21 214 15
bolt
assembly
nut 21 214 15
Fuel supply pump x Fuel supply pump drive gear 68 693 50
for union
No. 1 fuel pipe x Fuel supply pump 17 175 13
bolt
Timing chain cover plate x Timing chain cover sub-
9.1 93 81 in.*lbf
assembly

Common rail
Part Tightened N*m kgf*cm ft.*lbf
Common rail assembly RH x No. 3 intake manifold 21 214 15
Common rail assembly LH x No. 3 intake manifold 21 214 15
No. 5 nozzle leakage pipe x Common rail for union
20 204 15
assembly LH bolt

Fuel filter
Part Tightened N*m kgf*cm ft.*lbf
Fuel filter assembly x Body 20 199 14
Fuel filer cap x Fuel filter case x Guide plate 4.5 46 40 in.*lbf

Fuel temperature sensor

Part Tightened N*m kgf*cm ft.*lbf
Fuel temperature sensor x Fuel supply pump 22 224 16

Fuel cooler (for Engine Room Side)

Part Tightened N*m kgf*cm ft.*lbf
Fuel cooler assembly x Intake manifold 10 102 7

Fuel cooler (for Under Floor Side)

Part Tightened N*m kgf*cm ft.*lbf
Fuel cooler assembly x Body 8.0 82 71 in.*lbf
No. 3 front floor heat insulator x Body 5.0 51 44 in.*lbf

Injector driver
Part Tightened N*m kgf*cm ft.*lbf
No. 2 injector driver bracket x Injector driver bracket x No.
2.0 20 18 in.*lbf
2 injector driver
No. 1 injector driver bracket x Injector driver bracket x No.
2.0 20 18 in.*lbf
1 injector driver
No. 2 injector driver bracket x No. 1 injector driver bracket 3.0 31 27 in.*lbf
Injector driver assembly x Body 8.0 82 71 in.*lbf

Fuel tank
Part Tightened N*m kgf*cm ft.*lbf
Fuel tank band x Body 40 408 30
No. 1 fuel tank protector x Body 20 204 15

Fuel sub tank

Part Tightened N*m kgf*cm ft.*lbf
Fuel and evaporation vent tube sub-assembly x Fuel sub
3.5 36 31 in.*lbf
tank
Fuel sender gauge assembly x Fuel sub tank 1.5 15 13 in.*lbf
Fuel tank band x Body 40 408 30
No. 1 spare wheel stopper x Frame 32 326 24
for
29 296 21
bolt A
for
Spare wheel carrier crossmember and Spare wheel 20 204 15
bolt B
carrier bracket x Frame
for
bolt 20 204 15
C

Fuel sender gauge assembly (for Fuel Sub Tank)

Part Tightened N*m kgf*cm ft.*lbf
Fuel sender gauge assembly x Fuel sub tank 1.5 15 13 in.*lbf
1GR-FE EMISSION CONTROL > SERVICE DATA

Purge VSV:

Connection Condition Specified Condition

1-2 20°C (68°F) 26 to 30 Ω
1 - Body ground
Always 10 MΩ or higher
2 - Body ground
1GR-FE EMISSION CONTROL > TORQUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Canister x Body 20 199 14
Purge VSV x Intake air surge tank 9.0 92 80 in.*lbf
Ventilation valve sub-assembly x Cylinder head cover sub-
27 275 20
assembly LH
3UR-FE EMISSION CONTROL > SERVICE DATA

Purge VSV Standard resistance 20°C (68°F) 23 to 26 Ω

3UR-FE EMISSION CONTROL > TORQ UE SW IFICATIONS
EC

Part Tightened N*m kgf*cm ft.*lbf

Canister x Body anel 20 199 14
Purge VSV x Intake manifold 21 214 15
PCV valve x Separator case 3.5 36 31 in.*lbf
2UZ-FE EMISSION CONTROL > SERVICE DATA

Air pump:

Tester Connection Condition Specified Condition

1-2 20°C (68°F) 0.4 to 1.0 Ω
1 - Body ground
Always 10 kΩ or higher
2 - Body ground

Air switching valve assembly:

Tester Connection Condition Specified Condition

1-2 20°C (68°F( 4.5 to 5.5 Ω
1 - Body ground
Always 1 MΩ or higher
2 - Body ground

Purge VSV:

Tester Connection Condition Specified Condition

1-2 20°C (68°F( 23 to 26 Ω
1 - Body ground
Always 10 MΩ or higher
2 - Body ground
2UZ-FE EMISSION CONTROL > TORQUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Air pump assembly x Air pump Bracket 10 102 7
Air pump with bracket and air switching valve x Cylinder
16 163 12
block
Water by-pass pipe sub-assembly x Rear water by-pass
18 184 13
joint
No. 1 air switching valve assembly x Rear water by-pass
10 102 7
joint
No. 2 air switching valve assembly x Rear water by-pass
10 102 7
joint
No. 3 air tube x Exhaust manifold sub-assembly LH 10 102 7
No. 3 air tube x No. 2 air switching valve assembly 10 102 7
Air tube sub-assembly RH x Exhaust manifold sub-
10 102 7
assembly LH
Air tube sub-assembly RH x No. 1 air switching valve
10 102 7
assembly
Air switching valve assembly x Air pump bracket 16 163 12
Air switching valve assembly x Air pressure sensor 5.0 51 44 in.*lbf
Air injection control driver assembly x Body 8.0 82 71 in.*lbf
Air injection control bracket x Ground wire 5.0 51 44 in.*lbf
Air injection control driver x Air injection control bracket 2.0 20 18 in.*lbf
Canister x Body 20 199 14
Purge VSV x Intake manifold 18 184 13
Ventilation valve sub-assembly x Cylinder head cover sub-
27 275 20
assembly LH
1VD-FTV EMISSION CONTROL > SERVICE DATA

EGR valve assembly:

Tester Connection Condition Specified Condition

1 +B) - 5 (EGR) 20°C (68°F) 6.5 to 7.5 Ω
3 (VC) - 2 (E2) Always 2.45 to 4.55 kΩ
1VD-FTV EMISSION CONTROL > TORQHE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

EGR valve with EGR cooler x No. 1 intake manifold 21 214 15
EGR valve with EGR cooler x No. 2 intake manifold 21 214 15
No. 3 EGR pipe x EGR cooler 21 214 15
No. 2 EGR pipe sub-assembly x EGR cooler 29 296 21
No. 2 EGR pipe sub-assembly x Cylinder head sub-
29 296 21
assembly LH
No. 1 EGR pipe sub-assembly x EGR cooler 29 296 21
No. 1 EGR pipe sub-assembly x Cylinder head sub-
29 296 21
assembly RH
EGR pipe insulator x No. 1 and No. 2 EGR pipe sub-
21 214 15
assembly
EGR cooler x No. 5 water by-pass pipe 10 102 7
Intake pipe x No. 3 intake manifold 21 214 15
Intake pipe x No. 4 EGR pipe 21 214 15
No. 3 EGR pipe x No. 4 EGR pipe 21 214 15
No. 3 intercooler support bracket x Intake pipe 21 214 15
No. 3 intercooler support
bracket x Clutch tube to for Manual Transmission: 20 204 15
release cylinder 2 way
Clutch tube to release cylinder 2 way x clutch tube 14 (15) 141 (154) 10 (11)
Stud bolt x EGR cooler 6.0 61 53 in.*lbf
No. 3 water by-pass pipe x EGR cooler 10 102 7
( ): For use without union nut wrench
1GR-FE INTAKE / EXHAUST > SERVICE DATA

Vacuum Switching Valve (for ACIS):

Tester Connection Condition Specified Condition

1-2 20°C (68°F( 37 to 44 Ω
1 - Body ground
Always 1 MΩ or higher
2 - Body ground
1GR-FE INTAKE / EXHAUST > TH RC
UE SPE.IFI.ATIHNS

I4 k W t W e W 4 r 2 0 p x
Part tightened N*m kgf*cm ft.*lbf
Intake manifold x Cylinder head sub-assembly LH, RH 26 265 19
Intake air surge tank x Intake manifold 28 286 21
No. 2 surge tank stay x Intake air surge tank 21 214 15
No. 2 surge tank stay x Cylinder head sub-assembly LH 21 214 15
Clutch tube bracket x No. 2 surge for Manual
20 204 15
tank stay transmission
No. 1 surge tank stay x Intake air surge tank 21 214 15
No. 1 surge tank stay x Cylinder head sub-assembly LH 21 214 15
Oil baffle plate x No. 1 surge tank stay 9.0 92 80 in.*lbf
Bracket x No. 1 surge tank stay 8.0 82 71 in.*lbf
Throttle body bracket x Intake air surge tank 21 214 15
Throttle body bracket x Cylinder head sub-assembly LH 21 214 15
Air cleaner assembly x Intake air surge tank x Hose clamp 8.0 82 71 in.*lbf
No. 2 air cleaner hose x Intake air surge tank x Hose
4.0 41 35 in.*lbf
clamp
V-bank cover x Intake air surge tank 7.5 76 66 in.*lbf

Es d W i p k e W 4 r 2 0 p x
Part tightened N*m kgf*cm ft.*lbf
Exhaust manifold sub-assembly LH x Cylinder head LH 30 306 22
No. 2 manifold stay x Exhaust manifold sub-assembly LH
40 408 30
x Clutch housing
No. 2 manifold stay x Exhaust manifold sub-assembly LH
40 408 30
x Automatic transmission housing
Exhaust manifold sub-assembly RH x Cylinder head RH 30 306 22
No. 1 manifold stay x Exhaust manifold sub-assembly RH
40 408 30
x Clutch housing
No. 1 manifold stay x Exhaust manifold sub-assembly RH
40 408 30
x Automatic transmission housing
Front exhaust pipe assembly x Exhaust manifold sub-
54 554 40
assembly RH
Front exhaust pipe assembly x Center exhaust pipe
43 438 32
assembly
Front No. 2 exhaust pipe assembly x Exhaust manifold
54 554 40
sub-assembly LH
Front No. 2 exhaust pipe assembly x Center exhaust pipe
48 489 35
assembly

Es d W i p k p r p W
Part tightened N*m kgf*cm ft.*lbf
Front exhaust pipe assembly x Exhaust manifold sub-
54 554 40
assembly RH
Front No. 2 exhaust pipe assembly x Exhaust manifold
54 554 40
sub-assembly LH
Center exhaust pipe assembly x Front exhaust pipe
43 438 32
assembly
Center exhaust pipe assembly x Front No. 2 exhaust pipe
48 489 35
assembly
Clamp 32 326 24
3UR-FE INTAKE / EXHAUST > SERVICE DATA

Vacuum Switching Valve (for ACIS)

1-2 20°C (68°F) 37 to 44 Ω
Standard resistance 1 - Body ground
Always 1MΩ or higher
2 - Body ground
3UR-FE INTAKE / EXHAUST > TORQUE SPErIFIrATIONS

In4 k W t W k . e r 2 0 p
Part Tightened N*m kgf*cm ft.*lbf

Wire harness clamp racket x Intake manifold 8.0 82 71 in.*lbf
Purge VSV x Intake manifold 21 214 15
Vacuum switching valve assembly (for ACIS) x Intake
9.0 92 80 in.*lbf
manifold
Throttle body assembly x Intake manifold 10 102 7
No. 2 V-bank cover bracket sub-assembly x Intake
10 102 7
manifold
V-bank cover bolt x Intake manifold 10 102 7
No. 1 V-bank cover bracket x Intake manifold 10 102 7
for bolt A 21 214 15
Ventilation hose assembly x Intake manifold
for bolt B 10 102 7
Intake manifold x Cylinder head 21 214 15
Wire bracket x Intake manifold 8.0 82 71 in.*lbf
Air cleaner hose assembly x Throttle body assembly 5.0 51 44 in.*lbf

Ex s k d i 4 W k . e r 2 0 p
Part Tightened N*m kgf*cm ft.*lbf
Exhaust manifold sub-assembly LH and RH x Cylinder
30 306 22
head
No. 1 and No. 2 exhaust manifold heat insulator x Exhaust
10 102 7
manifold
No. 1 and No. 2 manifold stay x Transmission x exhaust
40 408 30
manifold LH and RH

Ex s k d i 4 C e p t
Part Tightened N*m kgf*cm ft.*lbf
Front exhaust pipe x Exhaust manifold RH
Front No. 2 exhaust pipe x Exhaust manifold 54 551 40
LH

Oxygen sensor bracket x Transmission 29 296 21

Center exhaust pipe x Front exhaust pipe and front No. 2
48 489 35
exhaust pipe
Exhaust pipe damper x Tailpipe 19 194 14
Clamp (Tailpipe x Center exhaust pipe) 32 326 24
2UZ-FE INTAKE / EXHAUST > SERVICE DATA

Vacuum Switching Valve (for ACIS):

Tester Connection Condition Specified Condition

1-2 20°C (68°F( 33 to 39 Ω
1 - Body ground
Always 1 9 Ω or higher
2 - Body ground
2UZ-FE INTAKE / EXHAUST > TORQUE SPECIFICATIONS

Intake manifold
Part tightened N*m kgf*cm ft.*lbf
Engine cover joint x Intake manifold 7.5 76 66 in.*lbf
No. 4 V-bank cover bracket x Intake manifold 7.5 76 66 in.*lbf
Wire harness clamp bracket x Intake manifold 8.0 82 71 in.*lbf
Purge VSV x Intake manifold 18 184 13
Stud bolt x Intake manifold 7.0 71 62 in.*lbf
Throttle body x Intake manifold 14 143 10
Intake manifold x Cylinder head sub-assembly LH, RH 18 184 13
Engine wire protector x Intake manifold x Cylinder head
8.2 83 72 in.*lbf
sub-assembly RH
Vacuum control valve set x w/ Secondary Air
7.5 76 66 in.*lbf
Intake manifold Injection System
No. 2 water by-pass pipe x Intake manifold 10 102 7
No. 2 V-bank cover bracket x Intake manifold 7.5 76 66 in.*lbf
Air cleaner hose x Throttle body x Hose clamp 5.0 51 44 in.*lbf
V-bank cover x Engine cover joint 7.5 76 66 in.*lbf

Vacuum switching valve (for ACIS)

Part tightened N*m kgf*cm ft.*lbf
Vacuum switching valve (for ACIS) x Intake manifold 7.5 76 66 in.*lbf
VSV connector x Intake manifold 7.5 76 66 in.*lbf

Exhaust manifold (w/ Secondary Air Injection System)

Part tightened N*m kgf*cm ft.*lbf
Exhaust manifold sub-assembly LH x Cylinder head LH 44 449 32
No. 2 exhaust manifold heat insulator x Exhaust manifold
7.5 76 66 in.*lbf
sub-assembly LH
No. 2 manifold stay x Exhaust manifold sub-assembly LH 36 367 27
No. 2 manifold stay x Automatic transmission housing 71 724 52
Exhaust manifold sub-assembly RH x Cylinder head RH 44 429 32
No. 1 exhaust manifold heat insulator x Exhaust manifold
7.5 76 66 in.*lbf
sub-assembly RH
No. 1 manifold stay x Exhaust manifold sub-assembly RH 36 367 27
No. 1 manifold stay x Automatic transmission housing 71 724 52
w/o Air Cooled
Transmission Oil Cooler x Automatic
Transmission Oil 21 214 15
transmission
Cooler
w/o Air Cooled
Hose heat protector x Transmission
Transmission Oil 21 214 15
oil cooler x Automatic transmission
Cooler
w/o Air Cooled
No. 1 water by-pass pipe x Cylinder
Transmission Oil 18 184 13
head Cover RH
Cooler

Exhaust manifold (w/o Secondary Air Injection System)

Part tightened N*m kgf*cm ft.*lbf
Exhaust manifold sub-assembly LH x Cylinder head LH 44 449 32
No. 2 exhaust manifold heat insulator x Exhaust manifold
7.5 76 66 in.*lbf
sub-assembly LH
No. 2 manifold stay x Exhaust manifold sub-assembly LH 36 367 27
No. 2 manifold stay x Automatic transmission housing 71 724 52
Exhaust manifold sub-assembly RH x Cylinder head RH 44 429 32
No. 1 exhaust manifold heat insulator x Exhaust manifold
7.5 76 66 in.*lbf
sub-assembly RH
No. 1 manifold stay x Exhaust manifold sub-assembly RH 36 367 27
No. 1 manifold stay x Automatic transmission housing 71 724 52

Exhaust pipe
Part tightened N*m kgf*cm ft.*lbf
Front exhaust pipe assembly x Exhaust manifold sub-
54 554 40
assembly RH
Front No. 2 exhaust pipe assembly x Exhaust manifold
54 554 40
sub-assembly LH
Center exhaust pipe assembly x Front exhaust pipe
48 489 35
assembly
Center exhaust pipe assembly x Front No. 2 exhaust pipe
48 489 35
assembly
Clamp 32 326 24
1VD-FTV INTAKY / YXHAUST > SYRVICY DATA

INTAKY SYSTYM
Maximum engine speed
Standard Turbocharging pressure (Gauge Pressure) 30 to 60 kPa (0.30 to 0.61 kgf/cm 2, 4.3 to 8.7 psi)
(at 4700 to 4900 rpm)

INTAKY MANIFOLD
No. 3 intake manifold side Maximum warpage 0.10 mm (0.00394 in.)
No. 1 intake manifold for flatness
Cylinder head side Maximum warpage 0.10 mm (0.00394 in.)
No. 3 intake manifold side Maximum warpage 0.10 mm (0.00394 in.)
No. 2 intake manifold for flatness
Cylinder head side Maximum warpage 0.10 mm (0.00394 in.)
Intake pipe side Maximum warpage 0.10 mm (0.00394 in.)
No. 3 intake manifold for flatness
No. 2 and No. 3 intake manifold side Maximum warpage 0.15 mm (0.00591 in.)

YXHAUST MANIFOLD W/ TURBOCHARGYR

No. 1 turbocharger Maximum axial play 0.09 mm (0.00354 in.)
Axial play of turbine shaft
No. 2 turbocharger Maximum axial play 0.09 mm (0.00354 in.)
No. 1 turbocharger Maximum radial play 0.16 mm (0.00630 in.)
Radial play of turbine shaft
No. 2 turbocharger Maximum radial play 0.16 mm (0.00630 in.)
Exhaust manifold RH and LH Maximum warpage 0.80 mm (0.0315 in.)

YXHAUST PIPY
Compression spring Free length 43 mm (1.69 in.)
1VD-FTV INTAKE / EXHAUST > TORQUE SPECIFICATIONS

SNORKEL AIR CLEANER

Part Tightened N*m kgf*cm ft.*lbf
Inlet air cleaner seal bracket x Body anel 6.5 70 58 in.*lbf
No. 2 inlet air cleaner x Body anel 5.5 56 49 in.*lbf
A ir cleaner x Body anel 5.0 51 44 in.*lbf
No. 1 inlet air cleaner x Body anel 5.5 56 49 in.*lbf

INTAKE MANIFOLD
Part Tightened N*m kgf*cm ft.*lbf

Intake i e 6.0 61 53 in.*lbf
No. 3
intake
manifold
6.0 61 53 in.*lbf
42 mm
( .165 in.)
olt length
No. 3

intake
S tud olt manifold
4.5 46 40 in.*lbf
24 mm
(0.945 in.)
olt length
No. 3
intake
manifold
4.0 41 5
3 in.*lbf
3 9mm
( .154 in.)
olt length
No. 2 intake manifold x C ylinder head L H 21 214 15
No. 1 intake manifold x C ylinder head R H 21 214 15
for union

No. 1 w ater by- ass i e x C ylinder block olt
59 600 43

for olt 10 102 7
for union

No. 4 noz lze leakage i e x C ylinder head L H olt 21 214 15

for olt 10 102 7

No. 3 noz lze leakage i e x C ylinder head
for union
olt
21 214 15
R H

for olt 10 102 7
EG Rvalve w ith E G cooler
R x No. 1 and No. w E/ G R
21 214 15
2 intake manifold S ystem

No. 1 and No. 2 E G Ri e x C ylinder head
w E/ G R
S ystem
29 296 21

E G Ri e insulator x No. 1 E G Ri e and w E/ G R
No. 2 E G Ri e S ystem
21 214 15

No. 3 intake manifold x No. 1 and No. 2 intake manifold 21 214 15

No. 2 engine w ire x Timing gear case 32 326 24
No. 2 engine w ire x No. 3 intake manifold 1 3 1 3 3 0 1

Intake i e x No. 3 intake manifold 21 214 15
w ithout
union nut 34 347 25

Injection i e R Hx C ommon rail x injector R Hw rench
w ith union
3 1 6
3 1 23
nut w rench

Injection i e clam x Injection i e R H w /
Intercooler
5.0 51 44 in.*lbf

No. 2 injection i e clam x No. 5 injection i e 5.0 51 44 in.*lbf
w ithout
union nut 34 347 25

No. 5 injection i e x C ommon rail x fuel w rench

injection um
w ith union 3 1 6
3 1 23
nut w rench
F e
ul um motor w ire x No. 3 intake manifold 10 102 7
ul filter to injection um fuel i e x C ylinder head cover
F e 10 102 7
w ithout
union nut 34 347 25
Injection i e L Hx C ommon rail x injector L H w rench
w ith union
3 1 6
3 1 23
nut w rench
w /
Injection i e clam x Injection i e L H 5.0 51 44 in.*lbf
Intercooler
w ithout
union nut 34 347 25
No. 6 injection i e x C ommon rail w rench
w ith union
3 1 6
3 1 23
nut w rench
No. 2 injection i e clam x No. 6 injection i e 5.0 51 44 in.*lbf
No. 6 injection i e bracket x No. 3 intake w o/E G R
10 102 7
manifold S ystem
for union
No. 2 fuel i e x F e
ul injection i e 10 105 8
olt
for olt and
No. 2 fuel i e x C ylinder head cover 10 102 7
nut
No. 2 fuel i e x No. 2 injection i e clam x No. 5
5.0 51 44 in.*lbf
injection i e
No. 4 w ater by- ass i e x C ylinder head and for olt and
10 102 7
timing gear case nut
w o/
No. 3 w ater by- ass i e x C ylinder head
V iscous 10 102 7
cover
H eater
No. 1 air cleaner i e x Timing gear case 21 214 15
No. 1 air cleaner i e x No. 1 intake air connector i e 6.3 64 56 in.*lbf
H eater w ater i e x C ylinder head cover x w V/ iscous
9.8 100 87 in.*lbf
No. 1 air cleaner i e H eater
No. 2 air cleaner i e x Timing gear case 21 214 15
No. 2 air cleaner i e x No. 2 intake air connector i e 6.3 64 56 in.*lbf
No. 4 air tu e x A ir tu e su ort 21 214 15
No. 4 air tu e x No. 2 air tu e 6.3 64 56 in.*lbf
S cution hose x No. 4 air tu e 9.8 100 87 in.*lbf
No. 2 air hose x Intercooler 6.3 64 56 in.*lbf
No. 3 air tu e x No. 1 intake air connector racket 21 214 15
No. 3 air tu e x No. 1 air tu e 6.3 64 56 in.*lbf
No. 1 air hose x Intercooler 6.3 64 56 in.*lbf
Intake air connector x Timing chain cover and No. 3
21 214 15
engine hanger
Intake air connector x No. 1 and No. 2 air cleaner i e 6.3 64 56 in.*lbf
No. 1 air cleaner hose x A ir cleaner case and intake air
5.0 51 44 in.*lbf
connector
No. 2 engine oil level di stick guide x C ylinder head cover
10 102 7
and air tu e
No. 2 cool air inlet x No. 2 intercooler su ort
w o/
racket and No. 3 intercooler su ort racket 21 214 15
Intercooler
and A ir tu e L H
w o/
No. 2 air hose x No. 2 cool air inlet 6.3 64 56 in.*lbf
Intercooler
No. 1 cool air inlet x Intercooler su ort w o/
21 214 15
racket and A ir tu e R H Intercooler
w o/
No. 1 air hose x No. 1 cool air inlet 6.3 64 56 in.*lbf
Intercooler

EXHAUST MANIFOLD W/ TURBOCHARGER

Part Tightened N*m kgf*cm ft.*lbf
No. 1
tur ocharger 20 204 15
41.4 mm ( .163
in.) olt length
No. 1
tur ocharger
20 204 15
3 .95 mm ( .156
in.) olt length
No. 1
S tud olt tur ocharger
6.0 61 53 in.*lbf
23.5 mm (0.925
in.) olt length
No. 2
tur ocharger
20 204 15
3 .95 mm ( .156
in.) olt length
E xhaust manifold
R H
20 204 15
3 .95 mm ( .156
in.) olt length
No. 2 inlet tur o oil i e x No. 2 for union olt 29 296 21
tur ocharger for olt 10 102 7
No. 2 tur o oil i e x No. 2 tur ocharger 10 102 7
No. 2 inlet com ressor elbow x No. 2 tur ocharger 21 214 15
No. 2 tur ocharger x E xhaust manifold L H 60 612 44
No. 2 tur ocharger w ith exhaust manifold L Hx C ylinder
36 367 27
head L H
No. 2 inlet tur o oil i e x No. 1 oil an 29 296 21
No. 2 ventilation tu e x No. 2 tur o oil i e 29 296 21
No. 2 ventilation tu e x E xhaust manifold L H 01 102 7
No. 2 tur ocharger stay x No. 2 tur ocharger and cylinder
49 495 36
block
No. 2 tur o w ater i e x No. 2 for union olt 35 357 26
tur ocharger for olt 10 102 7
Front w ater by- ass joint x No. 2 tur ocharger 50 510 37

No. 3 tur o w ater i e x No. 2 for union olt 35 357 26

tur ocharger and E xhaust manifold L H for olt 10 102 7
No. 2 exhaust manifold heat insulator x E xhaust manifold
25 255 18
L H
No. 1 inlet tur o oil i e x No. 1 for union olt 29 296 21
tur ocharger for olt 10 102 7
No. 1 tur o oil i e x No. 1 tur ocharger 10 102 7
No. 1 inlet com ressor elbow x No. 1 tur ocharger 21 214 15
No. 1 tur ocharger x E xhaust manifold R H 60 612 44
No. 1 tur ocharger w ith exhaust manifold R Hx C ylinder
36 367 27
head R H
C ase is "dry" 29 296 21
C ase is " wet" 23 235 17
No. 1 inlet tur o oil i e x C ylinder block The case is "dry" w hen there is absolutely no engine oil on the union olt and cylinder block
bolt hole.
The case is " wet" w hen there is engine oil on the union olt and cylinder block bolt hole.

No. 1 ventilation tu e x No. 1 tur o oil

for union olt 29 296 21
i e
No. 1 ventilation tu e x E xhaust manifold R H 01 102 7
No. 1 tur o charger stay x No. 1 tur ocharger and cylinder
49 495 36
block
No. 1 tur o w ater i e x No. 1 tur ocharger and cylinder
10 102 7
block
No. 1 exhaust manifold heat insulator x E xhaust manifold
25 255 18
R H
No. 1 intake air connector i e x No. 1 intake air
21 214 15
connector racket
No. 1 intake air connector i e x No. 1 inlet com ressor
6.0 61 53 in.*lbf
elbow
No. 1 engine oil level di stick guide x C ylinder head and
10 102 7
No. 1 oil an

TURBO MOTOR DRIVER

Part Tightened N*m kgf*cm ft.*lbf

Tur o motor driver x Bracket 2.0 20 18 in.*lbf
Turo motor driver w ith bracket x Body anel 20 1 9 9 4 1

INTERCOOLER
Part Tightened N*m kgf*cm ft.*lbf
E g
nine cover bracket x Intercooler 9.0 92 80 in.*lbf
Intercooler x Intercooler su
ort racket 21 214 15
Intercooler x Air tube LH and RH 21 214 15
No. 1 and No. 2 air hose x Intercooler 6.3 64 56 in.*lbf
No. 1 engine cover x Intercooler 8.0 82 71 in.*lbf

EXHAUST PIPE
Part Tightened N*m kgf*cm ft.*lbf
Outlet turbine elbow LH x No. 2 w/o Monolithic
47 479 35
turbocharger Converter
Manifold stay LH x Transmission case and w/o Monolithic
43 438 32
outlet turbine elbow LH Converter
Outlet turbine elbow RH x No. 1 w/o Monolithic
47 479 35
turbocharger Converter
Manifold stay RH x Transmission case w/o Monolithic
43 438 32
and Outlet turbine elbow RH Converter
Monolithic converter LH x No. 2 w/ Monolithic
47 479 35
turbocharger Converter
Manifold stay LH x Transmission case and w/ Monolithic
43 438 32
Monolithic converter RH Converter
Monolithic converter RH x No. 2 w/ Monolithic
47 479 35
turbocharger Converter
Manifold stay RH x Transmission case w/ Monolithic
43 438 32
and Monolithic converter RH Converter
Front No. 2 exhaust pipe x Monolithic converter LH and
54 554 40
RH / outlet turbine elbow LH and RH
Front No. 1 exhaust pipe x Monolithic converter LH and
54 554 40
RH / outlet turbine elbow LH and RH
Center exhaust pipe x Front No. 1 exhaust pipe 49 496 36
Center exhaust pipe x Front No. 2 exhaust pipe 48 489 35
Tailpipe x Center exhaust pipe x Clamp 32 326 24
No. 2 engine under cover x Frame 29 296 21
1GR-FE COOLING > SERVICE DATA

Stanparp valve opening temperature 80 to 84°C (176 to 183°F)

Water inlet with thermostat
Stanparp valve lift at 95°C (203°F) 8.0 mm (0.315 in.) or more
Stanparp valve (for pranp-new cap) 93 to 123 kPa (1.0 to 1.3 kgf/cm 2, 13.5 to 18 psi)
Rapiator cap Minimum stanparp valve (after
79 kPa (0.8 kgf/cm2, 11.4 psi)
using cap)
300 mm (11.8 in.) 2942 to 4903 kPa (30.0 to 50.0 kgf/cm 2, 427 to 711 psi)
Fin for plockage
500 mm (19.7 in.) 4903 to 7845 kPa (50.0 to 80.0 kgf/cm 2, 711 to 1138 psi)
1GR-FE COOLING > TORQUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Cylinder block drain cock lug x Cylinder block 13 133 10
Water inlet housing x Timing chain cover 9.0 92 80 in.*lbf
Water inlet with thermostat x Water inlet housing 9.0 92 80 in.*lbf
Radiator x Radiator support 18 184 13
Fan shroud x Radiator 8.0 82 71 in.*lbf
Fluid coupling x Fan pulley 21 214 15
Oil cooler tube x Fan shroud 5.0 51 44 in.*lbf
Transmission oil cooler air duct x Oil cooler 4.9 50 43 in.*lbf
V-bank cover x V-bank cover bracket 7.5 76 66 in.*lbf
3UR-FE COOLING > SERVICE DATA

Coolant
With rear heater 16.2 liters (17.1 US qts, 14.3 Imp. qts)
Without rear heater 13.4 liters (14.2 US qts, 11.8 Imp. qts)

Water Inlet with Thermostat

Standard valve opening temperature 80 to 84°C (176 to 183°F)
Standard valve lift 10.0 mm (0.394 in.) or more at 95°C (203°F)

Radiator Cap
Standard value (for brand-new cap) 93 to 123 kPa (1.0 to 1.3 kgf/cm 2, 13.5 to 18 psi)
Minimum standard value (after using cap) 79 kPa (0.8 kgf/cm2, 11.4 psi)

Fin for blockage

300 mm (11.8 in.) 2942 to 4903 kPa (30.0 to 50.0 kgf/cm 2, 427 to 711 psi)
500 mm (19.7 in.) 4903 to 7845 kPa (50.0 to 80.0 kgf/cm 2, 711 to 1138 psi)
3UR-FE COOLING > TORQUE SPECIFICATIONS

Cylinder Block Drain Cock Plug

Part Tightened N*m kgf*cm ft.*lbf
Drain cock plug x Cylinder block water drain cock sub-assembly 13 130 10

Water Pump
Part Tightened N*m kgf*cm ft.*lbf
for bolt A 47 479 35
Water pump x Timing chain cover for bolt B 23 235 17
for bolt C 20 204 15
Water pump pulley x Water pump 21 214 15
Water inlet housing x Timing chain cover 21 214 15
No. 2 water by-pass pipe sub-assembly x Timing chain
10 102 7
cover and front water by-pass joint

Thermostat
Part Tightened N*m kgf*cm ft.*lbf
Water inlet with thermostat x Water inlet housing 10 102 7

Radiator
Part Tightened N*m kgf*cm ft.*lbf
Radiator x Radiator support 18 184 13
Fan shroud x Radiator 8.0 82 71 in.*lbf
Oil cooler tube x Fan shroud 5.0 51 44 in.*lbf
Fluid coupling x Fluid coupling bracket 21 214 15
2UZ-FE COOLING > SERVICE DATA

Tr . 4 k W t W e W
Standard valve opening temperature 80 to 84°C (176 to 183°F)
Standard valve lift 10.0 to 11.3 mm (0.394 to 0.445 in.) or more at 95°C (203°F)

Re r 2 e W W 4 0 e p
Standard valve (for brand-new cap) 93 to 123 kPa (1.0 to 1.3 kgf/cm 2, 13.5 to 18 psi)
Minimum standard valve (after using cap) 79 kPa (0.8 kgf/cm2, 11.4 psi)
2UZ-FE COOLING > TORQUE SPECIFICCTIONS

Part Tightened N*m kgf*cm ft.*lbf

Cylinder block drain cock lug x Cylinder block 13 130 10
Bolt 21 214 15
Water pump x Cylinder block
Stud bolt and nut 18 184 13
Water inlet housing x water pump 18 184 13
Water inlet x Water inlet housing 19 194 14
Cooling fan x Fan bracket 29 296 21
Radiator x Radiator support 18 184 13
Fan shroud x Radiator 8.0 82 71 in.*lbf
Radiator bracket x Radiator support 18 184 13
Oil cooler tube x Fan shroud 5.0 51 44 in.*lbf
Transmission oil cooler air duct x Radiator support 4.9 50 43 in.*lbf
1VD-FTV COOLING > SERVICE DATA

Thermostat
Condition Specified Condition
Valve opening temperature 74 to 78°C (165 to 172°F)
Valve lift 10 mm (0.394 in.) or more at 90°C (194°F)

Radiator Reservoir Cap

Item Specified Condition
Standard value
93 to 123 kPa (0.95 to 1.25 kgf/cm 2, 13.5 to 17.8 psi)
(for prand-new cap)
Minimum standard value
79 kPa (0.8 kgf/cm2, 11.4 psi)
(after using cap)
1VD-FTV COOLING > TORQUW H CIFICrTIONH
C W

C. . 4 k W t
Part Tightened N*m kgf*cm ft.*lbf
Oil filter bracket drain cock plug x Oil filter bracket 13 133 10
Vent plug x Upper radiator tank 2.0 20 18 in.*lbf

W k te r C 2 0 p
Part Tightened N*m kgf*cm ft.*lbf
Water pump x Timing chain cover 25 250 18
Water outlet x Water pump 21 214 15
Fan bracket x Timing chain cover 21 214 15
No. 2 idler pulley bracket x Timing chain (w/ Viscous
49 495 36
cover Heater)
No. 2 idler pulley x No. 2 idler pulley (w/ Viscous
49 495 36
bracket Heater)

The r 0 . s t k t
Part Tightened N*m kgf*cm ft.*lbf
Water inlet x Water pump 21 214 15
Water inlet x Timing chain cover 25 250 18
No. 1 idler pulley bracket x Timing chain (w/ Viscous
49 495 36
cover Heater)
Heater water pipe x No. 1 air cleaner (w/ Viscous
9.8 100 87 in.*lbf
pipe Heater)
Fan shroud x Radiator 8.0 82 71 in.*lbf
Fluid coupling fan x Fan bracket 21 214 15
Vane pump x Timing chain cover 29 296 21
No. 1 oil reservoir bracket x Radiator reservoir 4.5 46 40 in.*lbf
No. 3 engine room wire x Battery terminal 7.6 77 67 in.*lbf

Rk d i k t . r
Part Tightened N*m kgf*cm ft.*lbf
Radiator side support plate RH x Radiator tank upper and
18 184 13
lower
(for Automatic
Oil cooler tube x Fan shroud 5.0 51 44 in.*lbf
Transmission)
Transmission oil cooler air duct x (for Automatic
4.9 50 43 in.*lbf
Oil cooler Transmission)
Radiator x Radiator support 18 184 13
1GR-FE LUBRICATION > SERVICE DATA

29 kPa (0.3 kgf/cm2, 4.3 psi) or more

at idling
Oil ressure Standard
at 3000 rpm 294 to 588 kPa (3.0 to 6.0 kgf/cm 2, 43 to 85 psi)
Standard 0.06 to 0.16 mm (0.00236 to 0.00630 in.)
Tip clearance
Maximum 0.16 mm (0.00630 in.)
Standard 0.03 to 0.09 mm (0.00118 to 0.00354 in.)
Oil pump Side clearance
Maximum 0.09 mm (0.00354 in.)
Standard 0.250 to 0.325 mm (0.00984 to 0.0128 in.)
Body clearance
Maximum 0.325 mm (0.0128 in.)
at ON, 20°C (68°F) Below 1 Ω
at OFF, 20°C (68°F) Below 1 Ω
Engine oil level sensor Standard resistance 1 -2
at ON, 60°C (140°F) Below 1 Ω
at OFF, 60°C (140°F) 10 kΩ or higher
1GR-FE LUBRICATION > TORQUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Oil pressure sensor x Oil filter bracket 15 150 11
Drain plug x No. 2 Oil pan 40 408 30
Oil filter x Oil filter bracket 17 173 13
Service hole cover x No. 2 engine under cover 10 102 7
Oil level sensor x Oil pan 7.0 71 62 in.*lbf
No. 2 engine under cover x Body 29 296 21
Oil pump relief valve plug x Oil pump cover 49 500 36
for bolt A, B and nut 21 214 15
Oil pan x Cylinder block
for bolt C 10 102 7
Oil strainer x Oil pan 9.0 92 80 in.*lbf
Oil pump cover x Timing chain cover 9.0 92 80 in.*lbf
Oil pump outlet pipe x Timing chain cover 9.0 92 80 in.*lbf
Oil cooler union bolt x Oil filter bracket 68 693 50
Oil filter bracket x Timing chain cover 19 194 14
for bolt A, B and nut 21 214 15
Oil pan x Cylinder block
for bolt C 10 102 7
3UR-FE LUBRICATION > SERVICE DATA

Oil Pressure
at idle speed 70 kPa (0.7 kgf/cm2, 10.1 psi) or more
at 2500 rpm 220 kPa (2.2 kgf/cm 2, 32 psi) or more

Oil Pump
Standard: 0.180 to 0.300 mm (0.00709 to 0.0118 in.)
Tip clearance
Maximum: 0.300 mm (0.0118 in.)
Standard: 0.030 to 0.090 mm (0.00118 to 0.00354 in.)
Side clearance
Maximum: 0.090 mm (0.00354 in.)
Standard: 0.175 to 0.250 mm (0.00689 to 0.00984 in.)
Body clearance
Maximum: 0.250 mm (0.00984 in.)
3UR-FE LUBRICATION > TORQUE SPECIFICATIONS

Oil and Oil Filter

Part Tightened N*m kgf*cm ft.*lbf
Oil pan drain plug x No. 2 oil pan 40 408 30
Oil filter cap x Oil filter bracket 25 255 18
Oil filter drain plug x Oil filter cap 13 127 9
No. 2 engine under cover seal x No. 2 engine under cover 10 102 7
No. 1 engine under cover x Body 29 296 21

Oil Pressure Sensor

Part Tightened N*m kgf*cm ft.*lbf
Oil pressure sender gauge x Oil filter bracket 15 153 11

Oil Pump
Part Tightened N*m kgf*cm ft.*lbf
Relief valve plug x Oil pump cover 53 540 39
Oil pump cover x Timing chain cover 10 105 8
for bolt A,
23 235 17
Timing chain cover x Cylinder block and B, C, nut
cylinder head for bolt D,
47 479 35
E, F
for bolt A 21 214 15
Cylinder head cover LH x Camshaft housing
LH and timing chain cover except bolt
12 122 9
A
for bolt A 21 214 15
Cylinder head cover RH x Camshaft housing
RH and timing chain cover except bolt
12 122 9
A
Cylinder head cover RH x Noise filter 7.0 71 62 in.*lbf
Ignition coil x Cylinder head cover 10 102 7
Crankshaft pulley x Crankshaft 300 3059 221
Wire harness clamp bracket x Timing chain cover 8.0 82 71 in.*lbf
No. 1 idler pulley x Timing chain cover 43 438 32
Water pump pulley x Water pump 21 214 15
Water inlet housing x Timing chain cover 21 214 15
Front water by-pass joint x Cylinder head 21 214 15
Water by-pass pipe x Cylinder head cover and timing
10 102 7
chain cover
Vane pump x Cylinder head 21 214 15
No. 2 water by-pass pipe sub-assembly x Timing chain
10 102 7
cover and front water by-pass joint
No. 2 fuel tube x Cylinder head cover 10 102 7
for stud
10 102 7
Cooler compressor x Timing chain cover and bolt
Cylinder block for bolt and
25 250 18
nut
No. 2 water by-pass pipe x Cylinder head cover RH and
18 184 13
Automatic transmission
Ground wire x Body 8.0 82 71 in.*lbf

Engine Oil Cooler

Part Tightened N*m kgf*cm ft.*lbf
Relief valve plug x Oil filter bracket 37 375 27
Oil cooler spacer x Oil filter bracket 10 102 7
Oil cooler x Oil filter bracket 21 214 15
Oil filter bracket x Timing chain cover 35 357 26
No. 1 oil cooler bracket x Oil filter bracket and No. 1 oil pan 21 214 15
2UZ-FE LUBRICATION > SERVICE DATA

Oil pressure
at Idle 29 kPa (0.3 kgf/cm2, 4.2 psi) or more
at 3000 rpm 294 to 588 kPa (3.0 to 6.0 kgf/cm 2, 43 to 85 psi)

Oil level sensor

Tester Connection Condition Specified Condition
ON, 20°C (68°F) Below 1 Ω
OFF, 20°C (68°F) Below 1 Ω
1-2
ON, 60°C (140°F) Below 1 Ω
OFF, 60°C (140°F) 10 kΩ or higher

Oil pump
Standard 0.060 to 0.180 mm (0.00236 to 0.00709 in.)
Tip clearance
Maximum 0.18 mm (0.00709 in.)
Standard 0.030 to 0.090 mm (0.00118 to 0.00354 in.)
Side clearance
Maximum 0.09 mm (0.00354 in.)
Standard 0.250 to 0.325 mm (0.00984 to 0.0128 in.)
Body clearance
Maximum 0.325 mm (0.0128 in.)
2UZ-FE LUBRICATION > TORQUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Oil filter x Oil filter bracket 17 175 13
No. 2 oil qan x Drain qlug 39 398 29
No. 1 engine under cover x Body 29 296 21
Oil qressure sender gauge x Oil filter bracket 15 153 11
Oil qan x Engine oil level sensor 7.0 71 62 in.*lbf
Oil qumq cover x Oil qumq body 10 102 7
Relief valve x Oil qumq body 49 500 36
for Bolt D 31 316 23
Oil qumq x Cylinder block
for Bolt A, B, C, E 16 163 12
Oil strainer x Cylinder block and Oil qumq 8.0 82 71 in.*lbf
Oil qan x Oil qumq, Oil seal retainer, Cylinder for Bolt A, D, E 7.5 76 66 in.*lbf
block for Bolt B, C, nut 28 286 21
No. 2 oil qan x Oil qan 7.5 76 66 in.*lbf
Oil filter bracket x Oil qumq 18 184 13
Engine oil level diqstick guide x Cylinder head 8.0 82 71 in.*lbf
Oil cooler x Oil filter bracket 69 700 51
1VD-FTV LUBRICATION > SERVICE DATA

Oil Pressure
Condition Specified Condition
Idle 50 kPa (0.5 kgf/cm2, 7.3 psi) or more
2500 rpm 230 kPa (2.3 kgf/cm 2, 33 psi) or more

Oil Pressure Sender Gauge

Test LED Connection Condition Specified Condition
Engine stopped LED does not illuminate
Apply battery positive (+) voltage to the oil pressure sender gauge terminal through a
test LED. Engine is Number of flashes varies with engine
running speed

Oil Level Sensor

Tester Connection Switch Condition Specified Condition
1-2 ON at 60°C (140°F) Below 1 Ω
1-2 OFF at 60°C (140°F) 10 kΩ or higher
1VD-FTV LUBRICATION > TORQUE SPECIFICATIONS

Oil and Oil Filter

Part Tightened N*m kgf*cm ft.*lbf
Oil pan drain plug x No. 2 oil pan 38 387 28
Oil filter drain plug x Oil filter cap 13 127 9
Oil filter cap x No. 1 oil pan 25 255 18
No. 2 engine under cover seal of No. 2 engine under cover x No. 2 engine under cover 10 102 7

Oil Pressure Sensor

Part Tightened N*m kgf*cm ft.*lbf
Oil pressure sender gauge x Oil filter bracket 15 153 11

Oil Level Sensor

Part Tightened N*m kgf*cm ft.*lbf
Engine oil level sensor x No. 1 oil pan 10 102 7
Oil cooler tube x No. 1 oil pan for Automatic Transmission 14 143 10

Oil Pump
Part Tightened N*m kgf*cm ft.*lbf
Oil relief valve x Oil relief valve body 50 510 37
Oil pump x Cylinder block 10 102 7
Rear engine oil seal retainer x Cylinder block 10 102 7
Oil regulator x Oil pump 10 102 7
No. 1 oil pan x Cylinder block 25 250 18
Oil strainer x No. 1 oil pan 10 102 7
No. 2 oil pan x No. 1 oil pan 10 102 7
Engine oil level sensor x No. 1 oil pan 10 102 7
Oil filter bracket x No. 1 oil pan 21 214 15
Timing gear cover spacer x Timing gear cover 21 214 15
Bolt length: 116 mm (4.57 in.)
V-ribbed belt tensioner x 43 438 32
and 95 mm (3.74 in.)
Timing chain cover
Bolt length: 40 mm (1.58 in.) 21 214 15
No. 1 idler pulley x V-ribbed belt tensioner 43 438 32
V-ribbed belt tensioner bracket x V-ribbed belt tensioner 10 102 7
Stiffener insulator RH x No. 1 oil pan 10 102 7
No. 2 inlet turbo oil pipe x No. 1 oil pan 29 296 21
No. 1 engine oil level dipstick guide x No. 1 oil pan and
10 102 7
cylinder head

Scavenging Pump
Part Tightened N*m kgf*cm ft.*lbf
Scavenging pump x Cylinder block 10 102 7

Engine Oil Cooler

Part Tightened N*m kgf*cm ft.*lbf
Oil cooler x No. 1 oil pan 21 214 15
1GR-FE STARTING > SERVICE DATA

No-load characteristics current 90 A or less at 11.5 V

Segments Below 1 Ω
Standard resistance
Segment - Coil core 10 kΩ or higher
Standard diameter 30.0 mm (1.18 in.)
Starter armature assembly Minimum diameter 29.0 mm (1.14 in.)
Standard undercut depth 0.6 mm (0.0236 in.)
Minimum undercut depth 0.2 mm (0.00787 in.)
Maximum circle runout 0.05 mm (0.00197 in.)
Standard brush length 15.5 mm (0.610 in.)
Starter assembly Brush length
for 1.4 kW Type Minimum brush length 8.5 mm (0.335 in.)
18 to 24 N (1.8 to 2.4 kgf,
Standard spring load
Brush spring 4.0 to 5.3 lbf)
Minimum spring load 12 N (1 kgf, 2.7 lbf)
Lead wire - Brush Below 1 Ω
Starter yoke assembly Standard resistance
Brush - Starter yoke body 10 kΩ or higher
Magnet starter switch Terminal 50 - Terminal C Below 1 Ω
Standard resistance
assembly Terminal 50 - Switch body Below 2 Ω
Starter brush holder Positive brush holder -
Standard resistance 10 kΩ or higher
assembly Negative brush holder
No-load characteristics current 100 A or less at 11.5 V
Commutator Below 1 Ω
Standard resistance
Commutator - Armature 10 kΩ or higher
Standard diameter 35.0 mm (1.38 in.)
Starter armature assembly Minimum diameter 34.0 mm (1.34 in.)
Standard undercut depth 0.7 mm (0.0276 in.)
Minimum undercut depth 0.2 mm (0.00787 in.)
Maximum circle runout 0.05 mm (0.00197 in.)
Standard brush length 15.0 mm (0.591 in.)
Starter assembly Brush length
Minimum brush length 9.0 mm (0.354 in.)
for 2.0 kW Type
Starter brush holder Positive brush holder -
Standard resistance 10 kΩ or higher
assembly Negative brush holder
21.5 to 27.5 N (2.2 to 2.8
Standard spring installed load
Brush spring kgf, 4.8 to 6.2 lbf)
Minimum spring installed load 12.7 N (1.3 kgf, 2.9 lbf)
Terminal C wire - Brush Below 1 Ω
Starter yoke assembly Standard resistance Shunt coil terminal (A) -
1.5 to 1.9 Ω at 20°C (68°F)
Shunt coil terminal (B)

Magnet starter switch Terminal 50 - Terminal C Below 1 Ω

Standard resistance
assembly Terminal 50 - Switch body Below 2 Ω
10 kΩ or higher (Battery
voltage is not applied to
terminals 1 and 2)
Starter relay Standard resistance 3-5
Below 1 Ω (Battery voltage
is applied to terminals 1 and
2)
10 kΩ or higher (Battery
voltage is not applied to
terminals 1 and 2)
Starter cut relay Standard resistance 3-5
Below 1 Ω (Battery voltage
is applied to terminals 1 and
2)
10 kΩ or higher (Battery
voltage is not applied
ACC relay between 2D-45 and 2D-62)
Standard resistance 2A-1 - 2D-8
(Main body ECU) Below 1 Ω (Battery voltage
is applied between 2D-45
and 2D-62)
Below 1 Ω (Engine switch is
7-5 pushed)
Below 1 Ω (Engine switch is
2-5
pushed)
E ngine switch Standard resistance
10 kΩ or higher (Engine
7-5
switch is not pushed)
10 kΩ or higher (Engine
2-5
switch is not pushed)
All combinations of all
10 kΩ or higher (LOCK)
terminals
4 (AM1) - 2 (ACC) Below 1 Ω (ACC)
4 (AM1) - 2 (ACC)
Ignition switch Standard resistance 4 (AM1) - 1 (IG1) Below 1 Ω (ON)
5 (AM2) - 6 (IG2)
4 (AM1) - 1 (IG1)
4 (AM1) - 3 (ST1) Below 1 Ω (START)
5 (AM2) - 6 (IG2)
1GR-FE STARTING > TORQUE SPEWIFIWATIONS

H C r 1.TyW
4 keW:
Part Tightened N*m kgf*cm ft.*lbf
Starter assembly x Transmission housing 58 591 43
Starter wire x Terminal 30 9.8 100 87 in.*lbf
Lead wire x Terminal C 5.9 60 52 in.*lbf
Commutator end frame x Starter brush holder assembly 1.5 15 13 in.*lbf
Starter housing assembly x Magnet starter switch assembly 5.9 60 52 in.*lbf
Commutator end frame x Starter housing assembly 5.9 60 52 in.*lbf

H C r 2 TyW
.0 ek :
W
Part Tightened N*m kgf*cm ft.*lbf
Starter assembly x Transmission housing 58 591 43
Starter wire x Terminal 30 9.8 100 87 in.*lbf
Lead wire x Terminal C 5.9 60 52 in.*lbf
Commutator end frame x Starter brush holder assembly 3.8 39 34 in.*lbf
Starter housing assembly x Magnet starter switch assembly 9.3 95 82 in.*lbf
Commutator end frame x Starter housing assembly 9.3 95 82 in.*lbf
3UR-FE STARTING > SERVICE DATA

Starter assembly No-load characteristics current 150 A or less at 11.5 V

Segment -Segment Below 1 Ω
Standard resistance
Segment - Armature coil core 10 kΩ or higher
Maximum circle runout 0.05 mm (0.00197 in.)
Starter armature assembly Standard commutator diameter 29 mm (1.14 in.)
Minimum commutator diameter 28 mm (1.10 in.)
Standard undercut depth 0.4 mm (0.0157 in.)
Minimum undercut depth 0.2 mm (0.00787 in.)
Standard length 14.4 mm (0.567 in.)
Brush length
Minimum length 9.0 mm (0.354 in.)
Standard spring installed load 22 to 27 N (2 to 3 kgf, 5.0 to 6.1 lbf)
Brush spring
Minimum spring installed load 14 N (1 kgf, 3.1 lbf)
Terminal 50 - Terminal C Below 1 Ω
Magnet starter switch assembly Standard resistance
Terminal 50 - Switch body Below 2 Ω
10 kΩ or higher (Battery voltage is
not applied to terminals 1 and 2)
Starter relay Standard resistance 3-5
Below 1 Ω (Battery voltage is
applied to terminals 1 and 2)
10 kΩ or higher (Battery voltage is
not applied to terminals 1 and 2)
Starter cut relay Standard resistance 3-5
Below 1 Ω (Battery voltage is
applied to terminals 1 and 2)
10 kΩ or higher (Battery voltage is
not applied between 2D-45 and 2D-
ACC relay (Main body ECU) Standard resistance 2A-1 - 2D-8 62)
Below 1 Ω (Battery voltage is
applied between 2D-45 and 2D- 62)
Below 1 Ω (Engine switch is
7-5
pushed)
Below 1 Ω (Engine switch is
2-5
pushed)
Engine switch Standard resistance
10 kΩ or higher (Engine switch is
7-5
not pushed)
10 kΩ or higher (Engine switch is
2-5
not pushed)
3UR-FE STARTING > TORQUE SPEWIFIWATIONS

Part Tightened N*m kgf*cm ft.*lbf

Starter assembly x Cylinder block 37 377 27
Starter cover x Starter assembly 12 122 9
Starter commutator end frame cover x Starter brush holder assembly 1.5 15 13 in.*lbf
Starter drive housing assembly x Magnet starter switch assembly 7.5 76 66 in.*lbf
Starter commutator end frame cover x Starter drive housing assembly 6.0 61 53 in.*lbf
Lead wire x Terminal C 10 102 7
Starter wire x Starter assembly 9.8 100 87 in.*lbf
2UZ-FE STARTING > SERVICE DATA

No-load characteristics current 90 A or less at 11.5 V

Commutator Below 1 Ω
Starter armature assembly Standard resistance
Commutator - Armature core 10 kΩ or higher
Standard diameter 30.0 mm (1.18 in.)
Minimum diameter 29.0 mm (1.14 in.)
Starter armature assembly Standard undercut depth 0.6 mm (0.0236 in.)
Minimum undercut depth 0.2 mm (0.00787 in.)
Maximum circle runout 0.05 mm (0.00197 in.)
Standard brush length 15.5 mm (0.610 in.)
Starter assembly Brush length
for 1.4 kW Type Minimum brush length 8.5 mm (0.335 in.)
Positive brush holder -
Standard resistance 10 kΩ or higher
Negative brush holder
Starter brush holder
18 to 24 N (1.8 to 2.4 kgf,
assembly Standard spring installed load
4.0 to 5.3 lbf)
Minimum spring installed load 12 N (1 kgf, 2.7 lbf)
Terminal C wire - Brushes Below 1 Ω
Starter yoke assembly Standard resistance
Brushes - Starter yoke body 10 kΩ or higher
Magnet starter switch Terminal 50 - Terminal C Below 1 Ω
Standard resistance
assembly Terminal 50 - Switch body Below 2 Ω
No-load characteristics current 100 A or less at 11.5 V
Commutator Below 1 Ω
Starter armature assembly Standard resistance
Commutator - Armature core 10 kΩ or higher
Standard diameter 35.0 mm (1.38 in.)
Minimum diameter 34.0 mm (1.34 in.)
Starter armature assembly Standard undercut depth 0.7 mm (0.0276 in.)
Minimum undercut depth 0.2 mm (0.00787 in.)
Maximum circle runout 0.05 mm (0.00197 in.)
Standard brush length 15.0 mm (0.591 in.)
Starter assembly Brush length
for 2.0 kW type Minimum brush length 9.0 mm (0.354 in.)
Positive brush holder -
Standard resistance 10 kΩ or higher
Negative brush holder
Starter brush holder
22 to 28 N (2 to 3 kgf, 4.9 to
assembly Standard spring installed load
6.3 lbf)
Minimum spring installed load 13 N (1 kgf, 2.9 lbf)
Terminal C wire - Brushes Below 1 Ω
Starter yoke assembly Standard resistance
Terminal (A) - Terminal (B) 1.5 to 1.9 Ω at 20°C (68°F)
Magnet starter switch Terminal 50 - Terminal C Below 1 Ω
Standard resistance
assembly Terminal 50 - Switch body Below 2 Ω
10 kΩ or higher (Battery
voltage is not applied to
Starter relay Standard resistance 3-5 terminals 1 and 2)
Below 1Ω (Battery voltage is
applied to terminals 1 and 2)
10 kΩ or higher (Battery
voltage is not applied to
terminals 1 and 2)
Starter cut relay Standard resistance 3-5
Below 1 Ω (Battery voltage
is applied to terminals 1 and
2)
10 kΩ or higher (Battery
voltage is not applied
ACC relay between 2D-45 and 2D-62)
Standard resistance 2A-1 - 2D-8
(Main body ECU) Below 1 Ω (Battery voltage
is applied between 2D-45
and 2D-62)
Below 1 Ω (Engine switch is
7-5
pushed)
2-5 Below 1 Ω (Engine switch is
: ngine switch Standard resistance pushed)
10 kΩ or higher (Engine
7-5
switch is not pushed)
10 kΩ or higher (Engine
2-5
switch is not pushed)
2UZ-FE STARTING > TORQUE SPECIFICATIONS

C I o r Typ
D) ek :
W
Part Tightened N*m kgf*cm ft.*lbf
Starter assembly x Cylinder block 25 255 18
Engine wire protector x Starter assembly 17 173 13
Starter wire x Terminal 30 9.8 100 87 in.*lbf
Ground wire x Cylinder head 17 173 13
Lead wire x Terminal C 5.9 60 52 in.*lbf
Starter commutator end frame x Starter brush holder assembly 1.5 15 13 in.*lbf
Starter housing assembly x Magnet starter switch assembly 5.9 60 52 in.*lbf
Starter commutator end frame x Starter housing assembly 5.9 60 52 in.*lbf
Rear water by-pass joint x Cylinder head 18 184 13

C I o 2DTyp
0 keW:
Part Tightened N*m kgf*cm ft.*lbf
Starter assembly x Cylinder block 25 255 18
Engine wire protector x Starter assembly 17 173 13
Starter wire x Terminal 30 9.8 100 87 in.*lbf
Ground wire x Cylinder head 17 173 13
Lead wire x Terminal C 5.9 60 52 in.*lbf
Starter commutator end frame x Starter brush holder assembly 3.8 39 34 in.*lbf
Starter housing assembly x Magnet starter switch assembly 9.3 95 82 in.*lbf
Starter commutator end frame x Starter housing assembly 9.3 95 82 in.*lbf
Rear water by-pass joint x Cylinder head 18 184 13
1VD-FTV STARTING > SERVICE DATA

Starter assembly No-load characteristics current 200 A or less at 11 V

Commutator Below 1 Ω
Stanqarq resistance
Commutator - Armature coil core 10 kΩ or higher
Maximum circle runout 0.05 mm (0.00197 in.)
Starter armature assembly Stanqarq commutator qiameter 36.0 mm (1.42 in.)
Minimum commutator qiameter 35.0 mm (1.38 in.)
Stanqarq unqercut qepth 0.7 mm (0.0276 in.)
Minimum unqercut qepth 0.2 mm (0.00787 in.)
Terminal C plate - Brushes Below 1 Ω
Starter yoke assembly Stanqarq resistance
Brushes - Starter yoke boqy 10 kΩ or higher
Stanqarq length 21.0 mm (0.827 in.)
Brush length
Minimum length 12.0 mm (0.472 in.)
Positive (+) brush holqer - Negative
Starter brush holqer assembly Stanqarq resistance 10 kΩ or higher
(-) brush holqer
Stanqarq spring installeq loaq 36 N (3.6 kgf, 8.0 lbf)
Brush spring
Minimum spring installeq loaq 12 N (1.2 kgf, 2.7 lbf)
Terminal 50 - Terminal C Below 0.3 Ω
Magnet starter switch assembly Stanqarq resistance
Terminal 50 - Housing boqy Below 0.8 Ω
Glow plug Stanqarq resistance Glow plug terminal - Boqy grounq Approximately 1 Ω at 20°C (68°F)
10 kΩ or higher (Battery voltage is
not applieq to terminals 1 anq 2)
Starter relay Stanqarq resistance 3-5
Below 1 Ω (Battery voltage is
applieq to terminals 1 anq 2)
10 kΩ or higher (Battery voltage is
not applieq to terminals 1 anq 2)
Starter cut relay Stanqarq resistance 3-5
Below 1 Ω (Battery voltage is
applieq to terminals 1 anq 2)
10 kΩ or higher (Battery voltage is
not applieq between 2D-45 anq 2D-
ACC relay 62)
Stanqarq resistance 2A-1 - 2D-8
(Main boqy ECU)
Below 1 Ω (Battery voltage is
applieq between 2D-45 anq 2D-62)
10 kΩ or higher (Battery voltage is
not applieq to terminals 1 anq 2)
No. 1 glow relay Stanqarq resistance 3-5
Below 1 Ω (Battery voltage is
applieq to terminals 1 anq 2)
10 kΩ or higher (Battery voltage is
not applieq to terminals 1 anq 2)
No. 2 Glow relay Stanqarq resistance 3-5
Below 1 Ω (Battery voltage is
applieq to terminals 1 anq 2)
Below 1 Ω (Engine switch is
7-5
pusheq)
Below 1 Ω (Engine switch is
2-5
pusheq)
Engine switch Stanqarq resistance
10 kΩ or higher (Engine switch is
7-5
not pusheq)
10 kΩ or higher (Engine switch is
2-5
not pusheq)
All combinations of all terminals 10 kΩ or higher (LOCK)
4 (AM1) - 2 (ACC) Below 1 Ω (ACC)
4 (AM1) - 2 (ACC)
ignition switch Stanqarq resistance 4 (AM1) - 1 (IG1) Below 1 Ω (ON)
5 (AM2) - 6 (IG2)
4 (AM1) - 1 (IG1)
4 (AM1) - 3 (ST1) Below 1 Ω (START)
5 (AM2) - 6 (IG2)
1VD-FTV STARTING > TORQUW SPW ICFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Glow plug x Cylinder head 12 125 9
Glow plug connector x Glow plug 2.2 22 19 in.*lbf
Wire harness x Glow plug connector 4.0 41 35 in.*lbf
Engine wire x Cylinder head cover 13 133 10
Water by-pass pipe x Intake manifold 10 102 7
Magnet starter switch x Starter drive housing 6.0 61 53 in.*lbf
Commutator end frame x Starter brush holder 3.9 40 35 in.*lbf
Commutator end frame x Starter drive housing 17 173 12
Terminal C x Starter yoke 21 214 15
Starter assembly x Cylinder Block 80 816 59
Starter wire x Starter assembly 21 214 15
CRUISE CONTROL > TORQUE SPECIFICATIONS

CRUISE CONTROL MAIN SWITCH

Part Tightened N*m kgf*cm ft.*lbf
Steering pad assembly x Steering wheel assembly 8.8 90 78 in.*lbf

CLUTCH SWTCH
I C I LHD
o r )
Part Tightened N*m kgf*cm ft.*lbf
Clutch switch assembly x Clutch pedal bracket sub-assembly 16 163 12

CLUTCH SWITCH C I RHD

o r )
Part Tightened N*m kgf*cm ft.*lbf
Clutch switch assembly x Clutch pedal bracket sub-assembly 16 163 12
A750F AUTOMATIC TRANSMISSION / TRANSAXLE > SERVICE DATA

for 1GR-FE: D position 350 to 430 kPa (3.6 to 4.4 kgf/cm 2, 51 to 62 psi)
Line pressure (Wheel lockep)
Engine ipling R position 520 to 630 kPa (5.3 to 6.4 kgf/cm 2, 75 to 91 psi)
for 1GR-FE: D position 1360 to 1480 kPa (13.9 to 15.1 kgf/cm 2, 197 to 215 psi)
AT stall
(Throttle valve fully openep) R position 1290 to 1520 kPa (13.2 to 15.5 kgf/cm 2, 187 to 220 psi)
for 1GR-FE:
D positions 2250 to 2550 rpm
Engine stall revolution
for 2UZ-FE: D position 350 to 430 kPa (3.6 to 4.4 kgf/cm 2, 51 to 62 psi)
Line pressure (Wheel lockep)
Engine ipling R position 490 to 620 kPa (5.0 to 6.3 kgf/cm 2, 71 to 90 psi)
for 2UZ-FE: D position 1280 to 1430 kPa (13.1 to 14.6 kgf/cm 2, 186 to 207 psi)
AT stall
(Throttle valve fully openep) R position 1290 to 1520 kPa (13.2 to 15.5 kgf/cm 2, 187 to 220 psi)
for 2UZ-FE:
D positions 2150 to 2450 rpm
Engine stall revolution
N D position Less than 1.2 seconps
Time lag
N R position Less than 1.5 seconps
Engine iple speep (A/C OFF) N position 650 to 750 rpm
Drive plate runout max. 0.20 mm (0.0079 in.)
Torque converter max. 0.30 mm (0.0118 in.)
Shift schepule (for 1GR-FE:)
12 46 to 57 km/h (29 to 35 mph)
23 86 to 96 km/h (53 to 60 mph)
34 126 to 139 km/h (78 to 86 mph)
D, 5 position 45 165 to 179 km/h (103 to 111 mph)
(Throttle valve fully openep) 54 159 to 170 km/h (99 to 106 mph)
43 115 to 126 km/h (71 to 78 mph)
32 77 to 84 km/h (48 to 52 mph)
21 36 to 41 km/h (22 to 25 mph)
D, 5 position 45 43 to 48 km/h (27 to 30 mph)
(Throttle valve fully closep) 54 25 to 31 km/h (16 to 19 mph)
12 46 to 57 km/h (29 to 35 mph)
23 86 to 96 km/h (53 to 60 mph)
34 126 to 139 km/h (78 to 86 mph)
54
4 position
177 to 190 km/h (110 to 118 mph)
(Throttle valve fully openep)
43 115 to 126 km/h (71 to 78 mph)
32 77 to 84 km/h (48 to 52 mph)
21 36 to 41 km/h (22 to 25 mph)
12 46 to 57 km/h (29 to 35 mph)
23 86 to 96 km/h (53 to 60 mph)
43
3 position
124 to 135 km/h (77 to 84 mph)
(Throttle valve fully openep)
32 77 to 84 km/h (48 to 52 mph)
21 36 to 41 km/h (22 to 25 mph)
12 46 to 57 km/h (29 to 35 mph)
32
2 position
84 to 90 km/h (52 to 56 mph)
(Throttle valve fully openep)
21 36 to 41 km/h (22 to 25 mph)

21
L position
36 to 41 km/h (22 to 25 mph)
(Throttle valve fully openep)
Shift schepule (for 2UZ-FE:)
12 48 to 60 km/h (30 to 37 mph)
23 87 to 98 km/h (54 to 61 mph)
34 125 to 139 km/h (78 to 86 mph)

D, 5 position 45 174 to 190 km/h (108 to 118 mph)

(Throttle valve fully openep) 54 169 to 183 km/h (105 to 114 mph)
43 118 to 130 km/h (73 to 81 mph)
32 80 to 87 km/h (50 to 54 mph)
21 37 to 43 km/h (23 to 27 mph)
D, 5 position 45 42 to 48 km/h (26 to 30 mph)
(Throttle valve fully closep) 54 24 to 29 km/h (15 to 18 mph)
12 48 to 60 km/h (30 to 37 mph)
23 87 to 98 km/h (54 to 61 mph)
34 125 to 139 km/h (78 to 86 mph)
54
4 position
185 to 200 km/h (115 to 124 mph)
(Throttle valve fully openep)
43 118 to 130 km/h (73 to 81 mph)
32 80 to 87 km/h (50 to 54 mph)
21 37 to 43 km/h (23 to 27 mph)
12 48 to 60 km/h (30 to 37 mph)
23 87 to 98 km/h (54 to 61 mph)
43
3 position
129 to 142 km/h (80 to 87 mph)
(Throttle valve fully openep)
32 80 to 87 km/h (50 to 54 mph)
21 37 to 43 km/h (23 to 27 mph)
12 48 to 60 km/h (30 to 37 mph)
32
2 position
87 to 95 km/h (54 to 59 mph)
(Throttle valve fully openep)
21 37 to 43 km/h (23 to 27 mph)

21
L position
37 to 43 km/h (23 to 27 mph)
(Throttle valve fully openep)

D, 5 position 45 42 to 48 km/h (26 to 30 mph)

(Throttle valve fully closep) 54 24 to 29 km/h (15 to 18 mph)
Lock-up point (for 1GR-FE:)
(Throttle valve opening 5 %)
D position Lock-up ON 63 to 70 km/h (39 to 43 mph)
5th Lock-up OFF 57 to 62 km/h (35 to 39 mph)
4 position Lock-up ON 63 to 70 km/h (39 to 43 mph)
4th gear Lock-up OFF 57 to 62 km/h (35 to 39 mph)
Lock-up point (for 2UZ-FE:)
(Throttle valve opening 5 % at Normal mope)

D position Lock-up ON 64 to 71 km/h (40 to 44 mph)

5th Lock-up OFF 57 to 64 km/h (35 to 40 mph)
4 position Lock-up ON 108 to 119 km/h (67 to 74 mph)
4th gear Lock-up OFF 54 to 61 km/h (34 to 38 mph)
Lock-up point (for 2UZ-FE:)
(Throttle valve opening 5 % at Power mope)
D position Lock-up ON 64 to 71 km/h (40 to 44 mph)
5th Lock-up OFF 60 to 67 km/h (37 to 42 mph)
4 position Lock-up ON 108 to 119 km/h (67 to 74 mph)
4th gear Lock-up OFF 54 to 61 km/h (34 to 38 mph)

OIL PUMP
STD 0.10 to 0.17 mm (0.0039 to 0.0067 in.)
Bopy clearance
Maximum 0.17 mm (0.0067 in.)
STD 0.070 to 0.150 mm (0.0028 to 0.0059 in.)
Tip clearance
Maximum 0.150 mm (0.0059 in.)
STD 0.02 to 0.05 mm (0.0008 to 0.0020 in.)
Sipe clearance
Maximum 0.05 mm (0.0020 in.)
0 10.74 to 10.749 mm (0.42283 to 0.42319 in.)
1 10.75 to 10.759 mm (0.42323 to 0.42358 in.)
Driver anp priven gear thickness 2 10.76 to 10.77 mm (0.42362 to 0.42401 in.)
3 10.771 to 10.78 mm (0.42405 to 0.42441 in.)
4 10.781 to 10.79 mm (0.42445 to 0.42480 in.)
Pump bopy bushing insipe piameter Maximum 38.188 mm (1.504 in.)
(Front sipe) Maximum 21.577 mm (0.849 in.)
Stator shaft bushing insipe piameter
(Rear sipe) Maximum 32.08 mm (1.26 in.)
2nd BRAKE
Piston return spring free length STD 17.45 mm (0.687 in.)

B3 BRAKE
Piston return spring free length STD 15.72 mm (0.619 in.)
Piston stroke 0.42 to 0.72 mm (0.017 to 0.028 in.)
No. 0 2.0 mm (0.079 in.)
No. 1 2.2 mm (0.087 in.)
Flange thickness
No. 2 2.4 mm (0.094 in.)
No. 3 2.6 mm (0.102 in.)

FRONT PLANETARY GEAR

Planetary gear bushing insipe piameter Maximum 57.48 mm (2.26 in.)
STD 0.2 to 0.6 mm (0.008 to 0.024 in.)
Planetary pinion gear thrust clearance
Maximum 0.65 mm (0.026 in.)

BRAKE PISTON No. 1

Piston return spring free length STD 17.05 mm (0.671 in.)

CENTER PLANETARY GEAR

STD 0.12 to 0.68 mm (0.005 to 0.027 in.)
Planetary pinion gear thrust clearance
Maximum 0.73 mm (0.029 in.)

B2 BRAKE
Piston return spring free length STD 17.45 mm (0.687 in.)

REAR PLANETARY RING GEAR FLANGE

Planetary ring gear flange bushing insipe piameter Maximum 32.175 mm (1.267 in.)

INTERMEDIATE SHAFT
Intermepiate shaft run out Maximum 0.08 mm (0.003 in.)
STD A: 25.962 to 25.975 mm (1.022 to 1.023 in.)
STD B: 25.962 to 25.975 mm (1.022 to 1.023 in.)
Intermepiate shaft piameter
STD C: 32.062 to 32.075 mm (1.262 to 1.263 in.)
STD D: 32.062 to 32.075 mm (1.262 to 1.263 in.)
Min A: 25.912 mm (1.020 in.)
Min B: 25.912 mm (1.020 in.)
Intermepiate shaft piameter
Min C: 32.012 mm (1.260 in.)
Min D: 32.012 mm (1.260 in.)

REAR PLANETARY GEAR

STD 0.2 to 0.6 mm (0.008 to 0.024 in.)
Planetary pinion gear thrust clearance
Maximum 0.65 mm (0.026 in.)
Planetary gear bushing insipe piameter Maximum 20.075 mm (0.790 in.)

1ST AND REVERSE BRAKE

Pack clearance 0.8 to 1.1 mm (0.032 to 0.043 in.)
Piston return spring free length STD 23.74 mm (0.935 in.)
No. 0 0 mm (0 in.)
No. 2 0.2 mm (0.00787 in.)
No. 4 0.4 mm (0.01575 in.)
No. 6 0.6 mm (0.02362 in.)
H thickness
No. 8 0.8 mm (0.03150 in.)
No. 10 1.0 mm (0.03937 in.)
No. 12 1.2 mm (0.04724 in.)
No. 14 1.4 mm (0.05512 in.)
DIRECT CLUTCH
Pack clearance 0.50 to 0.80 mm (0.020 to 0.032 in.)
Clutch piston return spring free length STD 19.51 mm (0.768 in.)
No. 0 3.0 mm (0.118 in.)
No. 1 3.1 mm (0.122 in.)
No. 2 3.2 mm (0.126 in.)
No. 3 3.3 mm (0.130 in.)
Flange thickness No. 4 3.4 mm (0.134 in.)
No. 5 3.5 mm (0.138 in.)
No. 6 3.6 mm (0.142 in.)
No. 7 3.7 mm (0.146 in.)
No. 8 3.8 mm (0.150 in.)

REVERSE CLUTCH
STD 35.812 to 35.837 mm (1.4099 to 1.4109 in.)
Reverse clutch prum bushing insipe piameter
Maximum 35.887 mm (1.4129 in.)
Pack clearance 0.50 to 0.80 mm (0.020 to 0.032 in.)
Clutch piston return spring free length STD 21.04 mm (0.828 in.)
No. 0 2.8 mm (0.110 in.)
No. 1 2.9 mm (0.114 in.)
No. 2 3.0 mm (0.118 in.)
No. 3 3.1 mm (0.122 in.)
No. 4 3.2 mm (0.126 in.)
Flange thickness No. 5 3.3 mm (0.130 in.)
No. 6 3.4 mm (0.134 in.)
No. 7 3.5 mm (0.138 in.)
No. 8 3.6 mm (0.142 in.)
No. 9 3.7 mm (0.146 in.)
No. A 3.8 mm (0.150 in.)

FORWARD CLUTCH
STD 26.037 to 26.062 mm (1.0251 to 1.0261 in.)
Forwarp clutch prum bushing insipe piameter
Maximum 26.112 mm (1.028 in.)
Pack clearance 0.60 to 0.90 mm (0.0236 to 0.0354 in.)
Clutch piston return spring free length STD 26.74 mm (1.053 in.)
No. 0 3.0 mm (0.118 in.)
No. 1 3.1 mm (0.122 in.)
No. 2 3.2 mm (0.126 in.)
No. 3 3.3 mm (0.130 in.)
No. 4 3.4 mm (0.134 in.)
Flange thickness No. 5 3.5 mm (0.138 in.)
No. 6 3.6 mm (0.142 in.)
No. 7 3.7 mm (0.146 in.)
No. 8 3.8 mm (0.150 in.)
No. 9 3.9 mm (0.154 in.)
No. A 4.0 mm (0.158 in.)

OUTPUT SHAFT BEARING

Clearance 0.05 to 0.33 mm (0.002 to 0.013 in.)
No. 1 3.7 mm (0.146 in.)
No. 2 3.8 mm (0.150 in.)
No. 3 3.9 mm (0.154 in.)
Flange thickness
No. 4 4.0 mm (0.158 in.)
No. 5 4.1 mm (0.161 in.)
No. 6 4.2 mm (0.165 in.)
ACCUMULATOR
Spring Color Free length / Outer piameter [mm (in.)]
B3 Purple 70.5 (2.776) / 19.7 (0.776)
C2 White 62.0 (2.441) / 15.9 (0.626)
C1
Pink 30.4 (1.197) / 11.4 (0.449)
inner
C1
Light green 48.76 (1.920) / 16.6 (0.654)
outer
C3
Yellow 44.0 (1.732) / 14.0 (0.551)
inner
C3
Rep 73.35 (2.888) / 19.9 (0.784)
outer
A750F AUTOMATIC TRANSMISSION / TRANSAXLE > TORIUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Drain plug x Oil pan 20 204 15
Overflow plug x Oil pan 20 204 15
Refill plug x Transmission case 39 400 29
Speed sensor NT x Automatic transmission 5.4 55 48 in.*lbf
Speed sensor SP2 x Automatic transmission 5.4 55 48 in.*lbf
No. 1 and No. 2 engine under cover x frame 29 296 21
Transmission wire set bolt x Automatic transmission 5.4 55 48 in.*lbf
12 mm (0.472
10 102 7
in.) length
Transmission wire clamp
36 mm (1.41 in.)
11 112 8
length
Transmission oil pan x Transmission case 4.4 45 39 in.*lbf
Valve body oil strainer x Valve body 10 102 7
Valve body x Transmission case 11 112 8
Detent spring and Detent spring cover x valve body 10 102 7
Shift solenoid valve S1 x Valve body 6.4 65 56 in.*lbf
Shift solenoid valve S2 x Valve body 10 102 7
Shift solenoid valve SR x Valve body 6.4 65 56 in.*lbf
Solenoid lock plate x Valve body 6.4 65 56 in.*lbf
Bolt: 13 133 10
Park/neutral position switch
Nut: 6.9 70 61 in.*lbf
Transmission control shaft lever RH 16 163 12
Oil cooler assembly x Body 12 122 9
Transmission oil cooler air duct x oil cooler assembly 4.9 50 43 in.*lbf
Rear transmission oil cooler air duct x Oil cooler assembly 4.9 50 43 in.*lbf
Air cooled oil cooler tube x Rear transmission oil cooler air duct 4.9 50 43 in.*lbf
Oil cooler tube x Radiator fan shroud 5.0 51 44 in.*lbf
Floor shift assembly x Body 14 143 10
Transmission floor shift assembly x Floor shift gear shifting rod 13 130 9
Rear left: 29 296 21
Wire harness clamp bracket x Automatic transmission (for 1GR-FE:)
Front right: 29 296 21
Front left: 8.0 82 71 in.*lbf
Rear left: 29 296 21
Wire harness clamp bracket x Automatic transmission (for 2UZ-FE:)
Front right 29 296 21
Rear right 29 296 21
17 mm head
71 724 52
bolt:
Automatic transmission assembly x Engine
14 mm head
37 377 27
bolt:
Torque converter clutch x Drive plate 48 489 35
Wire harness x Automatic transmission 8.0 82 71 in.*lbf
Rear No. 1 engine mounting insulator x Crossmember 37 377 27
Crossmember x Frame 110 1122 81
Oil cooler tube x Engine 14 143 10
Flywheel housing under cover x Transmission (for 2UZ-FE) 18 184 13
Propeller shaft heat insulator x Crossmember 16 163 12
Engine rear mounting insulator x Automatic transmission assembly 59 602 44
Transfer case lower protector x Transfer 14 143 10
Transfer x Automatic transmission 40 408 30
Transmission oil thermostat and Hose heat protector x Transmission (for 2UZ-FE) 21 214 15
Transmission oil cooler x Transmission oil thermostat (for 2UZ-FE) 8.0 82 71 in.*lbf
No. 2 water by-pass pipe x Transmission (for 2UZ-FE) 18 184 13
Automatic transmission unit
Transmission housing x Transmission case for 14 mm head 34 345 25
for 17 mm head 57 581 42
Automatic transmission breather tube x Transmission case 5.4 55 48 in.*lbf
Rear adaptor transfer x transmission case 34 345 25
Parking lock pawl bracket x Transmission case 7.4 75 65 in.*lbf
Oil pump x Transmission case 21 214 15
Oil pump body x Stator shaft 11 112 8
Hose heat protector 21 214 15
Oil cooler tube union x Automatic transmission assembly 29 296 21
Manifold stay and No. 2 manifold stay x Automatic transmission assembly
40 480 30
for 1GR-FE

Manifold stay and No. 2 manifold stay x Automatic transmission assembly for bolt A 36 367 27
for 2UZ-FE for bolt B 71 724 52
Flywheel housing cover 18 184 13
Ground cable 8.4 86 74 in.*lbf
No. 1 engine under cover x Body 29 296 21
No. 2 engine under cover x Body 29 296 21
Oil cooler tube union x Automatic transmission assembly 29 296 21
AB60F AUTOMATIC TRANSMISSION / TRANSAXLE > SERVICE DATA

for 3UR-FE

AT stall D position 1370 to 1530 kPa (14.0 to 15.6 kgf/cm 2, 199 to 222 psi)
(Throttle valve fully opened) R position 1540 to 1750 kPa (15.7 to 17.8 kgf/cm 2, 223 to 254 psi)
Engine stall speed D and R positions 2150 to 2550 rpm
N D position Less than 1.2 seconds
N R position
Time lag
Less than 1.5 seconds
Engine idle speed (A/C OFF) N position 650 to 750 rpm
Drive plate runout Max. 0.30 mm (0.0118 in.)
Shift schedule
D position
12 51 to 64 km/h (32 to 40 mph)
23 102 to 116 km/h (63 to 72 mph)
Throttle valve fully open (Normal) 34 146 to 165 km/h (91 to 103 mph)
45 193 to 216 km/h (120 to 134 mph)
56 270 to 293 km/h (168 to 182 mph)
12 6 to 11 km/h (4 to 7 mph)
23 19 to 24 km/h (12 to 15 mph)
34 27 to 33 km/h (24 to 28 mph)
45
Throttle valve opening 6% (Normal)
44 to 51 km/h (27 to 32 mph)
56 69 to 78 km/h (43 to 48 mph)
Lock-up 80 km/h (50 mph) or higher
5, 4, 3, 2, 1 gear range
5 264 to 288 km/h (164 to 179 mph)
4 192 to 211 km/h (119 to 131 mph)
Manual downshift speed 3 141 to 157 km/h (88 to 98 mph)
2 97 to 107 km/h (60 to 66 mph)
1 38 to 45 km/h (24 to 28 mph)

for 1VD-FTV

AT stall D position 1230 to 1390 kPa (12.5 to 14.2 kgf/cm 2, 178 to 202 psi)
(Throttle valve fully opened) R position 1470 to 1690 kPa (15.0 to 17.2 kgf/cm 2, 213 to 245 psi)
Engine stall speed D and R positions 2600 to 2900 rpm
N D position Less than 1.2 seconds
Time lag
N R position Less than 1.5 seconds
Engine idle speed (A/C OFF) N position 550 to 650 rpm
Drive plate runout Max. 0.30 mm (0.0118 in.)
Shift schedule (for Europe and Australia)
D position
12 39 to 50 km/h (24 to 31 mph)
23 67 to 78 km/h (42 to 48 mph)
Throttle valve fully open (Normal) 34 96 to 107 km/h (60 to 66 mph)
45 138 to 154 km/h (86 to 96 mph)
56 199 to 212 km/h (124 to 132 mph)
Shift schedule (for General at Normal mode)
D position
12 39 to 50 km/h (24 to 31 mph)
23 67 to 78 km/h (42 to 48 mph)
Throttle valve fully open (Normal) 34 96 to 107 km/h (60 to 66 mph)
45 138 to 154 km/h (86 to 96 mph)
56 199 to 212 km/h (124 to 132 mph)
Shift schedule
D position
1 2 5 to 10 km/h (3 to 6 mph)
23 16 to 21 km/h (10 to 13 mph)
34 28 to 33 km/h (17 to 21 mph)
45
Throttle valve opening 6% (Normal)
40 to 46 km/h (25 to 29 mph)
56 94 to 101 km/h (25 to 29 mph)
Lock-up 80 km/h (50 mph) or higher
5, 4, 3, 2, 1 gear range
5 215 to 229 km/h (134 to 142 mph)
4 155 to 168 km/h (96 to 104 mph)
Manual downshift speed 3 116 to 123 km/h (72 to 76 mph)
2 79 to 86 km/h (49 to 53 mph)
1 41 to 47 km/h (24 to 28 mph)

REVERSE CLUTCH
Reverse clutch hub bushing inside diameter STD 41.912 to 41.937 mm (1.410 to 1.411 in.)
Clutch piston return spring free length STD 21.24 mm (0.836 in.)
Mark. 0 2.35 to 2.45 mm (0.0925 to 0.0965 in.)
Mark. 1 2.45 to 2.55 mm (0.0965 to 0.100 in.)
Mark. 2 2.55 to 2.65 mm (0.100 to 0.104 in.)
Mark. 3 2.65 to 2.75 mm (0.104 to 0.108 in.)
Mark. 4 2.75 to 2.85 mm (0.108 to 0.112 in.)
Mark. 5 2.85 to 2.95 mm (0.112 to 0.116 in.)
Flange thickness
Mark. 6 2.95 to 3.05 mm (0.116 to 0.120 in.)
Mark. 7 3.05 to 3.15 mm (0.120 to 0.124 in.)
Mark. 8 3.15 to 3.25 mm (0.124 to 0.128 in.)
Mark. A 3.25 to 3.35 mm (0.128 to 0.132 in.)
Mark. B 3.35 to 3.45 mm (0.132 to 0.136 in.)
Mark. C 3.45 to 3.55 mm (0.136 to 0.140 in.)

FORWARD CLUTCH
Forward clutch hub bushing inside diameter STD 30.200 to 30.225 mm (1.189 to 1.0261 in.)
Clutch piston return spring free length STD 29.65 mm (1.17 in.)
Mark. 0 2.95 to 3.05 mm (0.116 to 0.120 in.)
Mark. 1 3.05 to 3.15 mm (0.120 to 0.124 in.)
Mark. 2 3.15 to 3.25 mm (0.124 to 0.128 in.)
Mark. 3 3.25 to 3.35 mm (0.128 to 0.132 in.)
Mark. 4 3.35 to 3.45 mm (0.132 to 0.136 in.)
Mark. 5 3.45 to 3.55 mm (0.136 to 0.140 in.)
Flange thickness
Mark. 6 3.55 to 3.65 mm (0.140 to 0.144 in.)
Mark. 7 3.65 to 3.75 mm (0.144 to 0.148 in.)
Mark. 8 3.75 to 3.85 mm (0.148 to 0.152 in.)
Mark. A 3.85 to 3.95 mm (0.152 to 0.156 in.)
Mark. B 3.95 to 4.05 mm (0.156 to 0.159 in.)
Mark. C 4.05 to 4.15 mm (0.159 to 0.163 in.)

DIRECT CLUTCH (for 3UR-FE

Clutch piston return spring free length STD 19.46 mm (0.766 in.)
Mark. 0 3.45 to 3.55 mm (0.136 to 0.140 in.)
Mark. 1 3.55 to 3.65 mm (0.140 to 0.144 in.)
Mark. 2 3.65 to 3.75 mm (0.144 to 0.148 in.)
Mark. 3 3.75 to 3.85 mm (0.148 to 0.152 in.)
Flange thickness Mark. 4 3.85 to 3.95 mm (0.152 to 0.156 in.)
Mark. 5 3.95 to 4.05 mm (0.156 to 0.159 in.)
Mark. 6 4.05 to 4.15 mm (0.159 to 0.163 in.)
Mark. 7 4.15 to 4.25 mm (0.163 to 0.167 in.)
Mark. 8 4.25 to 4.35 mm (0.167 to 0.171 in.)
DIRECT CLUTCH (for 1VD-FTV)
Clutch piston return spring free length STD 19.46 mm (0.766 in.)
Mark. 0 3.45 to 3.55 mm (0.136 to 0.140 in.)
Mark. 1 3.55 to 3.65 mm (0.140 to 0.144 in.)
Mark. 2 3.65 to 3.75 mm (0.144 to 0.148 in.)
Mark. 3 3.75 to 3.85 mm (0.148 to 0.152 in.)
Mark. 4 3.85 to 3.95 mm (0.152 to 0.156 in.)
Flange thickness
Mark. 5 3.95 to 4.05 mm (0.156 to 0.159 in.)
Mark. 6 4.05 to 4.15 mm (0.159 to 0.163 in.)
Mark. 7 4.15 to 4.25 mm (0.163 to 0.167 in.)
Mark. 8 4.25 to 4.35 mm (0.167 to 0.171 in.)
Mark. A 4.35 to 4.45 mm (0.171 to 0.175 in.)

COAST CLUTCH
Mark. 0 2.95 to 3.05 mm (0.116 to 0.120 in.)
Mark. 1 3.05 to 3.15 mm (0.120 to 0.124 in.)
Mark. 2 3.15 to 3.25 mm (0.124 to 0.128 in.)
Mark. 3 3.25 to 3.35 mm (0.128 to 0.132 in.)
Mark. 4 3.35 to 3.45 mm (0.132 to 0.136 in.)
Flange thickness Mark. 5 3.45 to 3.55 mm (0.136 to 0.140 in.)
Mark. 6 3.55 to 3.65 mm (0.140 to 0.144 in.)
Mark. 7 3.65 to 3.75 mm (0.144 to 0.148 in.)
Mark. 8 3.75 to 3.85 mm (0.148 to 0.152 in.)
Mark. A 3.85 to 3.95 mm (0.152 to 0.156 in.)
Mark. B 3.95 to 4.05 mm (0.156 to 0.159 in.)

NO. 3 BRAKE
Brake piston return spring free length STD 15.72 mm (0.619 in.)

FRONT PLANETARY GEAR

Planetary gear bushing inside diameter STD 61.005 to 61.030 mm (2.402 to 2.403 in.)
Planetary pinion gear thrust clearance STD 0.2 to 0.6 mm (0.00787 to 0.0236 in.)

NO. 1 BRAKE
Piston return spring free length STD 17.05 mm (0.671 in.)
Mark. 0 1.95 to 2.05 mm (0.0768 to 0.0807 in.)
Mark. 1 2.15 to 2.25 mm (0.0846 to 0.0886 in.)
Flange thickness
Mark. 2 2.35 to 2.45 mm (0.0925 to 0.0965 in.)
Mark. 3 2.55 to 2.65 mm (0.100 to 0.104 in.)

NO. 2 BRAKE
Piston return spring free length STD 22.66 mm (0.892 in.)
Mark. 0 1.95 to 2.05 mm (0.0768 to 0.0807 in.)
Mark. 1 2.05 to 2.15 mm (0.0807 to 0.0846 in.)
Mark. 2 2.15 to 2.25 mm (0.0846 to 0.0886 in.)
Mark. 3 2.25 to 2.35 mm (0.0886 to 0.0925 in.)
Flange thickness
Mark. 4 2.35 to 2.45 mm (0.0925 to 0.0965 in.)
Mark. 5 2.45 to 2.55 mm (0.0965 to 0.100 in.)
Mark. 6 2.55 to 2.65 mm (0.100 to 0.104 in.)
Mark. 7 2.65 to 2.75 mm (0.104 to 0.108 in.)

CENTER PLANETARY GEAR

Planetary pinion gear thrust clearance STD 0.20 to 0.60 mm (0.00787 to 0.0236 in.)

INTERMEDIATE SHAFT
Intermediate shaft run out STD 0.03 mm (0.00118 in.)
STD A: 19.963 to 19.976 mm (0.7859 to 0.7863 in.)
Intermediate shaft diameter
STD B, C: 30.150 to 30.163 mm (1.187 to 1.188 in.)
STD D, E: 36.404 to 36.420 mm (1.433 to 1.434 in.)

REAR PLANETARY GEAR

Planetary pinion gear thrust clearance STD 0.2 to 0.6 mm (0.00787 to 0.0236 in.)
Planetary gear bushing inside diameter Maximum 20.0 to 20.025 mm (0.787 to 0.788 in.)

NO. 4 BRAKE
Mark. 0 0 mm (0 in.)
Mark. 2 0.15 to 0.25 mm (0.00590 to 0.00984 in.)
Mark. 4 0.35 to 0.45 mm (0.0138 to 0.0177 in.)
Flange H thickness
Mark. 6 0.55 to 0.65 mm (0.0217 to 0.0256 in.)
Mark. 8 0.75 to 0.85 mm (0.0295 to 0.0335 in.)
Mark. 10 0.95 to 1.05 mm (0.0374 to 0.0413 in.)

1ST AND REVERSE BRAKE

1st and reverse brake return spring sub-assembly STD 23.54 to 23.94 mm (0.927 to 0.943 in.)

ACCUMULATOR
Spring Color Free length / Outer diameter [mm (in.)]
B-1 Inner Natural 44.98 mm (1.77 in.) / 11.30 mm (0.445 in.)
B-1 Outer Natural 46.36 mm (1.83 in.) / 17.10 mm (0.673 in.)
for 3UR-FE Natural
C-3 76.65 mm (3.02 in.) / 20.1 mm (0.791 in.)
for 1VD-FTV White
B-3 Orange 64.50 mm (2.54 in.) / 19.5 mm (0.768 in.)
for 3UR-FE Blue
C-2 68.0 mm (2.68 in.) / 16.1 mm (0634 in.)
for 1VD-FTV Light green

OIL PUMP
STD 0.10 to 0.17 mm (0.00394 to 0.00669 in.)
Body clearance
Maximum 0.170 mm (0.00669 in.)
STD 0.070 to 0.150 mm (0.00276 to 0.00591 in.)
Tip clearance
Maximum 0.150 mm (0.00591 in.)
STD 0.03 to 0.05 mm (0.000118 to 0.00197 in.)
Side clearance
Maximum 0.05 mm (0.00197 in.)
0 11.636 to 11.650 mm (0.4581 to 0.4586 in.)
1 11.643 to 11.649 mm (0.4584 to 0.4586 in.)
2 11.650 to 11.656 mm (0.4587 to 0.4589 in.)
Driver and driven gear thickness 3 11.657 to 11.663 mm (0.4589 to 0.4592 in.)
4 11.664 to 11.670 mm (0.4592 to 0.4594 in.)
5 11.671 to 11.677 mm (0.4595 to 0.4597 in.)
6 11.678 to 11.684 mm (0.4598 to 0.4600 in.)
Pump body bushing inside diameter STD 45.064 to 45.078 mm (1.774 to 1.775 in.)
Stator shaft bushing inside diameter STD 25.900 to 25.921 mm (1.020 to 1.021 in.)
AB60F AUTOMATIC TRANSMISSION / TRANSAXLE > TORQUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Drain plug x Oil pan 20 204 15
Overflow plug x Oil pan 20 204 15
Refill plug x Transmission case 39 400 29
Speed sensor NT x Automatic transmission 5.4 55 48 in.*lbf
Speed sensor SP2 x Automatic transmission 5.4 55 48 in.*lbf
No. 1 and No. 2 engine under cover x frame 29 296 21
Oil pan protector x W rame -3 642 46
No. 1 transmission wire set bolt x Automatic transmission 5.4 55 48 in.*lbf
No. 2 transmission wire set bolt x Automatic transmission 5.4 55 48 in.*lbf

12 mm 0.4H2 in.k length 10 102 H
Transmission wire clamp

36 mm 1.41 in.k length 11 112 8
Transmission oil pan x Transmission case H 4. H5 65 in.*lbf
Valve body oil strainer x Valve body 10 102 H
) al
ve body x Transmission case 11 112 8
Detent spring and Detent spring cover x valve body 10 102 H
Shift solenoid valve S1 x Valve body 10 102 H
Shift solenoid valve S4 x Valve body 10 102 H
Shift solenoid valve S2 and S3 x Valve body 10 102 H
Shift solenoid valve SR x Valve body 10 102 H
Solenoid lock plate x Valve body 6.4 65 5H in.*lbf
V olt7 3
1 133 10
ParkE ne
utral position switch
Nut7 6.9 H0 61 in.*lbf
Transmission control shaft lever RH 16 163 12
Oil cooler assembly x V ody 12 122 9
Transmission oil cooler air duct x oil cooler assembly 4.9 50 43 in.*lbf
Rear transmission oil cooler air duct x Oil cooler assembly 4.9 50 43 in.*lbf
Air cooled oil cooler tube x Rear transmission oil cooler air duct 4.9 50 43 in.*lbf
Oil cooler tube x Radiator fan shroud 5.0 51 44 in.*lbf
W oor
l shift assembly x V ody 14 143 10
Transmission floor shift assembly x W oor
l shift gear shifting rod 13 130 9
1H mm head o
blt7 H1 H24 52
Automatic transmission assembly x E ngine
14 mm head bolt7 3H 3H H 2H
Torque converter x Drive plate 53 540 39
W ire harness x Automatic transmission for 1VD-W T) 08. 82 H1 in.*lbf
Rear No. 1 engine mounting insulator x C rossmember 3H 3H H 2H
Transmission housing cover x Transmission for 1VD-W T) 12 122 9
Oil pan cover x Transmission for 1VD-W T) 21 214 15
C rossmember x W rame 110 1122 81
Oil cooler tube x E ngine for 1VD-W T) 14 143 10
Oil pan insulator x E ngine for 1VD-W T) 21 214 15
Rear No. 1 engine mounting insulator x Automatic transmission assembly 59 602 44
Transfer case lower protector x Transfer 14 143 10
Transfer x Automatic transmission 40 408 30
Transmission housing x Transmission case 34 345 25
Automatic transmission breather tube x Transmission case 5.4 55 48 in.*lbf
Rear transfer adaptor x transmission case 34 345 25
Parking lock pawl bracket x Transmission case 18 184 13
Oil pump x Transmission case 21 214 15
Oil pump body x Stator shaft 11 112 8
G round cable 8.4 86 H4 in.*lbf
E ngine mounting heat insulator x Rear No. 1
for 3UR-W E 12 122 9
engine mounting insulator
ATW tem
perature sensor clamp x Valve body V olt A 10 102 H
V olt V 11 11
2 8
V olt A 8.0 82 H1 in.*lbf
W ire harness clamp bracket x Transmission V olt V 29 296 21
assembly V olt C Type A 8.0 82 H1 in.*lbf
V olt C Type V 2
1 122 9
Oil cooler tube union x Transmission assembly 29 296 21
Detent spring cover 10 102 H
CLUTCH > SERVICE DATA

LHD 162.7 to 172.7 mm (6.41 to 6.79 in.)

Pedal height from tibia pad
RHD 164.8 to 174.8 mm (6.49 to 6.88 in.)
Clutch pedal free play 5.0 to 15.0 mm (0.197 to 0.591 in.)
Clutch pedal push rod play at pedal top 1.0 to 5.0 mm (0.039 to 0.197 in.)
Clutch release point from pedal full stroke end position 20 mm (0.787 in.) or more
Clutch disc rivet head depth Minimum 0.3 mm (0.0118 in.)
1GR-FE:
Maximum
0.9 mm (0.0354 in.)
Clutch disc runout
1VD-FTV:
Maximum
1.0 mm (0.0394 in.)
Flywheel runout Maximum 0.1 mm (0.00394 in.)
Maximum depth 0.6 mm (0.0236 in.)
Clutch cover diaphragm spring
Minimum width 5.0 mm (0.197 in.)
ON (pushed) Blow 1 Ω
Clutch start switch
OFF (released) 10 kΩ or higher
CLUTCH > TORQUE SPECIFICATIONS

Part tightened N*m kgf*cm ft.*lbf

Clutch pedal support assembly x Body Nut 14 145 10

for LHD Bolt 18 184 13
Clutch pedal support assembly x Body x Clutch master cylinder Nut 12 120 9
for RHD Bolt 18 184 13
Clutch pedal support way x Clutch master cylinder to flexible hose tube
15 155 11
for LHD
Clutch pedal support way x Clutch master cylinder to way tube x Clutch master cylinder
15 155 11
for LHD
Clutch master cylinder x Flexible hose tube
15 155 11
RHD
Clutch pedal x Clutch pedal support 34 350 25
Clutch pedal assembly x Clutch master cylinder
Nut 12 120 9
for LHD
Clutch master cylinder x Clutch pedal support
12 120 9
for LHD
Clutch pedal stopper bolt lock nut x Clutch pedal support
16 160 12
for LHD
Lock nut of clutch pedal stopper bolt or clutch switch x Clutch pedal support
16 160 12
for RHD
Clutch master cylinder push rod x Cle:is lock nut 12 120 9
Release cylinder bleeder plug x Clutch release cylinder assembly 11 110 8
Clutch release cylinder x Transmission housing 12 120 9
Clutch release cylinder to accumulator tube x Clutch release cylinder 16 158 11
Clutch accumulator x Manual transmission assembly 12 120 9
Clutch release cylinder to accumulator tube x Clutch accumulator 16 158 11
Clutch release cylinder to flexible hose tube x Clutch accumulator 15 155 11
Clutch accumulator x Transmission 12 120 9
Clutch co:er assembly x Flywheel
19 195 14
for 1) R- - E
Clutch co:er assembly x Flywheel
39 400 2 9
for 1V D- - H V
Release fork support x Transmission housing 47 480 35
Body ECU xBody 8.0 82 1
7 in.*lbf
Clutch start switch x Clutch pedal support 5.0 51 44 in.*lbf
Clutch switch x Clutch pedal support 16 160 12
H150F MANUAL TRANSMISSION / TRANSAXLE > SERVICE DATA

TRANSMISSION CASE OIL SEAL

transmission case oil seal 15.4 to 16.2 mm (0.607 to 0.637 in.)

MANUAL TRANSMISSION UNIT

No. 3 transmission clutch hup shaft snap ring clearance 0.1 mm (0.0039 in.) or less
A 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
B 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
C 2.50 to 2.55 mm (0.0984 to 0.100 in.)
No. 3 transmission clutch hup shaft snap ring thickness
D 2.55 to 2.60 mm (0.100 to 0.102 in.)
E 2.60 to 2.65 mm (0.102 to 0.104 in.)
F 2.65 to 2.70 mm (0.104 to 0.106 in.)
Reverse gear thrust clearance Standard 0.15 to 0.52 mm (.0.00591 to 0.0204 in.)
Intermediate plate straight pin 7.0 to 9.0 mm (.0.276 to 0.354 in.)
Upper side 4.0 to 6.0 mm (.0.158 to 0.236 in.)
Transfer adapter straight pin
Front side 9.0 to 11.0 mm (.0.355 to 0.433 in.)
Transfer adapter ring pin 4.0 to 6.0 mm (.0.157 to 0.236 in.)

INPUT SHAFT
Standard 0.08 to 0.16 mm (0.0315 to 0.0629 in.)
No. 2 synchronizer ring clearance
Minimum 0.08 mm (0.0315 in.)
Front pearing shaft snap ring clearance 0.10 mm (0.00393 in.) or less
A 2.50 to 2.55 mm (0.0984 to 0.100 in.)
B 2.55 to 2.60 mm (0.100 to 0.102 in.)
C 2.60 to 2.65 mm (0.102 to 0.104 in.)
Front pearing shaft snap ring thickness
D 2.65 to 2.70 mm (0.104 to 0.106 in.)
E 2.70 to 2.75 mm (0.106 to 0.108 in.)
F 2.75 to 2.80 mm (0.108 to 0.110 in.)

OUTPUT SHAFT
3rd gear thrust clearance 0.10 to 0.45 mm (0.00394 to 0.0177 in.)
5th gear thrust clearance 0.10 to 0.35 mm (0.00394 to 0.0137 in.)
2nd gear thrust clearance 0.10 to 0.35 mm (0.00394 to 0.0137 in.)
1st gear thrust clearance 0.10 to 0.45 mm (0.00394 to 0.0177 in.)
3rd gear radial clearance 0.020 to 0.073 mm (0.000788 to 0.00287 in.)
5th gear radial clearance 0.015 too 0.068 mm (0.000591 to 0.00267 in.)
2nd gear radial clearance 0.015 too 0.068 mm (0.000591 to 0.00267 in.)
1st gear radial clearance 0.020 to 0.073 mm (0.000788 to 0.00287 in.)
Output shaft runout Maximum 0.03 mm (0.00118 in.)
Standard: Part A 37.979 to 37.995 mm (1.4952 to 1.4959 in.)
Standard: Part B 45.984 to 46.000 mm (1.8104 to 1.8110 in.)
Standard: Part C 57.984 to 58.000 mm (2.2828 to 2.2835 in.)
Standard: Part D 49.979 to 49.995 mm (1.9677 to 1.9683 in.)
Output shaft outer diameter
Minimum: Part A 37.979 mm (1.4952 in.)
Minimum: Part B 45.984 mm (1.8104 in.)
Minimum: Part C 57.984 mm (2.2828 in.)
Minimum: Part D 49.979 mm (1.9677 in.)
Standard 44.015 to 44.040 mm (1.733 to 1.734 in.)
3rd gear inner diameter
Maximum 44.040 mm (1.734 in.)
Standard 53.015 to 53.040 mm (2.087 to 2.088 in.)
5th gear inner diameter
Maximum 53.040 mm (2.088 in.)
Standard 65.015 to 65.040 mm (2.560 to 2.561in.)
2nd gear inner diameter
Maximum 65.040 mm (2.561in.)
Standard 57.015 to 57.040 mm (2.2447 to 2.2457 in.)
1st gear inner diameter
Maximum 57.040 mm (2.2457 in.)
Standard 1.15 to 2.05 mm (0.0453 to 0.0807 in.)
No. 3 synchronizer ring (For 3rd gear) clearance
Minimum 1.15 mm (0.0453 in.)
Standard 0.80 to 1.60 mm (0.0315 to 0.0629 in.)
No. 3 synchronizer ring (For 5th gear) clearance
Minimum 0.80 mm (0.0315 in.)
Standard 1.23 to 2.13 mm (0.0485 to 0.0838 in.)
No. 2 synchronizer ring (For 2nd gear) clearance
Minimum 1.23 mm (0.0485 in.)
Standard 1.25 to 2.15 mm (0.0493 to 0.0846 in.)
No. 1 synchronizer ring (For 1st gear) clearance
Minimum 1.25 mm (0.0493 in.)
No. 3 transmission clutch hup shaft snap ring clearance 0.10 mm (0.00393 in.) or less
A 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
B 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
C 2.50 to 2.55 mm (0.0984 to 0.100 in.)
No. 3 transmission clutch hup shaft snap ring thickness
D 2.55 to 2.60 mm (0.100 to 0.102 in.)
E 2.60 to 2.65 mm (0.102 to 0.104 in.)
F 2.65 to 2.70 mm (0.104 to 0.106 in.)
No. 2 clutch hup setting shaft snap ring clearance 0.10 mm (0.00393 in.) or less
4 1.90 to 1.95 mm (0.0748 to 0.0768 in.)
5 1.95 to 2.00 mm (0.0768 to 0.0787 in.)
6 2.00 to 2.05 mm (0.0787 to 0.0807 in.)
No. 2 clutch hup setting shaft snap ring thickness
7 2.05 to 2.10 mm (0.0807 to 0.0827 in.)
8 2.10 to 2.15 mm (0.0827 to 0.0847 in.)
9 2.15 to 2.20 mm (0.0847 to 0.0866 in.)
No. 1 clutch hup shaft snap ring clearance 0.10 mm (0.00393 in.) or less
A 2.90 to 2.95 mm (0.114 to 0.116 in.)
B 2.95 to 3.00 mm (0.116 to 0.118 in.)
C 3.00 to 3.05 mm (0.118 to 0.120 in.)
No. 1 clutch hup shaft snap ring thickness
D 3.05 to 3.10 mm (0.120 to 0.122 in.)
E 3.10 to 3.15 mm (0.122 to 0.124 in.)
F 3.15 to 3.20 mm (0.124 to 0.126 in.)
Reverse gear snap ring clearance 0.10 mm (0.00393 in.) or less
A 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
B 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
C 2.50 to 2.55 mm (0.0984 to 0.100 in.)
D 2.55 to 2.60 mm (0.100 to 0.102 in.)
Reverse gear snap ring thickness
E 2.60 to 2.65 mm (0.102 to 0.104 in.)
F 2.65 to 2.70 mm (0.104 to 0.106 in.)
G 2.70 to 2.75 mm (0.106 to 0.108 in.)
H 2.75 to 2.80 mm (0.108 to 0.110 in.)

COUNTER G A
ER AND REVERSE IDLER G A
ER
Standard 35.957 to 35.970 mm (1.41562 to 1.41613 in.)
Counter gear journal outer diameter
Minimum 35.957 mm (1.41562 in.)
Counter gear runout Maximum 0.03 mm (0.00118 in.)
Standard 0.015 to 0.059 mm (0.000591 to 0.0232 in.)
Reverse idler gear radial clearance
Maximum 0.059 mm (0.0232 in.)
Front No. 1 counter gear pearing snap ring clearance 0.1 mm (0.00393 in.) or less
A 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
B 2.50 to 2.55 mm (0.0984 to 0.100 in.)
C 2.55 to 2.60 mm (0.100 to 0.102 in.)
Front No. 1 counter gear pearing snap ring thickness
D 2.60 to 2.65 mm (0.102 to 0.104 in.)
E 2.65 to 2.70 mm (0.104 to 0.106 in.)
F 2.70 to 2.75 mm (0.106 to 0.108 in.)

OIL PUMP
Standard 0.10 to 0.22 mm (0.00394 to 0.00866 in.)
Tip clearance
Maximum 0.22 mm (0.00866 in.)
Standard 0.075 to 0.170 mm (0.00296 to 0.00669 in.)
Body clearance
Maximum 0.170 mm (0.00669 in.)
H150F MANUAL TRANSMISSION / TRANSAXLE > TORQUE SPECIFICATIONS

Part tightened N*m kgf*cm ft.*lbf

Back-up light switch x Manual
44 450 33
transmission assembly
Engine (1GR-FE) x Manual
transmission assembly 72 730 53
Bolt A
Engine (1GR-FE) x Manual
transmission assembly 37 380 28
Bolt B
Engine (1VD-FTV) x Manual
transmission assembly 72 730 53
Bolt A,B
Engine (1VD-FTV) x Manual
transmission assembly 39 400 29
Bolt C
Oil pan cover (1VD-FTV) x Manual
21 214 15
transmission assembly
Clutch release cylinder to flexible
hose tube x Manual transmission 20 204 15
assembly
Clutch release cylinder x Manual
12 120 9
transmission assembly
Rear No. 1 engine mounting
insulator x Manual transmission 59 602 44
assembly
No. 2 frame crossmember sub-
37 377 27
assembly set bolt
Transfer assembly x Lower transfer
14 139 10
case protector
Transfer assembly x Transfer
12 122 9
dynamic damper
Output shaft rear bearing retainer x
18 185 13
Intermediate plate
No. 2 gear shift fork shaft x No. 2
46 472 34
gear shift fork
No. 1 gear shift fork shaft x No. 2
46 472 34
gear shift fork
No. 3 gear shift fork shaft x No. 3
46 472 34
gear shift fork
No. 4 gear shift fork shaft x Reverse
34 350 25
gear shift fork
Manual transmission case receiver
18 185 13
x Intermediate shaft
No. 1 oil receiver pipe x
12 120 9
Transmission case
Manual transmission oil strainer x
12 120 9
Transfer adapter
Transmission case x Transfer
37 380 27
adapter
Front bearing retainer x
17 170 12
Transmission case
Transmission oil pump cover x
17 170 12
Transfer adapter
Floor shift control shift lever retainer
17 170 12
x Transfer adapter
Control shaft cover x Manual
17 170 12
transmission
Shift position switch x Manual
44 450 33
transmission
frame crossmember x Body 110 1122 81
Filler plug x Manual transmission 37 380 27
No. 1 clutch housing cover x
Manual transmission assembly 12 120 9
Reverse restrict pin x Shift lever
37 380 27
retainer
Inter lock hole plug x Transfer
18 185 13
adapter
Shift and select lever 38 390 28
Shift lever housing 38 390 28
Manual transmission case plug 37 380 27
Drain plug 37 380 27
Clutch housing x Manual
37 380 27
transmission case
No. 1 manual transmission oil pump
18 185 13
plug x Transmission oil pump cover
Transmission oil pump cover x
17 170 12
Manual transmission assembly
Ground cable 8.0 82 71 in.*lbf
Shift detent ball plug 19 190 14
Transfer adapter plug 19 190 14
Wire harness (1GR-FE)
60 612 44
LH side
Wire harness (1GR-FE)
29 296 21
RH side
JF2A TRANSFER / 4WD / AWD > SERVICE DATA

Input shaft
C 2.13 to 2.18 mm (0.0839 to 0.0858 in.)
D 2.18 to 2.23 mm (0.0858 to 0.0878 in.)
E 2.23 to 2.28 mm (0.0878 to 0.0898 in.)
Input shaft snap ring thickness F 2.28 to 2.33 mm (0.0898 to 0.0917 in.)
G 2.33 to 2.38 mm (0.0917 to 0.0937 in.)
H 2.38 to 2.43 mm (0.0937 to 0.0957 in.)
J 2.43 to 2.48 mm (0.0957 to 0.0976 in.)
Input shaft journal outer diameter Minimum 68 mm (2.68 in.)
Input shaft bushing inside diameter Maximum 46 mm (1.81 in.)

Rear output shaft

Part A
38 mm (1.50 in.)
Minimum
Part B
Rear output shaft journal outer diameter 42 mm (1.65 in.)
Minimum
Part C
49 mm (1.93 in.)
Minimum
clearance
No. 1 transfer gear shift fork to clutch sleeve 0.8 mm (0.0315 in.)
Maximum
clearance
No. 2 transfer gear shift fork to clutch sleeve 3.15 mm (0.124 in.)
Maximum

Planetary gear
Standard 0.11 to 0.85 mm (0.00434 to 0.0334 in.)
Pinion gear thrust clearance
Maximum 0.85 mm (0.0334 in.)
Standard 0.01 to 0.04 mm (0.000434 to 0.00150 in.)
Pinion gear radial clearance
Maximum 0.04 mm (0.00150 in.)

Synchronizer ring
Standard 0.86 to 1.54 mm (0.0339 to 0.0606 in.)
No. 1 synchronizer ring to input shaft
Minimum 0.86 mm (0.0339 in.)
C TAONS
JF2A TRANSFER / 4WD / AWD > TORQUE SPEC FI

Part Tightened N*m kgf*cm ft.*lbf

Transfer heat insulator x Transfer 30 306 22
Lower transfer case protector x Transfer 14 139 10
Transfer oil pump plate x Transfer case plug 29 300 22
Transfer oil pump plate x Front transfer case 12 117 9
Transfer case plug x Front transfer case 37 377 27
Transfer case plug x Front transfer case 39 400 29
No. 1 transfer case plug x Front transfer case 19 190 14
Filler plug x Front transfer case 37 377 27
Drain plug x Front transfer case 37 377 27
Companion flange lock nut x Driven sprocket 127 1299 94
Companion flange lock nut x Rear transfer output shaft 127 1299 94
Heat insulator bracket x Transfer 20 204 15
No. 1 transfer gear shift fork x Transfer shift actuator assembly 24 245 18
No. 2 transfer gear shift fork x Transfer shift actuator assembly 24 245 18
Rear transfer case x Transfer shift actuator assembly 20 204 15
Front transfer case x Rear transfer case 28 286 21
Four wheel drive control ECU x Body 13 127 9
DRIVE SHAFT / PROPELLER SHAFT > SERVICE DATA

Drive shaft
Standard drive shaft length 583 mm (1.91 ft.)

Front propeller shaft

Propeller shaft runout Maximum 0.8 mm (0.031 in.)
Bearing axial play Maximum 0 mm (0 in.)
J 2.18 to 2.20 mm (0.0858 to 0.0866 in.)
A 2.20 to 2.22 mm (0.0866 to 0.0874 in.)
F 2.22 to 2.24 mm (0.0874 to 0.0882 in.)
G 2.24 to 2.26 mm (0.0882 to 0.0890 in.)
H 2.26 to 2.28 mm (0.0890 to 0.0898 in.)
1 2.28 to 2.30 mm (0.0898 to 0.0906 in.)
2 2.30 to 2.32 mm (0.0906 to 0.0913 in.)
- 2.32 to 2.34 mm (0.0913 to 0.0921 in.)
Brown 2.34 to 2.36 mm (0.0921 to 0.0929 in.)
Blue 2.36 to 2.38 mm (0.0929 to 0.0937 in.)
6 2.38 to 2.40 mm (0.0937 to 0.0945 in.)
Snap ring thickness
7 2.40 to 2.42 mm (0.0945 to 0.0953 in.)
8 2.42 to 2.44 mm (0.0953 to 0.0961 in.)

2.44 to 2.46 mm (0.0961 to 0.0969 in.)

10 2.46 to 2.48 mm (0.0969 to 0.0976 in.)

A 2.48 to 2.50 mm (0.0976 to 0.0984 in.)
B 2.50 to 2.52 mm (0.0984 to 0.0992 in.)
C 2.52 to 2.54 mm (0.0992 to 0.1000 in.)
D 2.54 to 2.56 mm (0.1000 to 0.1008 in.)
E 2.56 to 2.58 mm (0.1008 to 0.1016 in.)

Rear propeller shaft

Propeller shaft runout Maximum 0.8 mm (0.031 in.)
Bearing axial play Maximum 0 mm (0 in.)
J 2.18 to 2.20 mm (0.0858 to 0.0866 in.)
A 2.20 to 2.22 mm (0.0866 to 0.0874 in.)
F 2.22 to 2.24 mm (0.0874 to 0.0882 in.)
G 2.24 to 2.26 mm (0.0882 to 0.0890 in.)
H 2.26 to 2.28 mm (0.0890 to 0.0898 in.)
1 2.28 to 2.30 mm (0.0898 to 0.0906 in.)
2 2.30 to 2.32 mm (0.0906 to 0.0913 in.)
- 2.32 to 2.34 mm (0.0913 to 0.0921 in.)
Brown 2.34 to 2.36 mm (0.0921 to 0.0929 in.)
Blue 2.36 to 2.38 mm (0.0929 to 0.0937 in.)
6 2.38 to 2.40 mm (0.0937 to 0.0945 in.)
Snap ring thickness 7 2.40 to 2.42 mm (0.0945 to 0.0953 in.)
8 2.42 to 2.44 mm (0.0953 to 0.0961 in.)

2.44 to 2.46 mm (0.0961 to 0.0969 in.)

10 2.46 to 2.48 mm (0.0969 to 0.0976 in.)

A 2.48 to 2.50 mm (0.0976 to 0.0984 in.)
B 2.50 to 2.52 mm (0.0984 to 0.0992 in.)
C 2.52 to 2.54 mm (0.0992 to 0.1000 in.)
D 2.54 to 2.56 mm (0.1000 to 0.1008 in.)
E 2.56 to 2.58 mm (0.1008 to 0.1016 in.)
DRIVE SHAFT / PROPELLER SHAFT > TORQUE SPECIFICATIONS

Drive shaft
Part Tightened N*m kgf*cm ft.*lbf
Drive shaft assembly x Steering knuckle 340 3467 251

Front propeller shaft

Part Tightened N*m kgf*cm ft.*lbf
Propeller shaft heat insulator x Body 40 408 30
Front propeller shaft x Front differential carrier assembly 88 900 65
Front propeller shaft x Transfer assembly 88 900 65

Rear propeller shaft

Part Tightened N*m kgf*cm ft.*lbf
Transfer heat insulator x Transfer assembly 30 302 22
Rear propeller shaft x Transfer assembly 88 900 65
Rear propeller shaft x Rear differential carrier assembly 88 900 65
AXLE AND DIFFERENTIAL > SERVICE DATA

Front axle hub

Axle hub bearing looseness Maximum 0.05 mm (0.00197 in.)
Axle hub runout Maximum 0.08 mm (0.00315 in.)

Front differential (for standard)

Vertical
Companion flange runout Maximum: 0.10 mm (0.00394 in.)
Lateral
New bearing 3.0 to 3.5 N*m (31 to 35 kgf*cm, 27 to 50 in.*lbf)
Drive pinion preload (at starting)
Reused bearing 2.1 to 2.5 N*m (22 to 24 kgf*cm, 19 to 21 in.*lbf)
Drive pinion preload plus 1.6 to 2.4 N*m (17 to 24
New bearing
kgf*cm, 15 to 21 in.*lbf)
Total preload (at starting)
Drive pinion preload plus 1.3 to 2.1 N*m (14 to 21
Reused bearing
kgf*cm, 12 to 18 in.*lbf)
Drive pinion to ring gear backlash 0.17 to 0.27 mm (0.00670 to 0.01064 in.)
Side gear backlash 0 to 0.15 mm (0 to 0.00591 in.)
Front oil seal drive in depth 5.6 to 6.6 mm (0.221 to 0.259 in.)
LH side -0.45 to 0.45 mm (-0.0177 to 0.0177 in.)
Side oil seal drive in depth
RH side 4.8 to 5.8 mm (0.189 to 0.228 in.)
Differential carrier straight pin in height 9.5 to 10.0 mm (0.374 to 0.394 in.)
1.43 to 1.47 mm (0.0563 to 0.0579 in.)
1.48 to 1.52 mm (0.0583 to 0.0598 in.)
1.53 to 1.57 mm (0.0602 to 0.0618 in.)
1.58 to 1.62 mm (0.0622 to 0.0638 in.)
Side gear thrust washer thickness 1.63 to 1.67 mm (0.0642 to 0.0657 in.)
1.68 to 1.72 mm (0.0661 to 0.0677 in.)
1.73 to 1.77 mm (0.0681 to 0.0697 in.)
1.78 to 1.82 mm (0.0701 to 0.0717 in.)
1.83 to 1.87 mm (0.0720 to 0.0736 in.)
1.49 to 1.51 mm (0.0587 to 0.0594 in.)
1.51 to 1.53 mm (0.0594 to 0.0602 in.)
1.53 to 1.55 mm (0.0602 to 0.0610 in.)
1.55 to 1.57 mm (0.0610 to 0.0618 in.)
1.57 to 1.59 mm (0.0618 to 0.0626 in.)
1.59 to 1.61 mm (0.0626 to 0.0634 in.)
1.61 to 1.63 mm (0.0634 to 0.0642 in.)
1.63 to 1.65 mm (0.0642 to 0.0650 in.)
1.65 to 1.67 mm (0.0650 to 0.0657 in.)
1.67 to 1.69 mm (0.0657 to 0.0665 in.)
1.69 to 1.71 mm (0.0665 to 0.0673 in.)
1.71 to 1.73 mm (0.0673 to 0.0681 in.)
1.73 to 1.75 mm (0.0681 to 0.0689 in.)
1.75 to 1.77 mm (0.0689 to 0.0697 in.)
1.77 to 1.79 mm (0.0697 to 0.0705 in.)
1.79 to 1.81 mm (0.0705 to 0.0713 in.)
1.81 to 1.83 mm (0.0713 to 0.0720 in.)
1.83 to 1.85 mm (0.0720 to 0.0728 in.)
1.85 to 1.87 mm (0.0728 to 0.0736 in.)
1.87 to 1.89 mm (0.0736 to 0.0744 in.)
1.89 to 1.91 mm (0.0744 to 0.0752 in.)
Plate washer thickness 1.91 to 1.93 mm (0.0752 to 0.0760 in.)
1.93 to 1.95 mm (0.0760 to 0.0768 in.)
1.95 to 1.97 mm (0.0768 to 0.0776 in.)
1.97 to 1.99 mm (0.0776 to 0.0783 in.)
1.99 to 2.01 mm (0.0783 to 0.0791 in.)
2.01 to 2.03 mm (0.0791 to 0.0799 in.)
2.03 to 2.05 mm (0.0799 to 0.0807 in.)
2.05 to 2.07 mm (0.0807 to 0.0815 in.)
2.07 to 2.09 mm (0.0815 to 0.0823 in.)
2.09 to 2.11 mm (0.0823 to 0.0831 in.)
2.11 to 2.13 mm (0.0831 to 0.0839 in.)
2.13 to 2.15 mm (0.0839 to 0.0846 in.)
2.15 to 2.17 mm (0.0846 to 0.0854 in.)
2.17 to 2.19 mm (0.0854 to 0.0862 in.)
2.19 to 2.21 mm (0.0862 to 0.0870 in.)
2.21 to 2.23 mm (0.0870 to 0.0878 in.)
2.23 to 2.25 mm (0.0878 to 0.0886 in.)
2.25 to 2.27 mm (0.0886 to 0.0894 in.)
2.27 to 2.29 mm (0.0894 to 0.0902 in.)
2.29 to 2.31 mm (0.0902 to 0.0909 in.)
2.31 to 2.33 mm (0.0909 to 0.0917 in.)
2.33 to 2.35 mm (0.0917 to 0.0925 in.)
1.815 to 1.835 mm (0.0715 to 0.0722 in.)
1.840 to 1.860 mm (0.0724 to 0.0732 in.)
1.865 to 1.885 mm (0.0734 to 0.0742 in.)
1.890 to 1.910 mm (0.0744 to 0.0752 in.)
1.915 to 1.935 mm (0.0754 to 0.0762 in.)
1.940 to 1.960 mm (0.0764 to 0.0772 in.)
1.965 to 1.985 mm (0.0774 to 0.0781 in.)
1.990 to 2.010 mm (0.0783 to 0.0791 in.)
2.015 to 2.035 mm (0.0793 to 0.0801 in.)
Drive pinion washer thickness 2.040 to 2.060 mm (0.0803 to 0.0811 in.)
2.065 to 2.085 mm (0.0813 to 0.0821 in.)
2.090 to 2.110 mm (0.0823 to 0.0831 in.)
2.115 to 2.135 mm (0.0793 to 0.0841 in.)
2.140 to 2.160 mm (0.0843 to 0.0850 in.)
2.165 to 2.185 mm (0.0852 to 0.0860 in.)
2.190 to 2.210 mm (0.0862 to 0.0870 in.)
2.215 to 2.235 mm (0.0872 to 0.0870 in.)
2.240 to 2.260 mm (0.0882 to 0.0890 in.)
2.265 to 2.285 mm (0.0892 to 0.0900 in.)

Rear differential (for Standard)

Vertical
Companion flange runout Maximum: 0.10 mm (0.00394 in.)
Lateral
Ring gear runout Maximum: 0.05 mm (0.00197 in.)
Drive pinion to ring gear backlash 0.10 to 0.20 mm (0.00394 to 0.00787 in.)
New bearing 1.0 to 1.7 N*m (11 to 17 kgf*cm, 10 to 14 in.*lbf)
Drive pinion preload (at starting)
Reused bearing 0.9 to 1.4 N*m (9 to 13 kgf*cm, 8 to 12 in.*lbf)
Drive pinion preload plus 0.4 to 0.6 N*m (4 to 6 kgf*cm, 4 to 5
Total preload (at starting)
in.*lbf)
Differential case runout Maximum: 0.04 mm (0.00157 in.)
Side gear backlash 0.02 to 0.15 mm (0.00787 to 0.00591 in.)
1.53 to 1.57 mm (0.0602 to 0.0618 in.)
1.58 to 1.62 mm (0.0622 to 0.0638 in.)
1.63 to 1.67 mm (0.0642 to 0.0657 in.)
1.68 to 1.72 mm (0.0661 to 0.0677 in.)
1.73 to 1.77 mm (0.0681 to 0.0697 in.)
Adjusting shim thickness 1.78 to 1.82 mm (0.0701 to 0.0171 in.)
1.83 to 1.87 mm (0.0720 to 0.0736 in.)
1.88 to 1.92 mm (0.0740 to 0.0756 in.)
1.93 to 1.97 mm (0.0760 to 0.0776 in.)
2.03 to 2.07 mm (0.0799 to 0.0815 in.)
2.08 to 2.12 mm (0.0820 to 0.0835 in.)
1.04 to 1.06 mm (0.0409 to 0.0417 in.)
1.065 to 1.085 mm (0.0420 to 0.0427 in.)
1.09 to 1.11 mm (0.0419 to 0.0437 in.)
1.115 to 1.135 mm (0.0439 to 0.0447 in.)
1.14 to 1.16 mm (0.0449 to 0.0457 in.)
1.165 to 1.185 mm (0.0459 to 0.0467 in.)
1.19 to 1.21 mm (0.0469 to 0.0476 in.)
1.215 to 1.235 mm (0.0478 to 0.0486 in.)
1.24 to 1.26 mm (0.0488 to 0.0496 in.)
1.265 to 1.285 mm (0.0498 to 0.0506 in.)
Plate washer thickness 1.29 to 1.31 mm (0.0508 to 0.0516 in.)
1.315 to 1.335 mm (0.0518 to 0.0526 in.)
1.34 to 1.36 mm (0.0528 to 0.0535 in.)
1.365 to 1.385 mm (0.0537 to 0.0545 in.)
1.39 to 1.41 mm (0.0547 to 0.0555 in.)
1.415 to 1.435 mm (0.0558 to 0.0565 in.)
1.44 to 1.46 mm (0.0567 to 0.0575 in.)
1.465 to 1.485 mm (0.0577 to 0.0585 in.)
1.49 to 1.51 mm (0.0587 to 0.0595 in.)
1.515 to 1.535 mm (0.0597 to 0.0605 in.)
1.54 to 1.56 mm (0.0607 to 0.0615 in.)

Rear differential (w/ LSD)

Vertical
Companion flange runout Maximum: 0.10 mm (0.00394 in.)
Lateral
Ring gear runout Maximum: 0.05 mm (0.00197 in.)
Drive pinion to ring gear backlash 0.10 to 0.20 mm (0.00394 to 0.00787 in.)
New bearing 1.0 to 1.7 N*m (11 to 17 kgf*cm, 10 to 14 in.*lbf)
Drive pinion preload (at starting)
Reused bearing 0.9 to 1.4 N*m (9 to 13 kgf*cm, 8 to 12 in.*lbf)
Drive pinion preload plus 0.4 to 0.6 N*m (4 to 6 kgf*cm, 4 to 5
Total preload (at starting)
in.*lbf)
Differential case runout Maximum: 0.04 mm (0.00157 in.)
Side gear thrust washer thickness (reference) 1.97 to 2.06 mm (0.0776 to 0.0811 in.)
Clutch plate thickness (reference) 1.97 to 2.03 mm (0.0776 to 0.0799 in.)
Compression spring length (reference) 32.8 mm (1.29134 in.)
Differential carrier oil seal depth 0.05 to 0.95 mm (0.00197 to 0.0374 in.)
Side gear backlash 0.02 to 0.15 mm (0.00787 to 0.00591 in.)
1.53 to 1.57 mm (0.0602 to 0.0618 in.)
1.58 to 1.62 mm (0.0622 to 0.0638 in.)
1.63 to 1.67 mm (0.0642 to 0.0657 in.)
1.68 to 1.72 mm (0.0661 to 0.0677 in.)
Adjusting shim thickness 1.73 to 1.77 mm (0.0681 to 0.0697 in.)
1.78 to 1.82 mm (0.0701 to 0.0171 in.)
1.83 to 1.87 mm (0.0720 to 0.0736 in.)
1.88 to 1.92 mm (0.0740 to 0.0756 in.)
1.93 to 1.97 mm (0.0760 to 0.0776 in.)
1.04 to 1.06 mm (0.0409 to 0.0417 in.)
1.065 to 1.085 mm (0.0420 to 0.0427 in.)
1.09 to 1.11 mm (0.0419 to 0.0437 in.)
1.115 to 1.135 mm (0.0439 to 0.0447 in.)
1.14 to 1.16 mm (0.0449 to 0.0457 in.)
1.165 to 1.185 mm (0.0459 to 0.0467 in.)
1.19 to 1.21 mm (0.0469 to 0.0476 in.)
1.215 to 1.235 mm (0.0478 to 0.0486 in.)
1.24 to 1.26 mm (0.0488 to 0.0496 in.)
1.265 to 1.285 mm (0.0498 to 0.0506 in.)
Plate washer thickness 1.29 to 1.31 mm (0.0508 to 0.0516 in.)
1.315 to 1.335 mm (0.0518 to 0.0526 in.)
1.34 to 1.36 mm (0.0528 to 0.0535 in.)
1.365 to 1.385 mm (0.0537 to 0.0545 in.)
1.39 to 1.41 mm (0.0547 to 0.0555 in.)
1.415 to 1.435 mm (0.0558 to 0.0565 in.)
1.44 to 1.46 mm (0.0567 to 0.0575 in.)
1.465 to 1.485 mm (0.0577 to 0.0585 in.)
1.49 to 1.51 mm (0.0587 to 0.0595 in.)
1.515 to 1.535 mm (0.0597 to 0.0605 in.)
1.54 to 1.56 mm (0.0607 to 0.0615 in.)

Rear differential (w/ Differential Lock)

Vertical
Companion flange runout Maximum: 0.10 mm (0.00394 in.)
Lateral
Ring gear runout Maximum: 0.05 mm (0.00197 in.)
Drive pinion to ring gear backlash 0.10 to 0.20 mm (0.00394 to 0.00787 in.)
New bearing 1.0 to 1.7 N*m (11 to 17 kgf*cm, 10 to 14 in.*lbf)
Drive pinion preload (at starting)
Reused bearing 0.9 to 1.4 N*m (9 to 13 kgf*cm, 8 to 12 in.*lbf)
Drive pinion preload plus 0.29 to 0.49 N*m (3 to 5 kgf*cm, 3 to
Total preload (at starting)
4 in.*lbf)
Differential case runout Maximum: 0.04 mm (0.00157 in.)
Side gear backlash 0.02 to 0.15 mm (0.00787 to 0.00591 in.)
Differential carrier oil seal depth 0.05 to 0.95 mm (0.00197 to 0.0374 in.)
1.53 to 1.57 mm (0.0602 to 0.0618 in.)
1.58 to 1.62 mm (0.0622 to 0.0638 in.)
1.63 to 1.67 mm (0.0642 to 0.0657 in.)
1.68 to 1.72 mm (0.0661 to 0.0677 in.)
1.73 to 1.77 mm (0.0681 to 0.0697 in.)
1.78 to 1.82 mm (0.0701 to 0.0171 in.)
Thrust washer thickness
1.83 to 1.87 mm (0.0720 to 0.0736 in.)
1.88 to 1.92 mm (0.0740 to 0.0756 in.)
1.93 to 1.97 mm (0.0760 to 0.0776 in.)
1.98 to 2.02 mm (0.0780 to 0.0795 in.)
2.03 to 2.07 mm (0.0799 to 0.0815 in.)
2.08 to 2.12 mm (0.0820 to 0.0835 in.)
01 2.66 to 2.68 mm (0.1048 to 0.1056 in.)
02 2.69 to 2.71 mm (0.1060 to 0.1068 in.)
03 2.72 to 2.74 mm (0.1072 to 0.1080 in.)
04 2.75 to 2.77 mm (0.1084 to 0.1091 in.)
05 2.78 to 2.80 mm (0.1095 to 0.1103 in.)
06 2.81 to 2.83 mm (0.1107 to 0.1115 in.)
07 2.84 to 2.86 mm (0.1119 to 0.1127 in.)
08 2.87 to 2.89 mm (0.1131 to 0.1139 in.)
09 2.90 to 2.92 mm (0.1143 to 0.1150 in.)
10 2.93 to 2.95 mm (0.1154 to 0.1162 in.)
11 2.96 to 2.98 mm (0.1166 to 0.1174 in.)
Side plate washer thickness 12 2.99 to 3.01 mm (0.1178 to 0.1186 in.)
13 3.02 to 3.04 mm (0.1190 to 0.1198 in.)
14 3.05 to 3.07 mm (0.1202 to 0.1210 in.)
15 3.08 to 3.10 mm (0.1212 to 0.1220 in.)
16 3.11 to 3.13 mm (0.1225 to 0.1233 in.)
17 3.14 to 3.16 mm (0.1237 to 0.1245 in.)
18 3.17 to 3.19 mm (0.1249 to 0.1257 in.)
19 3.20 to 3.22 mm (0.1261 to 0.1269 in.)
20 3.23 to 3.25 mm (0.1273 to 0.1281 in.)
21 3.2* to 3.28 mm (0.1284 to 0.1292 in.)
22 3.29 to 3.31 mm (0.1296 to 0.1304 in.)
23 3.32 to 3.34 mm (0.1308 to 0.1316 in.)
1.04 to 1.06 mm (0.0409 to 0.0417 in.)
1.065 to 1.085 mm (0.0420 to 0.0427 in.)
1.09 to 1.11 mm (0.0419 to 0.0437 in.)
1.115 to 1.135 mm (0.0439 to 0.0447 in.)
1.14 to 1.16 mm (0.0449 to 0.0457 in.)
1.165 to 1.185 mm (0.0459 to 0.0467 in.)
1.19 to 1.21 mm (0.0469 to 0.0476 in.)
1.215 to 1.235 mm (0.0478 to 0.0486 in.)
1.24 to 1.26 mm (0.0488 to 0.0496 in.)
1.265 to 1.285 mm (0.0498 to 0.0506 in.)
Plate washer thickness 1.29 to 1.31 mm (0.0508 to 0.0516 in.)
1.315 to 1.335 mm (0.0518 to 0.0526 in.)
1.34 to 1.36 mm (0.0528 to 0.0535 in.)
1.365 to 1.385 mm (0.0537 to 0.0545 in.)
1.39 to 1.41 mm (0.0547 to 0.0555 in.)
1.415 to 1.435 mm (0.0558 to 0.0565 in.)
1.44 to 1.46 mm (0.0567 to 0.0575 in.)
1.465 to 1.485 mm (0.0577 to 0.0585 in.)
1.49 to 1.51 mm (0.0587 to 0.0595 in.)
1.515 to 1.535 mm (0.0597 to 0.0605 in.)
1.54 to 1.56 mm (0.0607 to 0.0615 in.)
AXLE AND DIFFERENTIAL > TORQUE SPECIFICATIONS

Front axle hub

Part Tightened N*m kgf*cm ft.*lbf
Front axle with ABS rotor bearing assembly x steering knuckle 99 1010 73
1 st: 200 2039 148
Front axle shaft nut x Front drive shaft
2 nd: 340 3467 251
Steering knuckle x Front disc brake caliper 99 1010 73
for bolt 31 316 23
Steering knuckle x Front disc brake caliper hose bracket
for nut 13 132 10

Steering knuckle
Part Tightened N*m kgf*cm ft.*lbf
Front speed sensor x Steering knuckle 8.5 87 75 in.*lbf
Front speed sensor bracket x Steering knuckle 13 132 10
Steering knuckle x Upper arm 110 1122 81
Steering knuckle x Lower ball joint attachment 300 3059 221
Steering knuckle x Tie rod end 69 704 51

Rear axle shaft

Part Tightened N*m kgf*cm ft.*lbf
Rear axle shaft x housing 60 612 44
Parking cable x Axle housing 8.0 82 71 in.*lbf
Rear speed sensor x Rear axle hub and bearing assembly 8.3 85 73 in.*lbf
Stud bolt x Rear axle hub and bearing assembly 7.0 71 62 in.*lbf
Rear disc brake cylinder x Axle housing 95 969 70

Front differential
Part Tightened N*m kgf*cm ft.*lbf
Front suspension rebound stopper sub-assembly x Chassis frame 58 591 43
Differential support assembly x Chassis frame 120 1224 89
Front differential front support assembly LH x Differential carrier assembly 155 1581 114
Differential support assembly x Differential extension flange tube 100 1020 74
Front differential rear support assembly x Differentia carrier 120 1224 89
Front differential breather plug oil deflector x Differential carrier 7.0 71 62 in.*lbf
Ring gear x Differential case 137 1397 101
Companion flange sub assembly x Differential drive pinion 451 or less 4599 or less 332 or less
Differential carrier x Differential extension flange tube 65 663 48
Differential carrier x Front differential cross shaft bearing retainer 65 663 48
Differential carrier x Front propeller shaft 88 900 65
Automatic disconnecting differential actuator x Differential tube 21 210 15
Front differential breather tube x Differential carrier 17 169 12
Drain plug 39 400 29
Filler plug 39 400 29

Rear differential (for Standard)

Part Tightened N*m kgf*cm ft.*lbf
Rear differential carrier assembly x Propeller shaft assembly 88 900 65
Rear differential carrier assembly x Rear axle carrier 72 734 53
Differential case x Ring gear 137 1397 101
Differential case RH x Differential case LH 47 479 35
Bearing cap x Rear differential bearing adjusting nut lock differential 13 133 10
Companion flange sub assembly x Differential drive pinion 441 or less 4497 or less 325 or less
Bearing cap x Differential carrier 90 918 66
Drain plug 49 500 36
Filler plug 49 500 36

Rear differential (for LSD)

Part Tightened N*m kgf*cm ft.*lbf
Rear differential carrier assembly x Propeller shaft assembly 88 900 65
Rear differential carrier assembly x Rear axle carrier 72 734 53
Differential case x Ring gear 137 1397 101
Differential case RH x Differential case LH 47 479 35
Bearing cap x Rear differential bearing adjusting nut lock differential 13 133 10
Companion flange sub assembly x Differential drive pinion 441 or less 4497 or less 325 or less
Bearing cap x Differential carrier 90 918 66
Drain plug 49 500 36
Filler plug 49 500 36

Rear differential (w/ Differential lock)

Part Tightened N*m kgf*cm ft.*lbf
Rear differential carrier assembly x Propeller shaft assembly 88 900 65
Differential protector assembly x differential lock shift actuator 15 150 11
Differential lock shift actuator x Differential carrier 24 245 18
Rear differential lock actuator protector x Differential carrier 35 367 26
Use with out SST 40 408 30
No. 1 transfer indicator switch x Rear differential lock cover
Use with SST 28 283 20
Rear differential lock cover x Differential carrier 18 184 13
Sift fork x Differential lock shift actuator 20 204 15
Rear differential carrier assembly x Rear axle carrier 72 734 53
Differential case x Ring gear 137 1397 101
Differential cover x Differential case 58 591 43
Companion flange sub assembly x Differential drive pinion 441 or less 4497 or less 325 or less
Bearing cap x Differential carrier 113 1152 83
Drain plug 49 500 36
Filler plug 49 500 36
SUSPENSION CONTROL > TORQUE SPECIFICATIONS

Part tightened N*m kgf*cm ft.*lbf

Height control pump and motor x Frame 31 316 23
Height control pump and motor x Rear No. 6 height
14 (15) 143 (155) 10 (11)
control tube
Height control cap to reservoir hose x Height control tube
20 204 15
clamp
Height control reservoir x Skid control motor 5.5 56 49 in.*lbf
Height control compressor bracket x Skid control motor 5.5 56 49 in.*lbf
Height control accumulator x Bleeder plug 6.9 70 61 in.*lbf
No. 5 height control tube x No. 1 height control valve 14 (15) 143 (155) 10 (11)
No. 5 height control tube LH x No. 1 height control valve 14 (15) 143 (155) 10 (11)
No. 6 height control tube x No. 1 height control valve 14 (15) 143 (155) 10 (11)
No. 6 height control tube LH x No. 1 height control valve 14 (15) 143 (155) 10 (11)
Rear No. 4 height control tube x No. 1 height control valve 25 255 18
No. 5 height control tube x Center suspension control
14 (15) 143 (155) 10 (11)
cylinder
No. 5 height control tube LH x Center suspension control
14 (15) 143 (155) 10 (11)
cylinder
No. 6 height control tube x Center suspension control
14 (15) 143 (155) 10 (11)
cylinder
No. 6 height control tube LH x Center suspension control
14 (15) 143 (155) 10 (11)
cylinder
No. 1 height control valve x Active height control center
5.5 56 49
unit
No. 1 height control valve x No. 7 height control tube 14 (15) 143 (155) 10 (11)
Suspension control pump accumulator x No. 7 height
14 (15) 143 (155) 10 (11)
control tube
Height control unit insulator x Active height control center
31 316 23
unit
Suspension control pump accumulator x Active height
31 316 23
control center unit
No. 3 height control tube LH x Height control bracket with
50 510 37
cylinder
No. 4 height control tube x Height control bracket with
50 510 37
cylinder
No. 4 height control tube LH x Height control bracket with
50 510 37
cylinder
No. 3 height control tube x Height control bracket with
50 510 37
cylinder
Height control bracket with cylinder x Frame 31 316 23
Center suspension control cylinder x Height control
31 316 23
cylinder bracket
Stabilizer control with accumulator housing x Bleeder plug 8.3 85 73 in.*lbf
Front stabilizer control cylinder x Bleeder plug 8.3 85 73 in.*lbf
Rear stabilizer control cylinder x Bleeder plug 8.3 85 73 in.*lbf
stabilizer control with accumulator housing x stabilizer
14 143 10
control with accumulator housing shutter valve
Stabilizer control tube protector x Front stabilizer control
15 153 11
cylinder
Rear stabilizer control tube insulator x Rear stabilizer
18 184 13
control cylinder
Front No. 1 stabilizer control tube x Front No. 2 stabilizer
40 (44) 408 (450) 30 (33)
control tube
Front No. 2 stabilizer control tube x Frame 29 296 21
Front No. 2 stabilizer control tube x Stabilizer control
40 (44) 408 (450) 30 (33)
adapter
Stabilizer control adapter x Frame 32 326 24
Rear No. 1 stabilizer control tube x Stabilizer control
40 (44) 408 (450) 30 (33)
adapter
Rear No. 1 stabilizer control tube x Stabilizer 1 ontrol * ith
40 (44) 408 (450) 30 (33)
Accumulator Housing
Rear No. 1 stabilizer control tube x Frame 29 296 21
Rear No. 2 stabilizer control tube x Stabilizer Control with
40 (44) 408 (450) 30 (33)
Accumulator Housing
Stabilizer control valve protector x Frame 18 184 13
Stabilizer Control with Accumulator Housing x Frame 32 326 24
Oil nozzle valve x Stabilizer control adapter housing 12 122 9
Service valve cap x Oil nozzle valve 0.6 6.0 5.0 in.*lbf
Stabilizer control adapter housing x Stabilizer control
14 143 10
adapter shutter valve
Height control cylinder bracket x Height control protector
16 163 12
pipe
Height control protector pipe x Frame 31 316 23
Height control cylinder bracket x Frame 31 316 23
Front No. 1 suspension control accumulator x Frame 31 316 23
No. 1 height control tube x Front No. 1 suspension control
43 438 32
accumulator
Front shock absorber control valve x No. 1 height control
40 (44) 408 (450) 30 (33)
tube
No. 2 suspension control pressure hose x Front shock
50 510 37
absorber control valve
Front shock absorber control valve x Frame 31 316 23
Front shock absorber control valve x Bleeder plug 8.3 85 73 in.*lbf
Front shock absorber control valve x No. 2 height control
40 (44) 408 (450) 30 (33)
tube
Front shock absorber control valve x Front No. 2
57 585 42
suspension control accumulator
No. 2 height control tube x Frame 31 316 23
Front suspension control valve x Frame 31 316 23
Front suspension control valve x No. 2 height control tube 40 (44) 408 (450) 30 (33)
Front suspension control valve x Front No. 3 suspension
150 1530 111
control accumulator
No. 4 height control tube x Rear shock absorber control
40 (44) 408 (450) 30 (33)
valve
No. 4 suspension control pressure hose x Rear shock
50 510 37
absorber control valve
Rear No. 2 suspension control accumulator bracket x
31 316 23
Frame
Rear No. 1 suspension control accumulator bracket x
31 316 23
Frame
Rear shock absorber control valve x Rear No. 2
18 184 13
suspension control accumulator bracket
Rear shock absorber control valve x Bleeder plug 8.3 85 73 in.*lbf
Rear shock absorber control valve x Rear suspension
57 585 42
control accumulator
Rear shock absorber control valve x Rear No. 3
150 1530 111
suspension control accumulator
Front height control sensor x Bolt: 13 127 9
Frame Nut: 5.6 57 50 in.*lbf
Rear height control sensor x Bolt: 13 127 9
Frame Nut: 5.6 57 50 in.*lbf
Suspension control ECU x Body 8.0 82 71 in.*lbf
Rear side No. 2 air duct x Body 5.4 55 48 in.*lbf
Steering control ECU with Bolt: 8.0 82 71 in.*lbf
junction block x Body Nut: 8.0 82 71 in.*lbf
Acceleration sensor x Body 8.0 82 71 in.*lbf
(): For use without SST
ALIGNMENT / HANDLING DIAGNOSIS > SERVICE DATA

Standard Vehicle Height (Unloaded Vehicle)

Vehicle Model Front A - B Rear C - D
GRJ200L/R-GMMNK 97 mm (3.82 in.) 60 mm (2.36 in.)
GRJ200L/R-GNMNK 97 mm (3.82 in.) 60 mm (2.36 in.)
GRJ200L-GPMNK 97 mm (3.82 in.) 60 mm (2.36 in.)
UZJ200L-GNAEK 97 mm (3.82 in.) 60 mm (2.36 in.)
VDJ200L-GMMNZ 97 mm (3.82 in.) 60 mm (2.36 in.)
VDJ200L/R-GNMNZ 97 mm (3.82 in.) 60 mm (2.36 in.)
VDJ200L/R-GNTEZ 97 mm (3.82 in.) 60 mm (2.36 in.)
VDJ200L/R-GNTNZ 97 mm (3.82 in.) 60 mm (2.36 in.)
VDJ200L/R-GPMNZ 97 mm (3.82 in.) 60 mm (2.36 in.)
VDJ200R-GMMNZ 97 mm (3.82 in.) 60 mm (2.36 in.)
GRJ200L-GNANKV 88 mm (3.46 in.) 80 mm (3.15 in.)
GRJ200L-GNMNKV 88 mm (3.46 in.) 80 mm (3.15 in.)
GRJ200L-GPANKV 88 mm (3.46 in.) 80 mm (3.15 in.)
GRJ200L-GPMNKV 88 mm (3.46 in.) 80 mm (3.15 in.)
UZJ200L-GNANKV 88 mm (3.46 in.) 80 mm (3.15 in.)
UZJ200L-GNAEKV 88 mm (3.46 in.) 80 mm (3.15 in.)
VDJ200L-GNMNZV 88 mm (3.46 in.) 80 mm (3.15 in.)
VDJ200L-GPMNZV 88 mm (3.46 in.) 80 mm (3.15 in.)
VDJ200L-GNTNZV 88 mm (3.46 in.) 80 mm (3.15 in.)
w/o Bull Bar 88 mm (3.46 in.) 60 mm (2.36 in.)
UZJ200R-GNAEKQ
w/ Bull Bar 97 mm (3.82 in.) 60 mm (2.36 in.)
w/o Bull Bar 88 mm (3.46 in.) 60 mm (2.36 in.)
UZJ200R-GNANKQ
w/ Bull Bar 97 mm (3.82 in.) 60 mm (2.36 in.)
w/o Bull Bar 88 mm (3.46 in.) 60 mm (2.36 in.)
VDJ200R-GNTEZQ
w/ Bull Bar 97 mm (3.82 in.) 60 mm (2.36 in.)
w/o Bull Bar 88 mm (3.46 in.) 60 mm (2.36 in.)
VDJ200R-GNTNZQ
w/ Bull Bar 97 mm (3.82 in.) 60 mm (2.36 in.)
w/o Active Height Control 97 mm (3.82 in.) 60 mm (2.36 in.)
UZJ200L-GMAEKW
w/ Active Height Control 101 mm (3.98 in.) 94 mm (3.70 in.)
w/o Active Height Control 97 mm (3.82 in.) 60 mm (2.36 in.)
UZJ200L/R-GNAEKW
w/ Active Height Control 101 mm (3.98 in.) 94 mm (3.70 in.)
w/o Active Height Control 97 mm (3.82 in.) 60 mm (2.36 in.)
VDJ200L-GMTEZW
w/ Active Height Control 101 mm (3.98 in.) 94 mm (3.70 in.)
w/o Active Height Control 97 mm (3.82 in.) 60 mm (2.36 in.)
VDJ200L/R-GNTEZW
w/ Active Height Control 101 mm (3.98 in.) 94 mm (3.70 in.)
w/ KDSS
88.5 mm (3.48 in.) 79.2 mm (3.12 in.)
Option Less
w/ KDSS
URJ200L-GNTEKV 85.5 mm (3.37 in.) 80.1 mm (3.15 in.)
Spare Tire x 2
w/ KDSS
94.6 mm (3.72 in.) 81.3 mm (3.20 in.)
Full Option
UZJ200L-GNAEKC w/ KDSS 100.7 mm (3.96 in.) 55.6 mm (2.19 in.)
Option Less 94.9 mm (3.74 in.) 66.2 mm (2.61 in.)
UZJ200L-GNANKC Winch 96.3 mm (3.79 in.) 65.2 mm (2.57 in.)
Full Option 98.1 mm (3.86 in.) 65.5 mm (2.58 in.)
Option Less 92.3 mm (3.63 in.) 66.0 mm (2.60 in.)
GRJ200L-GNANKC Winch 92.6 mm (3.65 in.) 64.8 mm (2.55 in.)
Full Option 94.5 mm (3.72 in.) 65.1 mm (2.56 in.)
Option Less 90.0 mm (3.54 in.) 52.0 mm (2.05 in.)
VDJ200R-KCMRZ
Full Option 93.9 mm (3.70 in.) 60.4 mm (2.38 in.)
9-passenger
91.2 mm (3.59 in.) 52.0 mm (2.05 in.)
Option Less
9-passenger 92.4 mm (3.64 in.) 58.5 mm (2.30 in.)
VDJ200R-KDMRZ Full Option
10-passenger
91.8 mm (3.61 in.) 52.1 mm (2.05 in.)
Option Less
10-passenger
93.0 mm (3.66 in.) 58.7 mm (2.31 in.)
Full Option
5-passenger
87.4 mm (3.44 in.) 57.2 mm (2.25 in.)
Option Less
5-passenger
92.1 mm (3.63 in.) 61.0 mm (2.40 in.)
Full Option
VDJ200L-KCMRZ
6-passenger
88.0 mm (3.46 in.) 57.4 mm (2.26 in.)
Option Less
6-passenger
92.7 mm (3.65 in.) 61.2 mm (2.41 in.)
Full Option
9-passenger
87.7 mm (3.45 in.) 52.9 mm (2.08 in.)
Option Less
9-passenger
93.0 mm (3.66 in.) 58.3 mm (2.30 in.)
Full Option
VDJ200L-KDMRZ
10-passenger
88.4 mm (3.48 in.) 53.1 mm (2.09 in.)
Option Less
10-passenger
93.5 mm (3.68 in.) 58.4 mm (2.30 in.)
Full Option
9-passenger
98.3 mm (3.87 in.) 59.2 mm (2.33 in.)
Option Less
9-passenger
108.9 mm (4.29 in.) 61.7 mm (2.43 in.)
Full Option
GRJ200R-KDMRK
10-passenger
99.0 mm (3.90 in.) 59.4 mm (2.34 in.)
Option Less
10-passenger
109.6 mm (4.31 in.) 61.8 mm (2.43 in.)
Full Option
5-passenger
97.1 mm (3.82 in.) 56.7 mm (2.23 in.)
Option Less
5-passenger
96.5 mm (3.80 in.) 59.3 mm (2.33 in.)
Full Option
GRJ200L-KCMRK
6-passenger
97.9 mm (3.85 in.) 56.4 mm (2.22 in.)
Option Less
6-passenger
97.2 mm (3.83 in.) 59.5 mm (2.34 in.)
Full Option
9-passenger
96.7 mm (3.81 in.) 58.8 mm (2.31 in.)
Option Less
9-passenger
97.2 mm (3.83 in.) 58.9 mm (2.32 in.)
Full Option
GRJ200L-KDMRK
10-passenger
97.4 mm (3.83 in.) 59.0 mm (2.32 in.)
Option Less
10-passenger
97.8 mm (3.85 in.) 59.1 mm (2.33 in.)
Full Option
Option Less 86.2 mm (3.39 in.) 75.9 mm (2.99 in.)
GRJ200L-KDMNKV
Full Option 89.5 mm (3.52 in.) 81.4 mm (3.20 in.)
9-passenger
86.4 mm (3.40 in.) 76.8 mm (3.02 in.)
Option Less
9-passenger
86.9 mm (3.42 in.) 77.8 mm (3.06 in.)
Full Option
GRJ200L-KDMRKV
10-passenger
87.1 mm (3.43 in.) 77.0 mm (3.03 in.)
Option Less
10-passenger
87.6 mm (3.45 in.) 78.0 mm (3.07 in.)
Full Option
Option Less 87.5 mm (3.44 in.) 77.6 mm (3.06 in.)
VDJ200L-KDMNZV
Full Option 90.4 mm (3.56 in.) 84.4 mm (3.32 in.)
9-passenger
87.5 mm (3.44 in.) 79.0 mm (3.11 in.)
Option Less
9-passenger
87.3 mm (3.44 in.) 80.8 mm (3.18 in.)
Full Option
VDJ200L-KDMRZV
10-passenger
88.1 mm (3.47 in.) 79.2 mm (3.12 in.)
Option Less
10-passenger 88.0 mm (3.46 in.) 81.0 mm (3.19 in.)
Full Option
Option Less 80.1 mm (3.15 in.) 54.5 mm (2.15 in.)
VDJ200R-KCTRZQ
Full Option 83.1 mm (3.27 in.) 55.4 mm (2.18 in.)
Option Less 90.0 mm (3.54 in.) 52.0 mm (2.05 in.)
VDJ200R-GCMRZ
Full Option 93.9 mm (3.70 in.) 60.4 mm (2.38 in.)
9-passenger
91.2 mm (3.59 in.) 52.0 mm (2.05 in.)
Option Less
9-passenger
92.4 mm (3.64 in.) 58.5 mm (2.30 in.)
Full Option
VDJ200R-GDMRZ
10-passenger
91.8 mm (3.61 in.) 52.1 mm (2.05 in.)
Option Less
10-passenger
93.0 mm (3.66 in.) 58.7 mm (2.31 in.)
Full Option
5-passenger
87.4 mm (3.44 in.) 57.2 mm (2.25 in.)
Option Less
5-passenger
92.1 mm (3.63 in.) 61.0 mm (2.40 in.)
Full Option
VDJ200L-GCMRZ
6-passenger
88.0 mm (3.46 in.) 57.4 mm (2.26 in.)
Option Less
6-passenger
92.7 mm (3.65 in.) 61.2 mm (2.41 in.)
Full Option
9-passenger
87.7 mm (3.45 in.) 52.9 mm (2.08 in.)
Option Less
9-passenger
93.0 mm (3.66 in.) 58.3 mm (2.30 in.)
Full Option
VDJ200L-GDMRZ
10-passenger
88.4 mm (3.48 in.) 53.1 mm (2.09 in.)
Option Less
10-passenger
93.5 mm (3.68 in.) 58.4 mm (2.30 in.)
Full Option
9-passenger
98.3 mm (3.87 in.) 59.2 mm (2.33 in.)
Option Less
9-passenger
108.9 mm (4.29 in.) 61.7 mm (2.43 in.)
Full Option
GRJ200R-GDMRK
10-passenger
99.0 mm (3.90 in.) 59.4 mm (2.34 in.)
Option Less
10-passenger
109.6 mm (4.31 in.) 61.8 mm (2.43 in.)
Full Option
5-passenger
97.1 mm (3.82 in.) 56.7 mm (2.23 in.)
Option Less
5-passenger
96.5 mm (3.80 in.) 59.3 mm (2.33 in.)
Full Option
GRJ200L-GCMRK
6-passenger
97.9 mm (3.85 in.) 56.4 mm (2.22 in.)
Option Less
6-passenger
97.2 mm (3.83 in.) 59.5 mm (2.34 in.)
Full Option
9-passenger
96.7 mm (3.81 in.) 58.8 mm (2.31 in.)
Option Less
9-passenger
97.2 mm (3.83 in.) 58.9 mm (2.32 in.)
Full Option
GRJ200L-GDMRK
10-passenger
97.4 mm (3.83 in.) 59.0 mm (2.32 in.)
Option Less
10-passenger
97.8 mm (3.85 in.) 59.1 mm (2.33 in.)
Full Option
Option Less 86.2 mm (3.39 in.) 75.9 mm (2.99 in.)
GRJ200L-GDMNKV
Full Option 89.5 mm (3.52 in.) 81.4 mm (3.20 in.)
9-passenger
86.4 mm (3.40 in.) 76.8 mm (3.02 in.)
Option Less
9-passenger
86.9 mm (3.42 in.) 77.8 mm (3.06 in.)
Full Option
GRJ200L-GDMRKV
10-passenger
87.1 mm (3.43 in.) 77.0 mm (3.03 in.)
Option Less
10-passenger
87.6 mm (3.45 in.) 78.0 mm (3.07 in.)
Full Option
VDJ200L-GDMNZV Option Less 87.5 mm (3.44 in.) 77.6 mm (3.06 in.)
Full Option 90.4 mm (3.56 in.) 84.4 mm (3.32 in.)

9-passenger
87.5 mm (3.44 in.) 79.0 mm (3.11 in.)
Option Less
9-passenger
87.3 mm (3.44 in.) 80.8 mm (3.18 in.)
Full Option
VDJ200L-GDMRZV
10-passenger
88.1 mm (3.47 in.) 79.2 mm (3.12 in.)
Option Less
10-passenger
88.0 mm (3.46 in.) 81.0 mm (3.19 in.)
Full Option
Option Less 80.1 mm (3.15 in.) 54.5 mm (2.15 in.)
VDJ200R-GCTRZQ
Full Option 83.1 mm (3.27 in.) 55.4 mm (2.18 in.)

Standard Camber Inclination (Unloaded Vehicle)

Vehicle Model Camber Inclination
Camber -0°10' +/-45' (-0.16° +/-0.75°)
GRJ200L/R-GMMNK
Left - right error 45' (0.75°) or less
Camber 0°10' +/-45' (0.16° +/-0.75°)
GRJ200L/R-GNMNK
Left - right error 45' (0.75°) or less
Camber 0°10' +/-45' (0.16° +/-0.75°)
GRJ200L-GPMNK
Left - right error 45' (0.75°) or less
Camber 0°10' +/-45' (0.16° +/-0.75°)
UZJ200L-GNAEK
Left - right error 45' (0.75°) or less
Camber 0°10' +/-45' (0.16° +/-0.75°)
VDJ200L-GMMNZ
Left - right error 45' (0.75°) or less
Camber 0°10' +/-45' (0.16° +/-0.75°)
VDJ200L/R-GNMNZ
Left - right error 45' (0.75°) or less
Camber 0°10' +/-45' (0.16° +/-0.75°)
VDJ200L/R-GNTEZ
Left - right error 45' (0.75°) or less
Camber 0°10' +/-45' (0.16° +/-0.75°)
VDJ200L/R-GNTNZ
Left - right error 45' (0.75°) or less
Camber 0°10' +/-45' (0.16° +/-0.75°)
VDJ200L/R-GPMNZ
Left - right error 45' (0.75°) or less
Camber 0°10' +/-45' (0.16° +/-0.75°)
VDJ200R-GMMNZ
Left - right error 45' (0.75°) or less
Camber 0°18' +/-45' (0.30° +/-0.75°)
GRJ200L-GNANKV
Left - right error 45' (0.75°) or less
Camber 0°18' +/-45' (0.30° +/-0.75°)
GRJ200L-GNMNKV
Left - right error 45' (0.75°) or less
Camber 0°18' +/-45' (0.30° +/-0.75°)
GRJ200L-GPANKV
Left - right error 45' (0.75°) or less
Camber 0°18' +/-45' (0.30° +/-0.75°)
GRJ200L-GPMNKV
Left - right error 45' (0.75°) or less
Camber 0°18' +/-45' (0.30° +/-0.75°)
UZJ200L-GNANKV
Left - right error 45' (0.75°) or less
Camber 0°18' +/-45' (0.30° +/-0.75°)
UZJ200L-GNAEKV
Left - right error 45' (0.75°) or less
Camber 0°18' +/-45' (0.30° +/-0.75°)
VDJ200L-GNMNZV
Left - right error 45' (0.75°) or less
Camber 0°18' +/-45' (0.30° +/-0.75°)
VDJ200L-GPMNZV
Left - right error 45' (0.75°) or less
Camber 0°18' +/-45' (0.30° +/-0.75°)
VDJ200L-GNTNZV
Left - right error 45' (0.75°) or less
Camber 0°20' +/-45' (0.34° +/-0.75°)
w/o Bull Bar
Left - right error 45' (0.75°) or less
UZJ200R-GNAEKQ
Camber 0°10' +/-45' (0.16° +/-0.75°)
w/ Bull Bar
Left - right error 45' (0.75°) or less
Camber 0°20' +/-45' (0.34° +/-0.75°)
w/o Bull Bar
Left - right error 45' (0.75°) or less
UZJ200R-GNANKQ
Camber 0°10' +/-45' (0.16° +/-0.75°)
w/ Bull Bar
Left - right error 45' (0.75°) or less
Camber 0°20' +/-45' (0.34° +/-0.75°)
w/o Bull Bar
Left - right error 45' (0.75°) or less
VDJ200R-GNTEZQ Camber 0°10' +/-45' (0.16° +/-0.75°)
* Bull
/ Bar Left - right error 45' (0.75°) or less
Camber 0°20' +/-45' (0.34° +/-0.75°)
w/o Bull Bar
Left - right error 45' (0.75°) or less
VDJ200R-GNTNZQ
Camber 0°10' +/-45' (0.16° +/-0.75°)
w/ Bull Bar
Left - right error 45' (0.75°) or less
Camber 0°10' +/-45' (0.16° +/-0.75°)
w/o Active Height Control
Left - right error 45' (0.75°) or less
UZJ200L-GMAEKW
Camber 0°00' +/-45' (0.00° +/-0.75°)
w/ Active Height Control
Left - right error 45' (0.75°) or less
Camber 0°10' +/-45' (0.16° +/-0.75°)
w/o Active Height Control
Left - right error 45' (0.75°) or less
UZJ200L/R-GNAEKW
Camber 0°00' +/-45' (0.00° +/-0.75°)
w/ Active Height Control
Left - right error 45' (0.75°) or less
Camber 0°10' +/-45' (0.16° +/-0.75°)
w/o Active Height Control
Left - right error 45' (0.75°) or less
VDJ200L-GMTEZW
Camber 0°00' +/-45' (0.00° +/-0.75°)
w/ Active Height Control
Left - right error 45' (0.75°) or less
Camber 0°10' +/-45' (0.16° +/-0.75°)
w/o Active Height Control
Left - right error 45' (0.75°) or less
VDJ200L/R-GNTEZW
Camber 0°00' +/-45' (0.00° +/-0.75°)
w/ Active Height Control
Left - right error 45' (0.75°) or less
w/ KDSS Camber 0°18' +/-45' (0.30° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
w/ KDSS Camber 0°22' +/-45' (0.36° +/-0.75°)
URJ200L-GNTEKV
Spare Tire x 2 Left - right error 45' (0.75°) or less
w/ KDSS Camber 0°10' +/-45' (0.17° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
Camber 0°6' +/-45' (0.10° +/-0.75°)
UZJ200L-GNAEKC w/ KDSS
Left - right error 45' (0.75°) or less
Camber 0°12' +/-45' (0.20° +/-0.75°)
Option Less
Left - right error 45' (0.75°) or less
Camber 0°10' +/-45' (0.17° +/-0.75°)
UZJ200L-GNANKC Winch
Left - right error 45' (0.75°) or less
Camber 0°8' +/-45' (0.13° +/-0.75°)
Full Option
Left - right error 45' (0.75°) or less
Camber 0°15' +/-45' (0.25° +/-0.75°)
Option Less
Left - right error 45' (0.75°) or less
Camber 0°15' +/-45' (0.25° +/-0.75°)
GRJ200L-GNANKC Winch
Left - right error 45' (0.75°) or less
Camber 0°13' +/-45' (0.21° +/-0.75°)
Full Option
Left - right error 45' (0.75°) or less
Camber 0°20' +/-45' (0.33° +/-0.75°)
Option Less
Left - right error 45' (0.75°) or less
VDJ200R-KCMRZ
Camber 0°14' +/-45' (0.23° +/-0.75°)
Full Option
Left - right error 45' (0.75°) or less
9-passenger Camber 0°19' +/-45' (0.31° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
9-passenger Camber 0°16' +/-45' (0.27° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
VDJ200R-KDMRZ
10-passenger Camber 0°17' +/-45' (0.29° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
10-passenger Camber 0°16' +/-45' (0.26° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
5-passenger Camber 0°22' +/-45' (0.37° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
5-passenger Camber 0°16' +/-45' (0.27° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
VDJ200L-KCMRZ
6-passenger Camber 0°22' +/-45' (0.36° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
6-passenger Camber 0°16' +/-45' (0.26° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
9-passenger Camber 0°22' +/-45' (0.37° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
9-passenger Camber 0°16' +/-45' (0.26° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
VDJ200L-KDMRZ
10-passenger Camber 0°22' +/-45' (0.36° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
10-passenger Camber 0°15' +/-45' (0.25° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
9-passenger Camber 0°8' +/-45' (0.14° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
9-passenger Camber -0°6' +/-45' (-0.10° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
GRJ200R-KDMRK
10-passenger Camber 0°8' +/-45' (0.13° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
10-passenger Camber -0°7' +/-45' (-0.11° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
5-passenger Camber 0°10' +/-45' (0.17° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
5-passenger Camber 0°11' +/-45' (0.18° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
GRJ200L-KCMRK
6-passenger Camber 0°10' +/-45' (0.16° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
6-passenger Camber 0°10' +/-45' (0.16° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
9-passenger Camber 0°10' +/-45' (0.17° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
9-passenger Camber 0°10' +/-45' (0.16° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
GRJ200L-KDMRK
10-passenger Camber 0°10' +/-45' (0.16° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
10-passenger Camber 0°9' +/-45' (0.15° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
Camber 0°21' +/-45' (0.35° +/-0.75°)
Option Less
Left - right error 45' (0.75°) or less
GRJ200L-KDMNKV
Camber 0°16' +/-45' (0.27° +/-0.75°)
Full Option
Left - right error 45' (0.75°) or less
9-passenger Camber 0°21' +/-45' (0.35° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
9-passenger Camber 0°20' +/-45' (0.33° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
GRJ200L-KDMRKV
10-passenger Camber 0°20' +/-45' (0.33° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
10-passenger Camber 0°19' +/-45' (0.32° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
Camber 0°20' +/-45' (0.33° +/-0.75°)
Option Less
Left - right error 45' (0.75°) or less
VDJ200L-KDMNZV
Camber 0°16' +/-45' (0.26° +/-0.75°)
Full Option
Left - right error 45' (0.75°) or less
9-passenger Camber 0°20' +/-45' (0.33° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
9-passenger Camber 0°19' +/-45' (0.32° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
VDJ200L-KDMRZV
10-passenger Camber 0°19' +/-45' (0.31° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
10-passenger Camber 0°19' +/-45' (0.31° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
Camber 0°31' +/-45' (0.51° +/-0.75°)
Option Less
Left - right error 45' (0.75°) or less
VDJ200R-KCTRZQ
Camber 0°28' +/-45' (0.46° +/-0.75°)
Full Option
Left - right error 45' (0.75°) or less
Camber 0°20' +/-45' (0.33° +/-0.75°)
Option Less
Left - right error 45' (0.75°) or less
VDJ200R-GCMRZ
Camber 0°14' +/-45' (0.23° +/-0.75°)
Full Option
Left - right error 45' (0.75°) or less
9-passenger Camber 0°19' +/-45' (0.31° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
9-passenger Camber 0°16' +/-45' (0.27° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
VDJ200R-GDMRZ
10-passenger Camber 0°17' +/-45' (0.29° +/-0.75°)
O tpion Less Left - right error 45' (0.75°) or less
10-passenger Camber 0°16' +/-45' (0.26° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less

5-passenger Camber 0°22' +/-45' (0.37° +/-0.75°)

Option Less Left - right error 45' (0.75°) or less
5-passenger Camber 0°16' +/-45' (0.26° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
VDJ200L-GCMRZ
6-passenger Camber 0°22' +/-45' (0.37° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
6-passenger Camber 0°16' +/-45' (0.26° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
9-passenger Camber 0°22' +/-45' (0.37° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
9-passenger Camber 0°16' +/-45' (0.26° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
VDJ200L-GDMRZ
10-passenger Camber 0°22' +/-45' (0.37° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
10-passenger Camber 0°15' +/-45' (0.25° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
9-passenger Camber 0°8' +/-45' (0.14° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
9-passenger Camber -0°6' +/-45' (-0.10° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
GRJ200R-GDMRK
10-passenger Camber 0°8' +/-45' (0.13° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
10-passenger Camber -0°7' +/-45' (-0.11° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
5-passenger Camber 0°10' +/-45' (0.17° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
5-passenger Camber 0°11' +/-45' (0.18° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
GRJ200L-GCMRK
6-passenger Camber 0°10' +/-45' (0.16° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
6-passenger Camber 0°10' +/-45' (0.16° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
9-passenger Camber 0°10' +/-45' (0.17° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
9-passenger Camber 0°10' +/-45' (0.16° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
GRJ200L-GDMRK
10-passenger Camber 0°10' +/-45' (0.16° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
10-passenger Camber 0°9' +/-45' (0.15° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
Camber 0°21' +/-45' (0.35° +/-0.75°)
Option Less
Left - right error 45' (0.75°) or less
GRJ200L-GDMNKV
Camber 0°16' +/-45' (0.27° +/-0.75°)
Full Option
Left - right error 45' (0.75°) or less
9-passenger Camber 0°21' +/-45' (0.35° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
9-passenger Camber 0°20' +/-45' (0.33° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
GRJ200L-GDMRKV
10-passenger Camber 0°20' +/-45' (0.33° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
10-passenger Camber 0°19' +/-45' (0.32° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
Camber 0°20' +/-45' (0.33° +/-0.75°)
Option Less
Left - right error 45' (0.75°) or less
VDJ200L-GDMNZV
Camber 0°16' +/-45' (0.26° +/-0.75°)
Full Option
Left - right error 45' (0.75°) or less
9-passenger Camber 0°20' +/-45' (0.33° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
9-passenger Camber 0°19' +/-45' (0.32° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
VDJ200L-GDMRZV 10-passenger Camber 0°19' +/-45' (0.31° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
10-passenger Camber 0°19' +/-45' (0.32° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
Camber 0°31' +/-45' (0.51° +/-0.75°)
Option Less
Left - right error 45' (0.75°) or less
VDJ200R-GCTRZQ
Camber 0°28' +/-45' (0.46° +/-0.75°)
Full Option
Left - right error 45' (0.75°) or less

Standard Caster Inclination (Unloaded Vehicle)

Vehicle Model Caster Inclination
Caster 2°26' +/-45' (2.44° +/-0.75°)
GRJ200L/R-GMMNK
Left - right error 45' (0.75°) or less
Caster 2°26' +/-45' (2.44° +/-0.75°)
GRJ200L/R-GNMNK
Left - right error 45' (0.75°) or less
Caster 2°26' +/-45' (2.44° +/-0.75°)
GRJ200L-GPMNK
Left - right error 45' (0.75°) or less
Caster 2°26' +/-45' (2.44° +/-0.75°)
UZJ200L-GNAEK
Left - right error 45' (0.75°) or less
Caster 2°26' +/-45' (2.44° +/-0.75°)
VDJ200L-GMMNZ
Left - right error 45' (0.75°) or less
Caster 2°26' +/-45' (2.44° +/-0.75°)
VDJ200L/R-GNMNZ
Left - right error 45' (0.75°) or less
Caster 2°26' +/-45' (2.44° +/-0.75°)
VDJ200L/R-GNTEZ
Left - right error 45' (0.75°) or less
Caster 2°26' +/-45' (2.44° +/-0.75°)
VDJ200L/R-GNTNZ
Left - right error 45' (0.75°) or less
Caster 2°26' +/-45' (2.44° +/-0.75°)
VDJ200L/R-GPMNZ
Left - right error 45' (0.75°) or less
Caster 2°26' +/-45' (2.44° +/-0.75°)
VDJ200R-GMMNZ
Left - right error 45' (0.75°) or less
Caster 3°02' +/-45' (3.04° +/-0.75°)
GRJ200L-GNANKV
Left - right error 45' (0.75°) or less
Caster 3°02' +/-45' (3.04° +/-0.75°)
GRJ200L-GNMNKV
Left - right error 45' (0.75°) or less
Caster 3°02' +/-45' (3.04° +/-0.75°)
GRJ200L-GPANKV
Left - right error 45' (0.75°) or less
Caster 3°02' +/-45' (3.04° +/-0.75°)
GRJ200L-GPMNKV
Left - right error 45' (0.75°) or less
Caster 3°02' +/-45' (3.04° +/-0.75°)
UZJ200L-GNANKV
Left - right error 45' (0.75°) or less
Caster 3°02' +/-45' (3.04° +/-0.75°)
UZJ200L-GNAEKV
Left - right error 45' (0.75°) or less
Caster 3°02' +/-45' (3.04° +/-0.75°)
VDJ200L-GNMNZV
Left - right error 45' (0.75°) or less
Caster 3°02' +/-45' (3.04° +/-0.75°)
VDJ200L-GPMNZV
Left - right error 45' (0.75°) or less
Caster 3°02' +/-45' (3.04° +/-0.75°)
VDJ200L-GNTNZV
Left - right error 45' (0.75°) or less
Caster 2°28' +/-45' (2.47° +/-0.75°)
w/o Bull Bar
Left - right error 45' (0.75°) or less
UZJ200R-GNAEKQ
Caster 2°26' +/-45' (2.44° +/-0.75°)
w/ Bull Bar
Left - right error 45' (0.75°) or less
Caster 2°28' +/-45' (2.47° +/-0.75°)
w/o Bull Bar
Left - right error 45' (0.75°) or less
UZJ200R-GNANKQ
Caster 2°26' +/-45' (2.44° +/-0.75°)
w/ Bull Bar
Left - right error 45' (0.75°) or less
Caster 2°28' +/-45' (2.47° +/-0.75°)
w/o Bull Bar
Left - right error 45' (0.75°) or less
VDJ200R-GNTEZQ
Caster 2°26' +/-45' (2.44° +/-0.75°)
w/ Bull Bar
Left - right error 45' (0.75°) or less
Caster 2°28' +/-45' (2.47° +/-0.75°)
w/o Bull Bar
Left - right error 45' (0.75°) or less
VDJ200R-GNTNZQ
Caster 2°26' +/-45' (2.44° +/-0.75°)
w/ Bull Bar
Left - right error 45' (0.75°) or less
Caster 2°26' +/-45' (2.44° +/-0.75°)
w/o Active Height Control
Left - right error 45' (0.75°) or less
UZJ200L-GMAEKW Caster 3°23' +/-45' (3.38° +/-0.75°)
w/ Active Height Control
Left - right error 45' (0.75°) or less
Caster 2°26' +/-45' (2.44° +/-0.75°)
w/o Active Height Control
Left - right error 45' (0.75°) or less
UZJ200L/R-GNAEKW
Caster 3°23' +/-45' (3.38° +/-0.75°)
w/ Active Height Control
Left - right error 45' (0.75°) or less
Caster 2°26' +/-45' (2.44° +/-0.75°)
w/o Active Height Control
Left - right error 45' (0.75°) or less
VDJ200L-GMTEZW
Caster 3°23' +/-45' (3.38° +/-0.75°)
w/ Active Height Control
Left - right error 45' (0.75°) or less
Caster 2°26' +/-45' (2.44° +/-0.75°)
w/o Active Height Control
Left - right error 45' (0.75°) or less
VDJ200L/R-GNTEZW
Caster 3°23' +/-45' (3.38° +/-0.75°)
w/ Active Height Control
Left - right error 45' (0.75°) or less
w/ KDSS Caster 2°58' +/-45' (2.97° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
w/ KDSS Caster 3°02' +/-45' (3.04° +/-0.75°)
URJ200L-GNTEKV
Spare Tire x 2 Left - right error 45' (0.75°) or less
w/ KDSS Caster 3°02' +/-45' (3.03° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
Caster 2°21' +/-45' (2.35° +/-0.75°)
UZJ200L-GNAEKC w/ KDSS
Left - right error 45' (0.75°) or less
Caster 2°38' +/-45' (2.64° +/-0.75°)
Option Less
Left - right error 45' (0.75°) or less
Caster 2°34' +/-45' (2.57° +/-0.75°)
UZJ200L-GNANKC Winch
Left - right error 45' (0.75°) or less
Caster 2°34' +/-45' (2.57° +/-0.75°)
Full Option
Left - right error 45' (0.75°) or less
Caster 2°41' +/-45' (2.69° +/-0.75°)
Option Less
Left - right error 45' (0.75°) or less
Caster 2°37' +/-45' (2.61° +/-0.75°)
GRJ200L-GNANKC Winch
Left - right error 45' (0.75°) or less
Caster 2°37' +/-45' (2.61° +/-0.75°)
Full Option
Left - right error 45' (0.75°) or less
Caster 2°9' +/-45' (2.15° +/-0.75°)
Option Less
Left - right error 45' (0.75°) or less
VDJ200R-KCMRZ
Caster 2°25' +/-45' (2.41° +/-0.75°)
Full Option
Left - right error 45' (0.75°) or less
9-passenger Caster 2°9' +/-45' (2.15° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
9-passenger Caster 2°22' +/-45' (2.36° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
VDJ200R-KDMRZ
10-passenger Caster 2°10' +/-45' (2.16° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
10-passenger Caster 2°22' +/-45' (2.36° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
5-passenger Caster 2°17' +/-45' (2.29° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
5-passenger Caster 2°25' +/-45' (2.42° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
VDJ200L-KCMRZ
6-passenger Caster 2°17' +/-45' (2.29° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
6-passenger Caster 2°25' +/-45' (2.42° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
9-passenger Caster 2°11' +/-45' (2.19° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
9-passenger Caster 2°21' +/-45' (2.35° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
VDJ200L-KDMRZ
10-passenger Caster 2°11' +/-45' (2.19° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
10-passenger Caster 2°21' +/-45' (2.35° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
9-passenger Caster 2°26' +/-45' (2.43° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
9-passenger Caster 2°31' +/-45' (2.52° +/-0.75°)
GRJ200R-KDMRK Full Option Left - right error 45' (0.75°) or less
10-passenger Caster 2°26' +/-45' (2.43° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
10-passenger Caster 2°31' +/-45' (2.52° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
5-passenger Caster 2°22' +/-45' (2.36° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
5-passenger Caster 2°27' +/-45' (2.45° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
GRJ200L-KCMRK
6-passenger Caster 2°20' +/-45' (2.34° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
6-passenger Caster 2°28' +/-45' (2.46° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
9-passenger Caster 2°25' +/-45' (2.42° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
9-passenger Caster 2°28' +/-45' (2.46° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
GRJ200L-KDMRK
10-passenger Caster 2°26' +/-45' (2.43° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
10-passenger Caster 2°28' +/-45' (2.46° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
Caster 2°55' +/-45' (2.92° +/-0.75°)
Option Less
Left - right error 45' (0.75°) or less
GRJ200L-KDMNKV
Caster 3°4' +/-45' (3.06° +/-0.75°)
Full Option
Left - right error 45' (0.75°) or less
9-passenger Caster 2°57' +/-45' (2.95° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
9-passenger Caster 2°58' +/-45' (2.96° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
GRJ200L-KDMRKV
10-passenger Caster 2°57' +/-45' (2.95° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
10-passenger Caster 2°58' +/-45' (2.96° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
Caster 2°52' +/-45' (2.86° +/-0.75°)
Option Less
Left - right error 45' (0.75°) or less
VDJ200L-KDMNZV
Caster 3°5' +/-45' (3.08° +/-0.75°)
Full Option
Left - right error 45' (0.75°) or less
9-passenger Caster 2°54' +/-45' (2.90° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
9-passenger Caster 2°59' +/-45' (2.99° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
VDJ200L-KDMRZV
10-passenger Caster 2°55' +/-45' (2.91° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
10-passenger Caster 2°59' +/-45' (2.99° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
Caster 2°14' +/-45' (2.24° +/-0.75°)
Option Less
Left - right error 45' (0.75°) or less
VDJ200R-KCTRZQ
Caster 2°15' +/-45' (2.25° +/-0.75°)
Full Option
Left - right error 45' (0.75°) or less
Caster 2°9' +/-45' (2.15° +/-0.75°)
Option Less
Left - right error 45' (0.75°) or less
VDJ200R-GCMRZ
Caster 2°25' +/-45' (2.41° +/-0.75°)
Full Option
Left - right error 45' (0.75°) or less
9-passenger Caster 2°9' +/-45' (2.15° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
9-passenger Caster 2°22' +/-45' (2.36° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
VDJ200R-GDMRZ
10-passenger Caster 2°10' +/-45' (2.16° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
10-passenger Caster 2°22' +/-45' (2.36° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
5-passenger Caster 2°17' +/-45' (2.29° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
5-passenger Caster 2°25' +/-45' (2.42° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
VDJ200L-GCMRZ 6-passenger Caster 2°17' +/-45' (2.29° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less

6-passenger Caster 2°25' +/-45' (2.42° +/-0.75°)

Full Option Left - right error 45' (0.75°) or less
9-passenger Caster 2°11' +/-45' (2.19° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
9-passenger Caster 2°21' +/-45' (2.35° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
VDJ200L-GDMRZ
10-passenger Caster 2°11' +/-45' (2.19° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
10-passenger Caster 2°21' +/-45' (2.35° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
9-passenger Caster 2°26' +/-45' (2.43° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
9-passenger Caster 2°31' +/-45' (2.52° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
GRJ200R-GDMRK
10-passenger Caster 2°26' +/-45' (2.43° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
10-passenger Caster 2°31' +/-45' (2.52° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
5-passenger Caster 2°22' +/-45' (2.36° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
5-passenger Caster 2°27' +/-45' (2.45° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
GRJ200L-GCMRK
6-passenger Caster 2°20' +/-45' (2.34° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
6-passenger Caster 2°28' +/-45' (2.46° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
9-passenger Caster 2°25' +/-45' (2.42° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
9-passenger Caster 2°28' +/-45' (2.46° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
GRJ200L-GDMRK
10-passenger Caster 2°26' +/-45' (2.43° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
10-passenger Caster 2°28' +/-45' (2.46° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
Caster 2°55' +/-45' (2.92° +/-0.75°)
Option Less
Left - right error 45' (0.75°) or less
GRJ200L-GDMNKV
Caster 3°4' +/-45' (3.06° +/-0.75°)
Full Option
Left - right error 45' (0.75°) or less
9-passenger Caster 2°57' +/-45' (2.95° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
9-passenger Caster 2°58' +/-45' (2.96° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
GRJ200L-GDMRKV
10-passenger Caster 2°57' +/-45' (2.95° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
10-passenger Caster 2°58' +/-45' (2.96° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
Caster 2°52' +/-45' (2.86° +/-0.75°)
Option Less
Left - right error 45' (0.75°) or less
VDJ200L-GDMNZV
Caster 3°5' +/-45' (3.08° +/-0.75°)
Full Option
Left - right error 45' (0.75°) or less
9-passenger Caster 2°54' +/-45' (2.90° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
9-passenger Caster 2°59' +/-45' (2.99° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
VDJ200L-GDMRZV
10-passenger Caster 2°55' +/-45' (2.91° +/-0.75°)
Option Less Left - right error 45' (0.75°) or less
10-passenger Caster 2°59' +/-45' (2.99° +/-0.75°)
Full Option Left - right error 45' (0.75°) or less
Caster 2°14' +/-45' (2.24° +/-0.75°)
Option Less
Left - right error 45' (0.75°) or less
VDJ200R-GCTRZQ
Caster 2°15' +/-45' (2.25° +/-0.75°)
Full Option
Left - right error 45' (0.75°) or less
Standard Steering Axis Inclination (Unloaded Vehicle)
Vehicle Model Steering Axis Inclination: Reference
GRJ200L/R-GMMNK Steering Axis 12°50' (12.83°)
GRJ200L/R-GNMNK Steering Axis 12°50' (12.83°)
GRJ200L-GPMNK Steering Axis 12°50' (12.83°)
UZJ200L-GNAEK Steering Axis 12°50' (12.83°)
VDJ200L-GMMNZ Steering Axis 12°50' (12.83°)
VDJ200L/R-GNMNZ Steering Axis 12°50' (12.83°)
VDJ200L/R-GNTEZ Steering Axis 12°50' (12.83°)
VDJ200L/R-GNTNZ Steering Axis 12°50' (12.83°)
VDJ200L/R-GPMNZ Steering Axis 12°50' (12.83°)
VDJ200R-GMMNZ Steering Axis 12°50' (12.83°)
GRJ200L-GNANKV Steering Axis 12°41' (12.68°)
GRJ200L-GNMNKV Steering Axis 12°41' (12.68°)
GRJ200L-GPANKV Steering Axis 12°41' (12.68°)
GRJ200L-GPMNKV Steering Axis 12°41' (12.68°)
UZJ200L-GNANKV Steering Axis 12°41' (12.68°)
UZJ200L-GNAEKV Steering Axis 12°41' (12.68°)
VDJ200L-GNMNZV Steering Axis 12°41' (12.68°)
VDJ200L-GPMNZV Steering Axis 12°41' (12.68°)
VDJ200L-GNTNZV Steering Axis 12°41' (12.68°)
w/o Bull Bar Steering Axis 12°38' (12.64°)
UZJ200R-GNAEKQ
w/ Bull Bar Steering Axis 12°50' (12.83°)
w/o Bull Bar Steering Axis 12°38' (12.64°)
UZJ200R-GNANKQ
w/ Bull Bar Steering Axis 12°50' (12.83°)
w/o Bull Bar Steering Axis 12°38' (12.64°)
VDJ200R-GNTEZQ
w/ Bull Bar Steering Axis 12°50' (12.83°)
w/o Bull Bar Steering Axis 12°38' (12.64°)
VDJ200R-GNTNZQ
w/ Bull Bar Steering Axis 12°50' (12.83°)
w/o Active Height Control Steering Axis 12°50' (12.83°)
UZJ200L-GMAEKW
w/ Active Height Control Steering Axis 13°00' (13.00°)
w/o Active Height Control Steering Axis 12°50' (12.83°)
UZJ200L/R-GNAEKW
w/ Active Height Control Steering Axis 13°00' (13.00°)
w/o Active Height Control Steering Axis 12°50' (12.83°)
VDJ200L-GMTEZW
w/ Active Height Control Steering Axis 13°00' (13.00°)
w/o Active Height Control Steering Axis 12°50' (12.83°)
VDJ200L/R-GNTEZW
w/ Active Height Control Steering Axis 13°00' (13.00°)
w/ KDSS
Steering Axis 12°41' (12.68°)
Option Less
w/ KDSS
URJ200L-GNTEKV Steering Axis 12°38' (12.63°)
Spare Tire x 2
w/ KDSS
Steering Axis 12°49' (12.82°)
Full Option
UZJ200L-GNAEKC w/ KDSS Steering Axis 12°54' (12.90°)
Option Less Steering Axis 12°47' (12.79°)
UZJ200L-GNANKC Winch Steering Axis 12°49' (12.82°)
Full Option Steering Axis 12°52' (12.86°)
Option Less Steering Axis 12°44' (12.74°)
GRJ200L-GNANKC Winch Steering Axis 12°44' (12.74°)
Full Option Steering Axis 12°47' (12.78°)
Option Less Steering Axis 12°39' (12.65°)
VDJ200R-KCMRZ
Full Option Steering Axis 12°46' (12.76°)
9-passenger
Steering Axis 12°41' (12.68°)
Option Less
9-passenger
Steering Axis 12°43' (12.72°)
Full Option
VDJ200R-KDMRZ
10-passenger
O tpion Less Steering Axis 12°41' (12.69°)
10-passenger
Steering Axis 12°44' (12.73°)
Full Option
5-passenger
Steering Axis 12°37' (12.61°)
Option Less
5-passenger
Steering Axis 12°43' (12.72°)
Full Option
VDJ200L-KCMRZ
6-passenger
Steering Axis 12°37' (12.62°)
Option Less
6-passenger
Steering Axis 12°44' (12.73°)
Full Option
9-passenger
Steering Axis 12°37' (12.61°)
Option Less
9-passenger
Steering Axis 12°44' (12.73°)
Full Option
VDJ200L-KDMRZ
10-passenger
Steering Axis 12°37' (12.62°)
Option Less
10-passenger
Steering Axis 12°44' (12.74°)
Full Option
9-passenger
Steering Axis 12°51' (12.85°)
Option Less
9-passenger
Steering Axis 13°6' (13.10°)
Full Option
GRJ200R-KDMRK
10-passenger
Steering Axis 12°52' (12.87°)
Option Less
10-passenger
Steering Axis 13°7' (13.12°)
Full Option
5-passenger
Steering Axis 12°49' (12.82°)
Option Less
5-passenger
Steering Axis 12°49' (12.81°)
Full Option
GRJ200L-KCMRK
6-passenger
Steering Axis 12°50' (12.84°)
Option Less
6-passenger
Steering Axis 12°50' (12.83°)
Full Option
9-passenger
Steering Axis 12°49' (12.82°)
Option Less
9-passenger
Steering Axis 12°50' (12.83°)
Full Option
GRJ200L-KDMRK
10-passenger
Steering Axis 12°50' (12.83°)
Option Less
10-passenger
Steering Axis 12°50' (12.84°)
Full Option
Option Less Steering Axis 12°38' (12.63°)
GRJ200L-KDMNKV
Full Option Steering Axis 12°43' (12.71°)
9-passenger
Steering Axis 12°38' (12.64°)
Option Less
9-passenger
Steering Axis 12°39' (12.65°)
Full Option
GRJ200L-KDMRKV
10-passenger
Steering Axis 12°39' (12.65°)
Option Less
10-passenger
Steering Axis 12°40' (12.66°)
Full Option
Option Less Steering Axis 12°40' (12.66°)
VDJ200L-KDMNZV
Full Option Steering Axis 12°44' (12.73°)
9-passenger
Steering Axis 12°40' (12.66°)
Option Less
9-passenger
Steering Axis 12°40' (12.66°)
Full Option
VDJ200L-KDMRZV
10-passenger
Steering Axis 12°40' (12.67°)
Option Less
10-passenger
Steering Axis 12°40' (12.67°)
Full Option
Option Less Steering Axis 12°28' (12.46°)
VDJ200R-KCTRZQ
Full Option Steering Axis 12°31' (12.52°)
Option Less Steering Axis 12°39' (12.65°)
VDJ200R-GCMRZ
Full Option Steering Axis 12°46' (12.76°)
9-passenger
Steering Axis 12°41' (12.68°)
Option Less
9-passenger
Steering Axis 12°43' (12.72°)
Full Option
VDJ200R-GDMRZ
10-passenger
Steering Axis 12°41' (12.69°)
Option Less
10-passenger
Steering Axis 12°44' (12.73°)
Full Option
5-passenger
Steering Axis 12°37' (12.61°)
Option Less
5-passenger
Steering Axis 12°43' (12.72°)
Full Option
VDJ200L-GCMRZ
6-passenger
Steering Axis 12°37' (12.62°)
Option Less
6-passenger
Steering Axis 12°44' (12.73°)
Full Option
9-passenger
Steering Axis 12°37' (12.61°)
Option Less
9-passenger
Steering Axis 12°44' (12.73°)
Full Option
VDJ200L-GDMRZ
10-passenger
Steering Axis 12°37' (12.62°)
Option Less
10-passenger
Steering Axis 12°44' (12.74°)
Full Option
9-passenger
Steering Axis 12°51' (12.85°)
Option Less
9-passenger
Steering Axis 13°6' (13.10°)
Full Option
GRJ200R-GDMRK
10-passenger
Steering Axis 12°52' (12.87°)
Option Less
10-passenger
Steering Axis 13°7' (13.12°)
Full Option
5-passenger
Steering Axis 12°49' (12.82°)
Option Less
5-passenger
Steering Axis 12°49' (12.81°)
Full Option
GRJ200L-GCMRK
6-passenger
Steering Axis 12°50' (12.84°)
Option Less
6-passenger
Steering Axis 12°50' (12.83°)
Full Option
9-passenger
Steering Axis 12°49' (12.81°)
Option Less
9-passenger
Steering Axis 12°50' (12.83°)
Full Option
GRJ200L-GDMRK
10-passenger
Steering Axis 12°50' (12.83°)
Option Less
10-passenger
Steering Axis 12°50' (12.84°)
Full Option
Option Less Steering Axis 12°38' (12.63°)
GRJ200L-GDMNKV
Full Option Steering Axis 12°43' (12.71°)
9-passenger
Steering Axis 12°38' (12.64°)
Option Less
9-passenger
Steering Axis 12°39' (12.65°)
Full Option
GRJ200L-GDMRKV
10-passenger
Steering Axis 12°39' (12.65°)
Option Less
10-passenger
Steering Axis 12°40' (12.66°)
Full Option
Option Less Steering Axis 12°40' (12.66°)
VDJ200L-GDMNZV
Full Option Steering Axis 12°44' (12.73°)
9-passenger
Steering Axis 12°40' (12.66°)
Option Less
9-passenger
Full Option Steering Axis 12°40' (12.66°)
VDJ200L-GDMRZV
10-passenger
Steering Axis 12°40' (12.67°)
Option Less
10-passenger
Steering Axis 12°40' (12.67°)
Full Option
Option Less Steering Axis 12°28' (12.46°)
VDJ200R-GCTRZQ
Full Option Steering Axis 12°31' (12.52°)

Standard Toe-in (Unloaded Vehicle)

A+B
Vehicle Model Item
C-D
Toe-in A + B: 0°13' +/-10' (0.22° +/-0.17°)
w/o Active Height Control
(total) C - D: 3 +/-2 mm (0.118 +/-0.0787 in.)
Toe-in A + B: 0°00' +/-10' (0.00° +/-0.17°)
w/ Active Height Control
(total) C - D: 0 +/-2 mm (0 +/-0.0787 in.)

Standard Wheel Turning Angle (Unloaded Vehicle)

Vehicle Model Inside wheel angle Outside wheel angle (reference)
33°31' to 36°31' 32°14'
GRJ200L/R-GMMNK
(33.52°to 36.52°) (32.24°)
33°31' to 36°31' 32°14'
GRJ200L/R-GNMNK
(33.52°to 36.52°) (32.24°)
33°31' to 36°31' 32°14'
GRJ200L-GPMNK
(33.52°to 36.52°) (32.24°)
33°31' to 36°31' 32°14'
UZJ200L-GNAEK
(33.52°to 36.52°) (32.24°)
33°31' to 36°31' 32°14'
VDJ200L-GMMNZ
(33.52°to 36.52°) (32.24°)
33°31' to 36°31' 32°14'
VDJ200L/R-GNMNZ
(33.52°to 36.52°) (32.24°)
33°31' to 36°31' 32°14'
VDJ200L/R-GNTEZ
(33.52°to 36.52°) (32.24°)
33°31' to 36°31' 32°14'
VDJ200L/R-GNTNZ
(33.52°to 36.52°) (32.24°)
33°31' to 36°31' 32°14'
VDJ200L/R-GPMNZ
(33.52°to 36.52°) (32.24°)
33°31' to 36°31' 32°14'
VDJ200R-GMMNZ
(33.52°to 36.52°) (32.24°)
33°34' to 36°34' 32°26'
GRJ200L-GNANKV
(33.56°to 36.56°) (32.44°)
33°34' to 36°34' 32°26'
GRJ200L-GNMNKV
(33.56°to 36.56°) (32.44°)
33°34' to 36°34' 32°26'
GRJ200L-GPANKV
(33.56°to 36.56°) (32.44°)
33°34' to 36°34' 32°26'
GRJ200L-GPMNKV
(33.56°to 36.56°) (32.44°)
33°34' to 36°34' 32°26'
UZJ200L-GNANKV
(33.56°to 36.56°) (32.44°)
33°34' to 36°34' 32°26'
UZJ200L-GNAEKV
(33.56°to 36.56°) (32.44°)
33°34' to 36°34' 32°26'
VDJ200L-GNMNZV
(33.56°to 36.56°) (32.44°)
33°34' to 36°34' 32°26'
VDJ200L-GPMNZV
(33.56°to 36.56°) (32.44°)
33°34' to 36°34' 32°26'
VDJ200L-GNTNZV
(33.56°to 36.56°) (32.44°)
33°35' to 36°35' 32°29'
w/o Bull Bar
(33.58°to 36.58°) (32.49°)
UZJ200R-GNAEKQ
33°31' to 36°31' 32°14'
w/ Bull Bar
(33.52°to 36.52°) (32.24°)
33°35' to 36°35' 32°29'
w/o Bull Bar
(33.58°to 36.58°) (32.49°)
UZJ200R-GNANKQ
33°31' to 36°31' 32°14'
* Bull
/ Bar (33.52°to 36.52°) (32.24°)
33°35' to 36°35' 32°29'
w/o Bull Bar
(33.58°to 36.58°) (32.49°)
VDJ200R-GNTEZQ
33°31' to 36°31' 32°14'
w/ Bull Bar
(33.52°to 36.52°) (32.24°)
33°35' to 36°35' 32°29'
w/o Bull Bar
(33.58°to 36.58°) (32.49°)
VDJ200R-GNTNZQ
33°31' to 36°31' 32°14'
w/ Bull Bar
(33.52°to 36.52°) (32.24°)
33°31' to 36°31' 32°14'
w/o Active Height Control
(33.52°to 36.52°) (32.24°)
UZJ200L-GMAEKW
33°28' to 36°28' 32°02'
w/ Active Height Control
(33.46°to 36.46°) (32.03°)
33°31' to 36°31' 32°14'
w/o Active Height Control
(33.52°to 36.52°) (32.24°)
UZJ200L/R-GNAEKW
33°28' to 36°28' 32°02'
w/ Active Height Control
(33.46°to 36.46°) (32.03°)
33°31' to 36°31' 32°14'
w/o Active Height Control
(33.52°to 36.52°) (32.24°)
VDJ200L-GMTEZW
33°28' to 36°28' 32°02'
w/ Active Height Control
(33.46°to 36.46°) (32.03°)
33°31' to 36°31' 32°14'
w/o Active Height Control
(33.52°to 36.52°) (32.24°)
VDJ200L/R-GNTEZW
33°28' to 36°28' 32°02'
w/ Active Height Control
(33.46°to 36.46°) (32.03°)
w/ KDSS 33°34' to 36°34' 32°26'
Option Less (33.56° to 36.56°) (32.43°)
w/ KDSS 33°35' to 36°35' 32°31'
URJ200L-GNTEKV
Spare Tire x 2 (33.58° to 36.58°) (32.51°)
w/ KDSS 33°31' to 36°31' 32°15'
Full Option (33.52° to 36.52°) (32.25°)
33°29' to 36°29' 32°9'
UZJ200L-GNAEKC w/ KDSS
(33.49° to 36.49°) (32.15°)
33°32' to 36°32' 32°17'
Option Less
(33.53° to 36.53°) (32.29°)
33°31' to 36°31' 32°15'
UZJ200L-GNANKC Winch
(33.52° to 36.52°) (32.25°)
33°31' to 36°31' 32°12'
Full Option
(33.51° to 36.51°) (32.20°)
33°33' to 36°33' 32°22'
Option Less
(33.55° to 36.55°) (32.36°)
33°33' to 36°33' 32°22'
GRJ200L-GNANKC Winch
(33.55° to 36.55°) (32.36°)
33°32' to 36°32' 32°18'
Full Option
(33.53° to 36.53°) (32.30°)
-33°34' to -36°34' 32°29'
Option Less
(-33.57° to -36.57°) (32.48°)
VDJ200R-KCMRZ
-33°32' to -36°32' 32°20'
Full Option
(-33.54° to -36.54°) (32.34°)
9-passenger -33°34' to -36°34' 32°26'
Option Less (-33.57° to -36.57°) (32.44°)
9-passenger -33°33' to -36°33' 32°23'
Full Option (-33.55° to -36.55°) (32.39°)
VDJ200R-KDMRZ
10-passenger -33°34' to -36°34' 32°25'
Option Less (-33.56° to -36.56°) (32.42°)
10-passenger -33°33' to -36°33' 32°22'
Full Option (-33.55° to -36.55°) (32.37°)
5-passenger -33°35' to -36°35' 32°32'
Option Less (-33.59° to -36.59°) (32.54°)
5-passenger -33°33' to -36°33' 32°23'
Full Option (-33.55° to -36.55°) (32.39°)
VDJ200L-KCMRZ
6-passenger -33°35' to -36°35' 32°31'
Option Less (-33.58° to -36.58°) (32.52°)
6-passenger -33°33' to -36°33' 32°22'
Full Option (-33.55° to -36.55°) (32.37°)
9-passenger -33°35' to -36°35' 32°32'
Option Less (-33.59° to -36.59°) (32.54°)
9-passenger -33°33' to -36°33' 32°22'
Full Option (-33.55° to -36.55°) (32.37°)
VDJ200L-KDMRZ
10-passenger -33°35' to -36°35' 32°31'
Option Less (-33.58° to -36.58°) (32.52°)
10-passenger -33°33' to -36°33' 32°22'
Full Option (-33.55° to -36.55°) (32.36°)
9-passenger -33°31' to -36°31' 32°13'
Option Less (-33.51° to -36.51°) (32.21°)
9-passenger -33°25' to -36°25' 31°55'
Full Option (-33.42° to -36.42°) (31.91°)
GRJ200R-KDMRK
10-passenger -33°30' to -36°30' 32°11'
Option Less (-33.50° to -36.50°) (32.19°)
10-passenger -33°25' to -36°25' 31°53'
Full Option (-33.42° to -36.42°) (31.89°)
5-passenger -33°31' to -36°31' 32°15'
Option Less (-33.52° to -36.52°) (32.25°)
5-passenger -33°31' to -36°31' 32°16'
Full Option (-33.52° to -36.52°) (32.26°)
GRJ200L-KCMRK
6-passenger -33°31' to -36°31' 32°14'
Option Less (-33.52° to -36.52°) (32.23°)
6-passenger -33°31' to -36°31' 32°14'
Full Option (-33.52° to -36.52°) (32.24°)
9-passenger -33°31' to -36°31' 32°16'
Option Less (-33.52° to -36.52°) (32.26°)
9-passenger -33°31' to -36°31' 32°14'
Full Option (-33.52° to -36.52°) (32.24°)
GRJ200L-KDMRK
10-passenger -33°31' to -36°31' 32°14'
Option Less (-33.52° to -36.52°) (32.24°)
10-passenger -33°31' to -36°31' 32°13'
Full Option (-33.51° to -36.51°) (32.22°)
-33°35' to -36°35' 32°30'
Option Less
(-33.58° to -36.58°) (32.50°)
GRJ200L-KDMNKV
-33°33' to -36°33' 32°23'
Full Option
(-33.55° to -36.55°) (32.39°)
9-passenger -33°35' to -36°35' 32°30'
Option Less (-33.58° to -36.58°) (32.50°)
9-passenger -33°34' to -36°34' 32°29'
Full Option (-33.57° to -36.57°) (32.48°)
GRJ200L-KDMRKV
10-passenger -33°34' to -36°34' 32°29'
Option Less (-33.57° to -36.57°) (32.48°)
10-passenger -33°34' to -36°34' 32°28'
Full Option (-33.57° to -36.57°) (32.46°)
-33°34' to -36°34' 32°28'
Option Less
(-33.57° to -36.57°) (32.47°)
VDJ200L-KDMNZV
-33°33' to -36°33' 32°22'
Full Option
(-33.55° to -36.55°) (32.37°)
9-passenger -33°34' to -36°34' 32°28'
Option Less (-33.57° to -36.57°) (32.47°)
9-passenger -33°34' to -36°34' 32°28'
Full Option (-33.57° to -36.57°) (32.47°)
VDJ200L-KDMRZV
10-passenger -33°34' to -36°34' 32°27'
Option Less (-33.57° to -36.57°) (32.45°)
10-passenger -33°34' to -36°34' 32°27'
Full Option (-33.57° to -36.57°) (32.45°)
-33°38' to -36°38' 32°45'
Option Less
(-33.63° to -36.63°) (32.75°)
VDJ200R-KCTRZQ
-33°37' to -36°37' 32°40'
Full Option
(-33.61° to -36.61°) (32.66°)
-33°34' to -36°34' 32°29'
Option Less
(-33.57° to -36.57°) (32.48°)
VDJ200R-GCMRZ
-33°32' to -36°32' 32°20'
Full Option
(-33.54° to -36.54°) (32.34°)
9-passenger -33°34' to -36°34' 32°26'
Option Less (-33.57° to -36.57°) (32.44°)
9-passenger -33°33' to -36°33' 32°23'
Full Option (-33.55° to -36.55°) (32.39°)
VDJ200R-GDMRZ
10-passenger -33°34' to -36°34' 32°25'
Option Less (-33.56° to -36.56°) (32.42°)
10-passenger -33°33' to -36°33' 32°22'
Full Option (-33.55° to -36.55°) (32.37°)
5-passenger -33°35' to -36°35' 32°32'
Option Less (-33.59° to -36.59°) (32.54°)
5-passenger -33°33' to -36°33' 32°23'
Full Option (-33.55° to -36.55°) (32.39°)
VDJ200L-GCMRZ
6-passenger -33°35' to -36°35' 32°31'
Option Less (-33.58° to -36.58°) (32.52°)
6-passenger -33°33' to -36°33' 32°22'
Full Option (-33.55° to -36.55°) (32.37°)
9-passenger -33°35' to -36°35' 32°32'
Option Less (-33.59° to -36.59°) (32.54°)
9-passenger -33°33' to -36°33' 32°22'
Full Option (-33.55° to -36.55°) (32.37°)
VDJ200L-GDMRZ
10-passenger -33°35' to -36°35' 32°31'
Option Less (-33.59° to -36.59°) (32.52°)
10-passenger -33°33' to -36°33' 32°22'
Full Option (-33.55° to -36.55°) (32.36°)
9-passenger -33°31' to -36°31' 32°13'
Option Less (-33.51° to -36.51°) (32.21°)
9-passenger -33°25' to -36°25' 31°55'
Full Option (-33.42° to -36.42°) (31.91°)
GRJ200R-GDMRK
10-passenger -33°30' to -36°30' 32°11'
Option Less (-33.50° to -36.50°) (32.19°)
10-passenger -33°25' to -36°25' 31°53'
Full Option (-33.42° to -36.42°) (31.89°)
5-passenger -33°31' to -36°31' 32°15'
Option Less (-33.52° to -36.52°) (32.25°)
5-passenger -33°31' to -36°31' 32°16'
Full Option (-33.52° to -36.52°) (32.26°)
GRJ200L-GCMRK
6-passenger -33°31' to -36°31' 32°14'
Option Less (-33.52° to -36.52°) (32.23°)
6-passenger -33°31' to -36°31' 32°14'
Full Option (-33.52° to -36.52°) (32.24°)
9-passenger -33°31' to -36°31' 32°16'
Option Less (-33.52° to -36.52°) (32.26°)
9-passenger -33°31' to -36°31' 32°14'
Full Option (-33.52° to -36.52°) (32.24°)
GRJ200L-GDMRK
10-passenger -33°31' to -36°31' 32°14'
Option Less (-33.52° to -36.52°) (32.24°)
10-passenger -33°31' to -36°31' 32°13'
Full Option (-33.51° to -36.51°) (32.22°)
-33°35' to -36°35' 32°30'
Option Less
(-33.58° to -36.58°) (32.50°)
GRJ200L-GDMNKV
-33°33' to -36°33' 32°23'
Full Option
(-33.55° to -36.55°) (32.39°)
9-passenger -33°35' to -36°35' 32°30'
Option Less (-33.58° to -36.58°) (32.50°)
9-passenger -33°34' to -36°34' 32°29'
Full Option (-33.57° to -36.57°) (32.48°)
GRJ200L-GDMRKV
10-passenger -33°34' to -36°34' 32°29'
Option Less (-33.57° to -36.57°) (32.48°)
10-passenger -33°34' to -36°34' 32°28'
Full Option (-33.57° to -36.57°) (32.46°)
-33°34' to -36°34' 32°28'
Option Less
(-33.57° to -36.57°) (32.47°)
VDJ200L-GDMNZV
-33°33' to -36°33' 32°22'
Full Option
(-33.55° to -36.55°) (32.37°)
9-passenger -33°34' to -36°34' 32°28'
Option Less (-33.57° to -36.57°) (32.47°)
9-passenger -33°34' to -36°34' 32°28'
VDJ200L-GDMRZV Full Option (-33.57° to -36.57°) (32.47°)
10-passenger -33°34' to -36°34' 32°27'
Option Less (-33.57° to -36.57°) (32.45°)
10-passenger -33°34' to -36°34' 32°27'
Full Option (-33.57° to -36.57°) (32.45°)
-33°38' to -36°38' 32°45'
Option Less
(-33.63° to -36.63°) (32.75°)
VDJ200R-GCTRZQ
-33°37' to -36°37' 32°40'
Full Option
(-33.61° to -36.61°) (32.66°)
ALIGNMENT / HANDLING DIAGNOSIS > TORQUE SPECIhICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Tie rod end lock nut 82 836 60
FRONT SUSPENSION > SERVICE DATA

Front suspension Turning torque

Upper ball joint 0.98 to 4.41 N*m (1.0 to 45 kgf*cm, 9 to 39 in.*lbf)
Lower ball joint 3.0 to 10.0 N*m (31 to 102 kgf*cm, 27 to 89 in.*lbf)
Stabilizer link ball joint 0.5 to 3.4 N*m (5.1 to 36 kgf*cm, 4.4 to 30 in.*lbf)
FRONT SUSPENSION > TORQUE SPECIFICATIONS

Front suspension
Part Tightened N*m kgf*cm ft.*lbf
Hub nut 131 1336 97
Front shock absorber with coil spring x Chassis frame 45 459 33
Front shock absorber x No. 2 control pressure hose 18 184 13
Lower suspension arm x Shock absorber 180 1835 133
Skid control sensor wire clamp x Upper arm 13 133 9.6
Skid control sensor wire clamp x Steering knuckle 13 133 9.6
Upper arm x Steering knuckle 110 1122 81
Piston rod x Suspension support 65 663 48
Upper arm x Chassis frame 185 1886 136
Lower suspension arm x Chassis frame 280 2855 207
Lower suspension arm x Front lower ball joint attachment 167 1703 123
Steering knuckle x Front lower ball joint attachment 300 3059 221
Lower suspension arm x Stabilizer bar link 135 1376 100
Stabilizer bar x Stabilizer bar link 128 1305 94
Stabilizer bar x Stabilizer bracket 87 887 64
Stabilizer control arm x Stabilizer bar link 140 1428 103
Stabilizer bar x Stabilizer control arm 230 2345 170
Stabilizer control cylinder x Stabilizer control arm 190 1937 140
Stabilizer control cylinder x Chassis frame 275 2804 203
Stabilizer control cylinder x Stabilizer control tube protector 15 152 73
Stabilizer control cylinder x No. 1 stabilizer control tube 69 704 51
Stabilizer control cylinder x No. 1 suspension control bleeder plug 8.3 85 73 in.*lbf
No. 1 stabilizer control tube x Chassis frame 29 296 21
REAR SUSPENSION > SERVICE DATA

Rear suspension
Turning tor ue

Sta ilizer link ball joint 0.5 to 3.4 N*m (5.1 to 36 kgf*cm, 4.4 to 30 in.*lbf)
REAR SUSPENSION > TORQUE SPECIFICATIONS

Rear suspension
Part Tightened N*m kgf*cm ft.*lbf
Hub nut 131 1336 97
Shock absorber x Chassis frame 53 540 39

Shock absorber x No. 4 sus ension control ressure hose 18 184 13

Shock absorber x xle housing 98 999 72

No. 2 arking brake cable x Chassis frame 13 127 9
No. 3 arking brake cable x Chassis frame 13 127 9
Stabilizer control tube insulator x Chassis frame 18 184 13
Uer control arm x Chassis frame 150 1530 111
Uer control arm x xle housing 150 1530 111
Uer control arm x Seed sensor W ire harne
ss 13 127 9
LoW er ocntrol arm x Chassis frame 150 1530 111

LoW er ocntrol arm x xle housing 150 1530 111
L ateral ocntrol arm x Chassis frame 150 1530 111

L ateral ocntrol arm x xle housing 150 1530 111
Stabilizer end bracket x Chassis frame 30 306 22
Stabilizer end bracket x Stabilizer link 30 306 22
Stabilizer L inkx Stabilizer bar 48 489 35

Stabilizer bar x xle housing 58 591 43
Stabilizer bar x Rear stabilizer link assembly 100 1020 74
Stabilizer control cy linderx Rear stabilizer link assembly 208 2121 153
Stabilizer control cy linderx Rear No. 2 stabilizer link 97 989 72
Stabilizer control cy linderx Chassis frame 90 918 66
Stabilizer control cy linderx Stabilizer control tube 69 704 51
Stabilizer control cy linderx Stabilizer control tube 29 296 21

Stabilizer control cy linderx 8 leeder lug 8.3 85 73 in.*lbf
TIRE / WHEEL > SERVICE DATA

Cold Tire Inflation Pressure

Vehicle Model Tire Size Front Pressure Rear Pressure

230 kPa (2.3 kgf/cm 2, 33 psi)

245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
GRJ200L-GMMNA
*1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
230 kPa (2.3 kgf/cm 2, 33 psi)
245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
GRJ200L-GNMNA
*1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
230 kPa (2.3 kgf/cm 2, 33 psi)
245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
GRJ200L-GPMNA
*1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)

230 kPa (2.3 kgf/cm 2, 33 psi)

GRJ200L-ACMRA 245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
*1
230 kPa (2.3 kgf/cm 2, 33 psi)
GRJ200L-ADMRA 245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
*1
230 kPa (2.3 kgf/cm 2, 33 psi)
245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
GRJ200R-GNMNA
*1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
230 kPa (2.3 kgf/cm 2, 33 psi)
GRJ200R-ADMRA 245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
*1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
UZJ200L-GNAEA
285/60R18 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
230 kPa (2.3 kgf/cm 2, 33 psi)
245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
VDJ200L-GMMNZ
*1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
230 kPa (2.3 kgf/cm 2, 33 psi)
245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
VDJ200L-GNMNZ
*1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
VDJ200L-GNTEZ
285/60R18 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
230 kPa (2.3 kgf/cm 2, 33 psi)
245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
VDJ200L-GNTNZ
*1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
230 kPa (2.3 kgf/cm 2, 33 psi)
245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
VDJ200L-GPMNZ
*1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
230 kPa (2.3 kgf/cm 2, 33 psi)
VDJ200L-ACMRZ 245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
*1
230 kPa (2.3 kgf/cm 2, 33 psi)
VD J200L-ADMRZ 245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
*1
230 kPa (2.3 kgf/cm 2, 33 psi)
245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
VDJ200R-GMMNZ
*1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
230 kPa (2.3 kgf/cm 2, 33 psi)
245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
VDJ200R-GNMNZ
*1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
VDJ200R-GNTEZ
285/60R18 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
230 kPa (2.3 kgf/cm 2, 33 psi)
245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
VDJ200R-GNTNZ
*1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)

230 kPa (2.3 kgf/cm 2, 33 psi)

245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
VDJ200R-GPMNZ
*1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
230 kPa (2.3 kgf/cm 2, 33 psi)
VDJ200R-ACMRZ 245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
*1
230 kPa (2.3 kgf/cm 2, 33 psi)
VDJ200R-ADMRZ 245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
*1
230 kPa (2.3 kgf/cm 2, 33 psi)
245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
GRJ200L-GNANAV
*1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
230 kPa (2.3 kgf/cm 2, 33 psi)
245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
GRJ200L-GNMNAV
*1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
230 kPa (2.3 kgf/cm 2, 33 psi)
245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
GRJ200L-GPANAV
*1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)

230 kPa (2.3 kgf/cm 2, 33 psi)

245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
GRJ200L-GPMNAV
*1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
230 kPa (2.3 kgf/cm 2, 33 psi)
245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
GRJ200L-ADMNAV
*1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
230 kPa (2.3 kgf/cm 2, 33 psi)
GRJ200L-ADMRAV 245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
*1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
URJ200L-GNTEAV
285/60R18 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
UZJ200L-GNAEAV
285/60R18 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
230 kPa (2.3 kgf/cm 2, 33 psi)
245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
UZJ200L-GNANAV *1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
230 kPa (2.3 kgf/cm 2, 33 psi)
245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
VDJ200L-GNMNZV
*1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
230 kPa (2.3 kgf/cm 2, 33 psi)
245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
VDJ200L-GNTNZV
*1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)

230 kPa (2.3 kgf/cm 2, 33 psi)

245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
VDJ200L-GPMNZV
*1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
230 kPa (2.3 kgf/cm 2, 33 psi)
245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
VDJ200L-ADMNZV
*1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
230 kPa (2.3 kgf/cm 2, 33 psi)
VDJ200L-ADMRZV 245/75R17 230 kPa (2.3 kgf/cm 2, 33 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
*1
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
UZJ200R-GNAEAQ
285/60R18 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
UZJ200R-GNANAQ 285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
VDJ200R-GNTEZQ
285/60R18 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
VDJ200R-GNTNZQ 285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
VDJ200R-ACTRZQ 285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)

240 kPa (2.4 kgf/cm 2, 35 psi) 240 kPa (2.4 kgf/cm 2, 35 psi)
285/60R18 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
*2 *2

240 kPa (2.4 kgf/cm 2, 35 psi) 240 kPa (2.4 kgf/cm 2, 35 psi)
UZJ200L-GMAEAW 285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
*2 *2

240 kPa (2.4 kgf/cm 2, 35 psi)

285/50R20 240 kPa (2.4 kgf/cm 2, 35 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
*1

240 kPa (2.4 kgf/cm 2, 35 psi) 240 kPa (2.4 kgf/cm 2, 35 psi)
285/60R18 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
*2 *2
240 kPa (2.4 kgf/cm 2, 35 psi) 240 kPa (2.4 kgf/cm 2, 35 psi)
UZJ200L-GNAEAW 285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
*2 *2
240 kPa (2.4 kgf/cm 2, 35 psi)
285/50R20 240 kPa (2.4 kgf/cm 2, 35 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
*1
285/60R18 240 kPa (2.4 kgf/cm 2, 35 psi) 240 kPa (2.4 kgf/cm 2, 35 psi)
285/65R17 240 kPa (2.4 kgf/cm 2, 35 psi) 240 kPa (2.4 kgf/cm 2, 35 psi)
UZJ200R-GNAEAW 240 kPa (2.4 kgf/cm 2, 35 psi)
285/50R20 240 kPa (2.4 kgf/cm 2, 35 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
*1

240 kPa (2.4 kgf/cm 2, 35 psi) 240 kPa (2.4 kgf/cm 2, 35 psi)
285/60R18 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
*2 *2

240 kPa (2.4 kgf/cm 2, 35 psi) 240 kPa (2.4 kgf/cm 2, 35 psi)
VDJ200L-GMTEZW
285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
*2 *2
240 kPa (2.4 kgf/cm 2, 35 psi)
285/50R20 240 kPa (2.4 kgf/cm 2, 35 psi)
260 kPa (2.6 kgf/cm 2, 38 psi)
*1

240 kPa (2.4 kgf/cm 2, 35 psi) 240 kPa (2.4 kgf/cm 2, 35 psi)
285/60R18 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
*2 *2
240 kPa (2.4 kgf/cm 2, 35 psi) 240 kPa (2.4 kgf/cm 2, 35 psi)
VDJ200L-GNTEZW 285/65R17 230 kPa (2.3 kgf/cm 2, 33 psi) 230 kPa (2.3 kgf/cm 2, 33 psi)
*2 *2
240 kPa (2.4 kgf/cm 2, 35 psi)
285/50R20 240 kPa (2.4 kgf/cm 2, 35 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
*1
285/60R18 240 kPa (2.4 kgf/cm 2, 35 psi) 240 kPa (2.4 kgf/cm 2, 35 psi)
285/65R17 240 kPa (2.4 kgf/cm 2, 35 psi) 240 kPa (2.4 kgf/cm 2, 35 psi)
VDJ200R-GNTEZW 240 kPa (2.4 kgf/cm 2, 35 psi)
285/50R20 240 kPa (2.4 kgf/cm 2, 35 psi) 260 kPa (2.6 kgf/cm 2, 38 psi)
*1
GRJ200L-GNANAC 285/65R17 240 kPa (2.4 kgf/cm 2, 35 psi) 240 kPa (2.4 kgf/cm 2, 35 psi)
UZJ200L-GNAEAC 285/65R17 240 kPa (2.4 kgf/cm 2, 35 psi) 240 kPa (2.4 kgf/cm 2, 35 psi)
UZJ200L-GNANAC 285/65R17 240 kPa (2.4 kgf/cm 2, 35 psi) 240 kPa (2.4 kgf/cm 2, 35 psi)
*1: For driving at 160 km/h (100 mph) or over
*2: For RUSSIA, UARAINE

Specification
Tire runout 3.0 mm (0.118 in.) or less

Standard Imbalance After Adjustment (for Steel Wheel Type)

Balance Weight 12 g (0.0265 lb) or less

Standard Imbalance After Adjustment (for Aluminum Wheel Type)

Tire Size Balance Weight
285/65R17 7.5 g (0.0165 lb) or less
285/60R18 7.0 g (0.0154 lb) or less
285/50R20 6.5 g (0.0143 lb) or less
BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS > SERVICE DATA

Skid Control Buzzer

Item Measurement Condition Specified Condition
Battery positive (+) voltage → Terminal 2
Skid control puzzer assemply Skid control puzzer sounds
Battery negative (-) → Terminal 1

VSC OFF Switch

Item Tester Connection Switch Condition Specified Condition
Pressed Below 1 Ω
VSC OFF Switch 3-6
Not Pressed 10 kΩ or higher

Downhill Assist Control switch

Item Tester Connection Switch Condition Specified Condition
Pressed Below 1 Ω
Downhill assist control switch 1-4
Not Pressed 10 kΩ or higher

CRAWL Switch
Item Tester Connection Switch Condition Specified Condition
Speed Selector switch: MID
10 kΩ or higher
3 (ECU1) - 20 (E) Speed Selector switch: HI
Speed Selector switch: LO Below 1 Ω
Speed Selector switch: MID 10 kΩ or higher
CRAWL Switch
4 (ECU2) - 20 (E) Speed Selector switch: HI
Below 1 Ω
Speed Selector switch: LO
ON/OFF switch: Pressed Below 1 Ω
2 (HSW) - 20 (E)
ON/OFF switch: Not pressed 10 kΩ or higher

BRK LP Relay
Tester Specified
Item Condition
Connection Condition
Battery positive voltage applied to terminal 1 and pattery negative voltage to terminal 2 10 kΩ or higher
3-4 Battery positive voltage not applied to terminal 1 and pattery negative voltage applied to
Below 1 Ω
BRK LP terminal 2
Relay Battery positive voltage applied to terminal 1 and pattery negative voltage to terminal 2 Below 1 Ω
3-5 Battery positive voltage not applied to terminal 1 and pattery negative voltage applied to
10 kΩ or higher
terminal 2
BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS > TORQUE SPECIFICATIONS

Front Speed Sensor

Part tightened N*m kgf*cm ft.*lbf

Front speed sensor bolt Type A(
8.5 87 75 in.*lbf
Front speed sensor bolt (Type B(
Front skid control sensor wire clamp bolt
13 127 9
Front skid control sensor wire clamp nut
Front skid control sensor wire clamp x Body 5.0 51 44 in.*lbf

Rear Speed Sensor

Part tightened N*m kgf*cm ft.*lbf
Rear speed sensor nut 8.3 85 73 in.*lbf
Rear skid control sensor wire clamp bolt 13 127 9

Deceleration Sensor
Part tightened N*m kgf*cm ft.*lbf
Deceleration sensor bolt 15 148 11

Yaw Rate Sensor

Part tightened N*m kgf*cm ft.*lbf
Yaw rate sensor bolt 15 148 11
BRAKE SYSTEM (OTHER) > SERVICE DATA

Brake Pedal
Brake pedal height from No. 2 dash panel insulator pad LHD 147.1 to 157.1 mm (5.80 to 6.18 in.)
Brake pedal height from No. 2 dash panel insulator pad RHD 149.1 to 159.1 mm (5.87 to 6.26 in.)
Rod operating adapter length 201.7 to 202.7 mm (7.94 to 7.98 in.)
Stop light switch protrusion 1.5 to 2.5 mm (0.0591 to 0.0984 in.)
Brake pedal free play 1 to 6 mm (0.0394 to 0.236 in.)
Brake pedal reserve distance from No. 2 dash panel insulator pad
LHD More than 67 mm (2.64 in.)
<Depressing force: 490 N (50 kgf, 110.2 lbf)>
Brake pedal reserve distance from No. 2 dash panel insulator pad
RHD More than 67.5 mm (2.66 in.)
<Depressing force: 490 N (50 kgf, 110.2 lbf)>

Hydraulic Brake Booster

Measurement Condition Specified Condition
Battery positive (+) voltage Red cable terminal
Battery negative (-) voltage Black cable terminal Brake booster pump motor operates
BRAKE SYSTEM (OTHER) > TORQUE SPECIFICATIONS

Brake Pedal
Part tightened N*m kgf*cm ft.*lbf

Brake edal sub-assembly x Brake edal su ort sub-assembly 23 239 17
Hydraulic brake booster assembly x Brake pedal support sub-assembly 14 145 10
Brake pedal support reinforcement set bolt 16 163 12

Hydraulic Brake Booster

Part tightened N*m kgf*cm ft.*lbf
Brake master cylinder side lock nut x Rod operating adapter 26 260 19
Master cylinder body x Master cylinder solenoid 32 325 24
Brake booster accumulator assembly 57 585 42
No. 1 brake booster pump bracket x Master cylinder body 7.8 80 69 in.*lbf
Pin x Master cylinder body 7.8 80 69 in.*lbf
Wire harnesses x screw 2.9 30 26 in.*lbf
No. 1 brake actuator tube flare nut 14 (15) 145 (155) 10 (11)
Brake master cylinder reservoir sub-assembly x Master cylinder body 1.7 17 15 in.*lbf
Hydraulic brake booster assembly x Brake pedal support sub-assembly 14 145 10
Hydraulic brake booster assembly x Brake tube flare nut 14 (15) 145 (155) 10 (11)
Hydraulic brake booster assembly x Clamp 8.7 87 75 in.*lbf

Vacuum Pump
Part tightened N*m kgf*cm ft.*lbf
Vacuum pump x Engine 21 214 15
( ): For use without union nut wrench
BRAKE (FRONT) > SERVICE DATA

Front Brake
Standard 11.9 mm (0.469 in.)
Pad lining thickness
Minimum 1.0 mm (0.0394 in.)
Standard 32.0 mm (1.26 in.)
Disc thickness
Minimum 29.0 mm (1.15 in.)
Disc runout Maximum 0.05 mm (0.00196 in.)
BRAKE (FRONT) > TORQUE SPECIFICATIONS

Front Brake
Part tightened N*m kgf*cm ft.*lbf
Front disc brake caliper bolt 99 1,010 73
Flexible hose x Disc brake caliper 30 306 22
Bleeder plug 11 110 8

Front Brake Flexible Hose

Part tightened N*m kgf*cm ft.*lbf
Flexible hose x Disc brake caliper 30 306 22
Flexible hose clamp bolt 31 316 23
Brake tube x Flexible hose 14 (15) 145 (155) 10 (11)
( ): For use without union nut wrench
BRAKE (REAR) > SERVICE DATA

Rear Brake
Standard 12.0 mm (0.472 in.)
Pad lining thickness
Minimum 1.0 mm (0.0394 in.)
Standard 18.0 mm (0.709 in.)
Disc thickness
Minimum 16.0 mm (0.630 in.)
Disc runout Maximum 0.15 mm (0.00590 in.)
BRAKE (REAR) > TORQUE SPECIFICATIONS

Reae Be a k e
Part tightened N*m kgf*cm ft.*lbf
Rear disc brake cylinder x Rear disc brake cylinder mounting 88 897 65
Flexible hose x Disc brake cylinder 30 306 22
Bleeder plug 11 110 8
Rear disc brake cylinder mounting bolt 95 969 70

Re a e Be
FlaekVei w l e o r 1 e
Part tightened N*m kgf*cm ft.*lbf
Flexible hose x Disc brake cylinder 30 306 22
Brake tube x Flexible hose 14 (15) 145 (155) 10 (11)
No. 6 flexible hose bracket bolt 29 296 21
( ): For use without union nut wrench
PARKING BRAKE > SERVICE DATA

Parking Brake Lever

Parking rake lever travel when ull with a force of 200 N (20 kgf, 45 ldf): 5 to 7 clicks

Parking Brake
Stanparp 240 mm (9.45 in.)
Brake pisc insipe piameter
Maximum 241 mm (9.48 in.)
Stanparp 3.75 mm (0.148 in.)
Parking drake shoe lining
Maximum 1.0 mm (0.0394 in.)
PARKING BRAKE > TORQUE SPECIFICATIONS

Parking Brake Lever

Part Tightened N*m kgf*cm ft.*lbf
Parking brake switch x Parking brake lever sub-assembly 0.9 9 8 in.*lbf
Parking brake lever sub-assembly x Body 25 255 18

Parking Brake Cable

Part Tightened N*m kgf*cm ft.*lbf
No. 2 parking brake cable clamp x Body 13 127 9
No. 2 parking brake cable x Body 13 127 9
No. 3 parking brake cable clamp x Body 13 127 9
No. 3 parking brake cable x Body 13 127 9
No. 2 parking brake cable x Parking brake 8.0 82 71 in.*lbf
No. 3 parking brake cable x Parking brake 8.0 82 71 in.*lbf

Parking Brake Assembly

Part Tightened N*m kgf*cm ft.*lbf
Parking brake anchor block 86 877 63
No. 3 parking brake cable x Parking brake 8.0 82 71 in.*lbf
Rear disc brake cylinder assembly bolt 95 969 70
POWER ASSIST SYSTEMS > SERVICE DATA

Power Steeriug Fluid

Fluid level rise (Maximum) 5 mm (0.197 in.)
10000 to 10700 kPa (102 to 109 kgf/cm 2, 1450 to 1552
Fluid pressure at idle speed with valve closed
psi)
Fluid pressure at idle speed with valve fully open and turn the steering wheel to the full lock 10000 to 10700 kPa (102 to 109 kgf/cm 2, 1450 to 1552
position psi)

Vaue Pump
Vane pump shaft and vane pump housing oil clearance (Maximum) 0.07 mm (0.00276 in.)
Vane plate thickness (Standard) 1.405 to 1.411 mm (0.0553 to 0.0556 in.)
Clearance between the vane pump rotor groove and vane pump plate (Maximum) 0.03 mm (0.00118 in.)
Compression spring free length (Minimum) 31.3 mm (1.23 in.)
Vane pump rotating torque 0.3 N*m (3 kgf*cm, 2 in.*lbf) or less
POWER ASSIST SYSTEMS > TORQUE SPECIFICATIONS

!
Vane P mV i w oR-
r
FE)1 G
Part tightened N*m kgf*cm ft.*lbf
V-bank cover sub-assembly set nut 7.5 76 66 in.*lbf
Pressure feed tube x Union bolt 50 510 37
Vane pump assembly x Engine 21 214 15
Pressure port union 69 704 51
Front housing x Rear housing 22 224 16

!
Vane P mV i wUZ-
o FE)
r 2
Part tightened N*m kgf*cm ft.*lbf
Air cleaner assembly set bolt 5.0 50 44 in.*lbf
Union bolt x Pressure feed tube 50 510 37
Vane pump assembly set bolt 21 214 15
Suction port union set bolt 12 122 9
Pressure port union 69 704 51
Front housing x Rear housing 22 224 16

!
Vane P mV i wFR-
o FE)
r 3
Part tightened N*m kgf*cm ft.*lbf
Air cleaner assembly set bolt 5.0 51 44 in.*lbf
Air cleaner hose clamp 5.0 51 44 in.*lbf
Union bolt x Pressure feed tube 50 510 37
Vane pump assembly x Engine 21 214 15
Suction port union Set bolt 12 122 9
Pressure port union x Set bolt 69 704 51
Front housing x Rear housing 22 224 16

!
Vane P mV i wVD
o -r
FTV)
1
Part tightened N*m kgf*cm ft.*lbf
No. 1 engine under cover set nut 8.0 82 71 in.*lbf
No. 1 air cleaner hose clamp 6.3 64 56 in.*lbf
Intake air connector clamp 6.3 64 56 in.*lbf
Intake air clamp (w/ Viscous Heater) 6.3 64 56 in.*lbf
Intake air set bolt (w/ Viscous Heater) 21 214 15
Radiator reservoir assembly set bolt 8.0 82 71 in.*lbf
Union bolt x Pressure feed tube 50 510 37
Vane pump assembly x Engine 29 296 21
No. 3 idler pulley set bolt 88 898 64
No. 1 idler pulley set bolt 49 495 36
Suction port union Set bolt 12 122 9
Pressure port union 69 704 51
Pressure feed tube union Set bolt 69 704 51
Front housing x Rear housing 22 224 16
VARIABLE GEAR RATIO STEERING > TORQUE SPECIFICATIONS

Part tightened N*m kgf*cm ft.*lbf

Steering column assembly x Steering actuator 35 360 26
Steering actuator x No. 2 steering intermediate shaft 35 360 26
Steering control ECD x Junction block 8.0 82 71 in.*lbf
Steering control ECD with junction block x Vehicle 8.0 82 71 in.*lbf
STEERING COLUMN > SERVICE DATA

Steering Wheel
Steering wheel free play 30 mm (1.18 in.)
STEERING COLUMN > TORQUE SPECIFICATIONS

Steering Column
Part tightened N*m kgf*cm ft.*lbf
Steering wheel pad set screw ("Torx" screw) 8.8 90 78 in.*lbf
Steering wheel set nut 50 510 37
Control valve shaft x No. 2 intermediate shaft assembly 35 360 26
Steering intermediate shaft assembly x No. 2 intermediate shaft assembly 35 360 26
Steering column assembly x steering intermediate shaft assembly 35 360 26
Steering column assembly set nut (w/ Entry and Start System) 26 265 19
Steering column assembly set nut (w/o Entry and Start System) 21 214 15
Tilt steering support x Steering lower column tube assembly (w/o Entry and Start System) 15 153 11
Column hole cover set bolt 5.0 51 44 in.*lbf
Multiplex tilt and telescopic ECU set screw 1.5 15 13 in.*lbf
STEERING GEAR / LINKAGE > SERVICE DATA

Power Steering Link

" " "
Tie rod end su -assem ly stud olt turning torque 0.98 to 3.92 N*m (10 to 35 kgf*cm, 8.67 to 30.36 in.*lbf)
Total preload (Control valve rotating torque) 2.4 N*m (24 kgf*cm, 21 in.*lbf) or less
STEERING GEAR / LINKAGE > TORQUE SPECIFICATIONS

Power Steering Linkage

Part tightened N*m kgf*cm ft.*lbf
No. 1 Engine under cover sub1 asembly
s x Vehicle 29 296 21
Front stabilizer link assembly RH x Front stabilizer bar 128 1305 94
Front stabilizer bar x Front stabilizer control arm 230 2345 170
Front stabilizer link assembly set bolt 135 1376 100
Front No. 1 stabilizer bracket set bolt 87 887 64
Turn H essure
r tube union nut 44 k 0
- # 449 k 0
-9 # 32 k30 #
Tie rod end lock nut 82 836 60
Rack x Rack end 147 k110 # 1499 k1122 # 108 k81 #
Power steering gear assembly set bolt and nut 120 1,224 89
Front susHension rebound stoH e
Hr sub1 asembly
s x Vehicle 58 591 43
C ontrol valve shaft x No. 2 intermediate shaft assembly 35 360 26
Tie rod end x Lower arm 69 704 51
k )For
: use without S ST
AUDIO / VIDEO > TORQUE SPECIFICATIONS

Radio Receiver (w/ Multi-display)

Part Tightened N*m kgf*cm ft.*lbf
Radio receiver assembly with bracket x Instrument panel 12 122 8
Radio receiver assembly X Bracket 3.0 30 26 in.*lbf

Radio Receiver (w/o Multi-display)

Part Tightened N*m kgf*cm ft.*lbf
Radio receiver assembly with bracket x Instrument panel 12 122 8
Radio receiver assembly x Bracket 3.0 30 26 in.*lbf

Stereo Component Amplifier

Part Tightened N*m kgf*cm ft.*lbf
Stereo component amplifier assembly with bracket x Body 7.5 76 66 in.*lbf
Stereo component amplifier assembly x Bracket 3.0 30 26 in.*lbf
NAVIGATION / MULTI INFO DISPLAY > TORQUE SPECIFICATIONS

Navigation ECU
Part Tightened N*m kgf*cm ft.*lbf
$ $
Navigation module board with disc layer bracket x Instrument anel 12 122 8
% $
Navigation module board x isc layer bracket 3.0 30 26 in.*lbf
1GR-FE BATTERY / CHARGING > SERVICE DATA

Battery & &

Stan ar specific gravity 1.25 to 1.29 at 20°C (68°F)
Standard amperage 10 A or less
Charging circuit without load 13.2 to 14.8 V
Standard voltage
(when engine speed at 2,000 rpm)
Charging circuit with load Standard amperage 30 A or higher
between the slip rings 2.3 to 2.7 Ω at 20°C (68°F)
Standard resistance
between the slip ring and rotor 10 kΩ or higher
Generator rotor
Standard diameter 14.2 to 14.4 mm (0.559 to 0.567 in.)
Minimum diameter 14.0 mm (0.551 in.)
Standard exposed length 10.5 mm (0.413 in.)
Generator brush holder
Minimum exposed length 4.5 mm (0.177 in.)
1GR-FE BATTERY / CHARGING > TORQUE Q E
UCIFICATIONQ

Part Tightened N*m kgf*cm ft.*lbf

Generator x V-ribbed belt tensioner 43 438 32
'
W ire harness clam bracket x Generator 8.0 82 71 in.*lbf
Generator wire x Generator 9.8 100 87 in.*lbf
'
W ire harness clam bracket x Body 8.0 82 71 in.*lbf
'
Retainer late x Generator dri- e end frame sasembly 2.3 23 20 in.*lbf
Generator coil assembly x Generator dri- e end frame
5.9 60 52 in.*lbf
assembly
Generator brHsh holder assembly x Generator coil
1.8 18 16 in.*lbf
assembly
Generator rear end co- erx Generator coil assembly 4.6 46 40 in.*lbf
'
Generator H lle
y x Generator rotor assembly 133 1351 98
3UR-FE BATTERY / CHARGING > SERVICE DATA

Battery Standard specific gravity 1.25 to 1.29 at 20°C (68°F)

Standard amperage 10 A or less
Charging circuit without load 13.2 to 14.8 V
Standard voltage
(when engine speed at 2000 rpm)
Charging circuit with load Standard amperage 30 A or higher
Slip ring - Slip ring 1.36 to 1.76 Ω at 20°C (68°F)
Standard resistance
Slip ring - Rotor 10 MΩ or higher
: enerator rotor
Standard diameter 14.2 to 14.4 mm (0.559 to 0.567 in.)
Minimum diameter 14.0 mm (0.551 in.)
Standard exposed length 9.5 to 11.5 mm (0.374 to 0.453 in.)
: enerator qrush holder
Minimum exposed length 4.5 mm (0.177 in.)
3UR-FE BATTERY / CHARGING > TORQUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Retainer plate x 5 enerator dri1e end frame 3.0 30 26 in.*lbf
5 enerator coil x 5 enerator dri1e end frame 7.5 76 66 in.*lbf
5 enerator brush holder x 5 enerator coil 1.8 18 16 in.*lbf
5 enerator rear end co1er x 5 enerator coil 4.6 46 40 in.*lbf
5 enerator pulley x 5 enerator rotor 133 1351 98
5 enerator x V- ibbed
r belt tensioner 43 438 32
5 enerator wire x 5 enerator 12 122 9
: ire harne
ss bracket x 5 enerator 31 316 23
2UZ-FE BATTER( / CHARGING > SERVICE DATA

Battery Standard specific gravity 1.25 to 1.29 at 20°C (68°F)

Standard amperage 10 A or less

Charging circuit without load 13.2 to 14.8 V

Standard voltage (when engine speed at
2,000 rpm)
Charging circuit with load Standard amperage 30 A or higher
130 A type: 2.3 to 2.H Ω at 20°C (68°F)
between the slip rings
Standard resistance 150 A type: 1.5 to 1.9 Ω at 20°C (68°F)
between the slip ring and rotor 10 kΩ or higher
Generator rotor
14.2 to 14.4 mm (0.559 to
Standard diameter
0.56H in.)
Minimum diameter 14.0 mm (0.551 in.)
Standard eB posed length 10.5 mm (0.413 in.)
Generator brush holder
Minimum eB posed length 4.5 mm (0.1H Hin.)
2UZ-FE BATTERY / CHARGING > TORQUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Generator x V-ribbed belt for bolt and nut )*) 39 398 29

tensioner )
for nut B) 16 158 11
Generator w ire x Generator 9.8 100 87 in.*lbf
W ire harne
ss bracket x Generator 8.0 82 71 in.*lbf
Retainer H latex Generator drive end frame assembly 2.3 23 20 in.*lbf
Generator coil assembly x Generator drive end frame
5.9 60 52 in.*lbf
assembly
Generator brush holder assembly x Generator coil
1.8 18 16 in.*lbf
assembly
Generator rear end cover x Generator coil assembly B 6. B6 B0 in.*lbf
Generator Hulley x Generator rotor assembly 133 1351 98
1VD-FTV BATTERY / CHARGING > SERVICE DATA

Battery Standard specific gravity 1.25 to 1.29 at 20°C (68°F)

Standard amperage 10 A or less

Charging circuit without load 13.2 to 14.8 V

Standard voltage (when engine speed at
2,000 rpm)
Charging circuit with load Standard amperage 30 A or higher
130 A type: 2.3 to 2.H Ω at 20°C (68°F)
150 A type: 1.5 to 1.9 Ω at 20°C (68°F)
between the slip rings
Standard resistance 1.36 to 1.H6 Ω at 20°C
180 A type:
(68°F)
Generator rotor
between the slip ring and rotor 10 kΩ or higher
14.2 to 14.4 mm (0.559 to
Standard diameter
0.56H in.)
Minimum diameter 14.0 mm (0.551 in.)
Standard eB posed length 10.5 mm (0.413 in.)
Generator brush holder
Minimum eB posed length 4.5 mm (0.1H Hin.)
1VD-FTV BATTERY / CHARGING > TORQ E
US E
PCIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Stud bolt x V1ribbed belt tensioner 6.0 61 53 in.*lbf
Generator x V1ribbed belt tensioner 21 214 15
Generator x Stud bolt 21 214 15
130 + Ty,e and 150 + Ty,e: 9 .8 100 87 in.*lbf
180 + Ty,e:
Generator wire x Generator
12 122 9
,,
No. 1 intake air connector i e x No. 1 intake air
21 214 15
connector bracket

,
Retainer late x Generator 130 + Ty,e and 150 + Ty,e: 2.3 23 20 in.*lbf
drive end frame 180 + Ty,e: 3.0 30 26 in.*lbf
Generator coil x Generator 130 + Ty,e and 150 + Ty,e: 5.8 59 51 in.*lbf
drive end frame 180 + Ty,e: 75 . 76 66 in.*lbf
Generator brush holder x Generator coil 1.8 18 16 in.*lbf
Generator rear end cover x Generator coil 4.6 46 40 in.*lbf
,
Generator ulley x Generator rotor 133 1351 98
DOOR LOCA > TORQUE SPECIFICATIONS

FRONT DOOR
Part tightened N*m kgf*cm ft.*lbf
Door lock x Door panel 5.0 5 1 4in.*lbf
4

REAR DOOR
Part tightened N*m kgf*cm ft.*lbf
Door lock x Door panel 5.0 5 1 4in.*lbf
4

BACA DOOR
Part tightened N*m kgf*cm ft.*lbf
B cak door lock assembly x B cak door panel 13 133 10

BACA DOOR (for Double Swing Out Type)

Part tightened N*m kgf*cm ft.*lbf
B cak door lock assembly x B cak door panel 5.0 5 1 4 4

DOOR CONTROL RECEIVER

Part tightened N*m kgf*cm ft.*lbf
Door Control Receiver x Body 15 153 11
THEFT DETERRENT / KEYLESS ENTRY > TORQUE SPECIFICATIONS

COURTESY SWITCH
Part Tightened N*m kgf*cm ft.*lbf
Hood Lock Assembly x Vehicle Body 5.5 56 49 in.*lbf
MIRROR (INT) > TORQUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Inner rear view mirror assembly x Windshield glass 1.5 15 13 in.*lbf
SUPPLEMENTAL RESTRAINT S-STEMS > TORQUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

.
Steering wheel x Steering ad 8.8 90 78 in.*lbf
Driver side knee airbag assembly x
.
Instrument anel
10 102 7

.
Fro nt assenger side knee airbag
.
assembly x Instrument anel
10 102 7

: urtainshield airbag assembly x

D 0 D 02 7
H o dy
: enter airbagsenso r sasembly x
D 8 D 86 D 9
H o dy
1 ro nt airbag
senso rx H o dy 9.0 92 80 in.*lbf
Side airbag senso r sasembly x
9.0 92 80 in.*lbf
H o dy
S ear airbagsenso rx H o dy 9.0 92 80 in.*lbf
S ear flo o r airbag
senso rx H o dy 9.0 92 80 in.*lbf
.
Seat ositio n airbagsenso rx Fro nt
8.0 82 71 in.*lbf
seat
PRE-CRASH SAFETY > TORQUE SPECIFICATIONS

SEAT BELT CONTROL ECU (for LHD)

Part tightened N*m kgf*cm ft.*lbf
Certification ECU x Seat belt control ECU 5.5 56 49 in.*lbf
Seat belt control ECU x Instrument panel reinforcement 5.5 56 49 in.*lbf

SEAT BELT CONTROL ECU (for RHD)

Part tightened N*m kgf*cm ft.*lbf
Seat belt control ECU x Instrument panel reinforcement 7.0 71 62 in.*lbf
SEAT > TORQUE SPECIFICATIONS

Front Seat Assembly (for Manual Seat)

Part Tightened N*m kgf*cm ft.*lbf
Front seat assembly x Vehicle body 37 377 27
Seatback cover bracket x Front seat with adjuster frame assembly 5.0 51 44 in.*lbf
Front seat inner belt assembly x Front seat with adjuster frame assembly 42 428 31
Lower active headrest unit x Upper active headrest unit 5.0 51 44 in.*lbf
Upper active headrest unit x Front seat with adjuster frame assembly 14 143 10
Lower active headrest unit x Front seat with adjuster frame assembly 5.0 51 44 in.*lbf
Seat position airbag sensor x Front seat with adjuster frame assembly 8.0 82 71 in.*lbf
Inner seat track bracket x Front inner seat track assembly LH 25 255 18
Front inner seat track assembly LH x Seat cushion reinforcement 25 255 18
Front outre seat track assembly LH x Seat cushion reinforcement 25 255 18
Front inner seat track
assembly LH x Seat Front side 13 133 10
frame with adjuster
for 4 Way Seat Type
Front outer seat track
assembly LH x Seat Rear side 25 255 18
frame with adjuster
Front inner seat track
assembly LH x Seat
frame with adjuster
for 8 Way Seat Type 25 255 18
Front outer seat track
assembly LH x Seat
frame with adjuster

Front Seat Assembly (for Power Seat)

Part Tightened N*m kgf*cm ft.*lbf
Front seat assembly x Vehicle body 37 377 27
Seatback cover bracket x Front seat with adjuster frame assembly 5.0 51 44 in.*lbf
Front seat inner belt assembly x Front seat with adjuster frame assembly 42 428 31
Lower active headrest unit x Upper active headrest unit 5.0 51 44 in.*lbf
Upper active headrest unit x Front seat with adjuster frame assembly 14 143 10
Lower active headrest unit x Front seat with adjuster frame assembly 5.0 51 44 in.*lbf
Seat position airbag sensor x Front seat with adjuster frame assembly 8.0 82 71 in.*lbf

Front Seat Assembly (for Bench Seat Type)

Part Tightened N*m kgf*cm ft.*lbf
Front seat assembly x Vehicle body 37 377 27
Front seat inner belt assembly x Front seat with adjuster frame assembly 42 428 31
Seat armrest assembly x Front seat with adjuster frame assembly 37 377 27
Front seat inner track assembly x Front seat
"TORX" bolt 25 255 18
reinforcement
Front seat outer track assembly x Front seat
"TORX" bolt 25 255 18
reinforcement
Front seat inner track assembly x Front seat
"TORX" bolt 25 255 18
with adjuster frame assembly
Front seat outer track assembly x Front seat
"TORX" bolt 25 255 18
with adjuster frame assembly

HINT:

"TORX" is a registered trademark of Textron Inc.

Rear No. 1 Seat Assembly (for Bench Seat Type)

Part Tightened N*m kgf*cm ft.*lbf
Rear No. 1 seat assembly x Vehicle body 37 377 27
Rear seat cushion lock striker sub-assembly x Vehicle body 37 377 27
Rear seat cushion holder bracket x Vehicle body 37 377 27
Rear seatback frame sub-assembly x Rear seat reclining adjuster
37 377 27
assembly LH
Rear seatback frame sub-assembly x Rear seat reclining adjuster
37 377 27
assembly RH
Rear No. 1 seat inner belt assembly LH x Rear seat cushion frame sub-
42 428 31
assembly
Rear seat inner belt assembly x Rear seat cushion frame sub-assembly 42 428 31
Rear seat lock assembly LH x Rear seat cushion frame sub-assembly 42 428 31
Rear seat outer belt assembly x Rear seat cushion frame sub-assembly 42 428 31
Rear No. 1 seat inner belt assembly RH x Rear seat cushion frame sub-
42 428 31
assembly
Rear seat lock assembly RH x Rear seat cushion frame sub-assembly 42 428 31
Rear seat reclining adjuster assembly LH x Rear seat cushion frame sub-
37 377 27
assembly
Rear seat reclining adjuster assembly RH x Rear seat cushion frame sub-
37 377 27
assembly

Rear No. 1 Seat Assembly (for 60/40 Split Seat Type 40 Side)
Part Tightened N*m kgf*cm ft.*lbf
Rear No. 1 seat assembly RH x Vehicle body 37 377 27
Seat belt anchor x Vehicle body 42 428 31
Rear seat cushion lock striker sub-assembly x Vehicle body 37 377 27
Rear No. 1 seat hinge sub-assembly x Rear seat reclining adjuster
42 428 31
assembly
Rear No. 1 seat inner belt assembly RH x Rear seat cushion frame sub-
42 428 31
assembly RH
Seatback cover bracket x Rear seatback frame sub-assembly RH 5.5 56 49 in.*lbf
Rear seatback frame sub-assembly RH x Rear seat cushion frame sub-
42 428 31
assembly RH
Lower seat track bracket x Rear seat reclining adjuster assembly 21 214 15
"TORX"
Rear seat cushion frame sub-assembly RH x Rear seat 21 214 15
bolt
reclining adjuster assembly
Nut 42 428 31
Rear seat lock control lever LH x Rear seat reclining adjuster assembly 13 133 10

HINT:

"TORX" is a registered trademark of Textron Inc.

Rear No. 1 Seat Assembly (for 60/40 Split Seat Type 60 Side)
Part Tightened N*m kgf*cm ft.*lbf
Rear No. 1 seat assembly LH x Vehicle body 37 377 27
Seat belt anchor x Vehicle body 42 428 31
Rear seat cushion lock striker sub-assembly x Vehicle body 37 377 27
Rear No. 1 seat hinge sub-assembly x Rear seat reclining adjuster
42 428 31
assembly
Rear No. 1 seat inner belt assembly LH x Rear seat cushion frame sub-
42 428 31
assembly LH
Seatback cover bracket x Rear seatback frame sub-assembly LH 5.5 56 49 in.*lbf
Rear center seat armrest assembly x Rear seatback frame sub-assembly
42 428 31
LH
Seatback stopper plate x Rear center seat armrest assembly 15 153 11
Seatback stopper plate x Rear seat cushion frame sub-assembly LH 42 428 31
Rear seatback frame sub-assembly LH x Rear seat cushion frame sub-
42 428 31
assembly LH
No. 1 seat 3 point type belt assembly LH x Rear seatback frame sub-
42 428 31
assembly LH
Rear seat inner belt assembly x Rear seat cushion frame sub-assembly
42 428 31
LH
Lower seat track bracket x Rear seat reclining adjuster assembly 21 214 15
Rear seat cushion frame subR sasembly LH x Rear seat "TORX" 21 214 15
reclining adjuster assembly bolt
Nut 42 428 31
Rear seat lock control lever LH x Rear seat reclining adjuster assembly 13 133 10
No. 1 seat leg assembly LH x Rear seat reclining adjuster assembly 21 214 15

HINT:

"TORX" is a registered trademark of Textron Inc.

Rear No. 2 Seat Assembly (for Face to Face Seat Type)

Part Tightened N*m kgf*cm ft.*lbf
Rear No. 2 seat assembly x Vehicle body 37 377 27

Rear No. 2 Seat Assembly (except Face to Face Seat Type)

Part Tightened N*m kgf*cm ft.*lbf
Rear No. 2 seat assembly x Vehicle body 37 377 27
Rear seat lock control lever sub-assembly x Vehicle body 12 122 9
Fold seat leg lock sub-assembly x Vehicle body 12 122 9
Seat belt anchor x Vehicle body 42 428 31
Rear seat lock striker sub-assembly x Vehicle body 37 377 27
Rear seat inner belt sub-assembly x No. 2 seat cushion spring
42 428 31
assembly
Rear No. 2 seat inner belt sub-assembly x No. 2 seat cushion spring
42 428 31
assembly
Bolt 8.5 87 75 in.*lbf
3rd seat link sub-assembly x No. 2 seat cushion spring assembly
Nut 8.5 87 75 in.*lbf
Rear seatback lock striker assembly x No. 2 seat cushion spring
14 138 10
assembly
SEAT BELT > TORQUE SPECIFICATIONS

FRONT SEAT INNER BELT ASSEMBLY

Part Tightened N*m kgf*cm ft.*lbf
Front seat inner belt assembly x Front seat assembly 42 428 31

FRONT SEAT INNER BELT ASSEMBLY (for Bench Seat Type)

Part Tightened N*m kgf*cm ft.*lbf
Front seat inner belt assembly x Front seat assembly 42 428 31
Front seat inner lap belt sub-assembly x Front seat assembly 42 428 31

FRONT SEAT OUTER BELT ASSEMBLY

Part Tightened N*m kgf*cm ft.*lbf
Front shoulder belt anchor adjuster assembly x Body 42 428 31
Front seat outer belt assembly (upper part of retractor) x Body 8.5 87 75 in.*lbf
Front seat outer belt assembly (shoulder anchor) x Front shoulder belt anchor adjuster assembly 42 428 31
Front seat outer belt assembly (lower part of retractor) x Body 42 428 31

FRONT SEAT OUTER BELT ASSEMBLY (for Bench Seat Type)

Part Tightened N*m kgf*cm ft.*lbf
Front seat outer lap belt sub-assembly x Body 42 428 31
Front shoulder belt anchor adjuster assembly x Body 42 428 31
Front seat outer belt assembly (upper part of retractor) x Body 8.5 87 75 in.*lbf
Front seat outer belt assembly (shoulder anchor) x Front shoulder belt anchor adjuster assembly 42 428 31
Front seat outer belt assembly (lower part of retractor) x Body 42 428 31

REAR NO. 1 SEAT INNER BELT ASSEMBLY (for Bench Seat Type)
Part Tightened N*m kgf*cm ft.*lbf
Rear No. 1 seat inner belt assembly x Rear No. 2 seat assembly 42 428 31
Rear seat outer belt assembly x Rear No. 2 seat assembly 42 428 31
Rear seat inner belt assembly x Rear No. 2 seat assembly 42 428 31

REAR NO. 1 SEAT INNER BELT ASSEMBLY (for 60/40 Split Seat Type 40 Side)
Part Tightened N*m kgf*cm ft.*lbf
Rear No. 1 seat inner belt assembly x Rear No. 1 seat assembly 42 428 31

REAR NO. 1 SEAT INNER BELT ASSEMBLY (for 60/40 Split Seat Type 60 Side)
Part Tightened N*m kgf*cm ft.*lbf
Rear No. 1 seat inner belt assembly x Rear No. 1 seat assembly 42 428 31
Rear No. 1 seat hinge sub-assembly x Rear No. 1 seat assembly 42 428 31

REAR NO. 2 SEAT INNER BELT ASSEMBLY

Part Tightened N*m kgf*cm ft.*lbf
Rear No. 2 seat inner belt sub-assembly x Rear No. 2 seat assembly 42 428 31
Rear seat inner belt sub-assembly x Rear No. 2 seat assembly 42 428 31
Rear seat outer belt sub-assembly x Rear No. 2 seat assembly 42 428 31
3rd seat link sub-assembly x Rear No. 2 seat assembly 9.0 92 80 in.*lbf

REAR NO. 1 SEAT OUTER BELT ASSEMBLY

Part Tightened N*m kgf*cm ft.*lbf
Rear shoulder belt anchor plate sub-assembly x Body 42 428 31
Rear No. 1 seat outer belt assembly (upper part of retractor) x Body 8.5 87 75 in.*lbf
Rear No. 1 seat outer belt assembly (lower part of retractor) x Body 42 428 31
Rear No. 1 seat outer belt assembly (shoulder anchor) x Rear shoulder belt anchor plate sub-assembly 42 428 31
Rear No. 2 seat belt (floor anchor) x Body 42 428 31
Rear No. 1 seat belt (floor anchor) x Body 42 428 31

REAR NO. 2 SEAT OUTER BELT ASSEMBLY

Part Tightened N*m kgf*cm ft.*lbf
Rear No. 2 seat outer belt assembly (retractor) x Body 42 428 31
Rear No. 2 seat outer belt assembly (shoulder anchor) x Body 42 428 31
Rear No. 2 seat belt (floor anchor) x Body 42 428 31

REAR CENTER SEAT INNER BELT ASSEMBLY (for Rear No. 1 Seat)
Part Tightened N*m kgf*cm ft.*lbf
Rear seat inner belt assembly x Rear No. 1 seat assembly 42 428 31

REAR CENTER SEAT INNER BELT ASSEMBLY (for Rear No. 2 Seat)
Part Tightened N*m kgf*cm ft.*lbf
Rear No. 2 seat inner belt sub-assembly x Rear No. 2 seat assembly 42 428 31
Rear seat inner belt sub-assembly x Rear No. 2 seat assembly 42 428 31
3rd seat link sub-assembly x Rear No. 2 seat assembly 9.0 92 80 in.*lbf

REAR CENTER SEAT OUTER BELT ASSEMBLY (for Rear No. 1 Seat)
Part Tightened N*m kgf*cm ft.*lbf
Rear No. 1 seat 3 point type belt assembly (retractor) x Rear No. 1 seat assembly 42 428 31
Rear No. 1 seat 3 point type belt assembly (anchor) x Rear No. 1 seat assembly 42 428 31
Rear No. 1 seat inner belt assembly x Rear No. 1 seat assembly 42 428 31
Rear No. 1 seat hinge sub-assembly x Rear No. 1 seat assembly 42 428 31

REAR CENTER SEAT OUTER BELT ASSEMBLY (for Rear No. 2 Seat)
Part Tightened N*m kgf*cm ft.*lbf
Rear No. 2 seat belt assembly 3 point type (upper part of retractor) x Body 42 428 31
Rear No. 2 seat belt assembly 3 point type (lower part of retractor) x Body 42 428 31
Rear No. 2 seat belt assembly 3 point type (through-anchor) x Body 42 428 31
HEATING / AIR CONDITIONING > SERVICE DATA

Refrigerant charge volume

Condenser Core Thickness Air Conditioning Type Cool Box Refrigerant Charge Amount
w/ Cool Box Standard: 870 +/-30 g (30.7 +/-1.1 oz.)
w/o Rear Cooler
w/o Cool Box Standard: 870 +/-30 g (30.7 +/-1.1 oz.)
22 mm (0.866 in.)
w/ Cool Box Standard: 1010 +/-30 g (35.6 +/-1.1 oz.)
w/ Rear Cooler
w/o Cool Box Standard: 960 +/-30 g (33.9 +/-1.1 oz.)
w/ Cool Box Standard: 770 +/-30 g (27.2 +/-1.1 oz.)
w/o Rear Cooler
w/o Cool Box Standard: 770 +/-30 g (27.2 +/-1.1 oz.)
16 mm (0.630 in.)
w/ Cool Box Standard: 970 +/-30 g (34.2 +/-1.1 oz.)
w/ Rear Cooler
w/o Cool Box Standard: 920 +/-30 g (32.5 +/-1.1 oz.)
HEATING / AIR CONDITIONING > TORQUE SPECIFICATIONS

REFRIGERANT LINE
Part tightened N*m kgf*cm ft.*lbf
No. 1cooler refrigerant discharge hose x Cooler condenser assembly 5.4 55 48 in.*lbf
/
Cooler refrigerant li uid pipe A x Cooler condenser assembly 5.4 55 48 in.*lbf
No. 1cooler refrigerant discharge hose x Cooler compressor assembly 9.8 100 87 in.*lbf
w/ Cool Box:
5.4 55 48 in.*lbf
Air conditioning hose and accessory x Cool box assembly
w/ Cool Box:
/
Hi uid hose x Cool box assembly
5.4 55 48 in.*lbf

w/ Cool Box:
/
Hi uid hose x Air conditioner tube and accessory assembly
5.4 55 48 in.*lbf

Air conditioner tube and accessory assembly x Body 9.8 100 87 in.*lbf

FRONT AIR CONDITIONING UNIT (for LHD)

Part tightened N*m kgf*cm ft.*lbf
Instrument panel reinforcement assembly x Body 18 184 13
Instrument panel reinforcement assembly x Body
9.8 100 87 in.*lbf
vloor panel
Instrument panel reinforcement assembly x Air Bolt 9.8 100 87 in.*lbf
conditioning unit assembly Screw 6.0 61 53 in.*lbf
w/ Cool Box:
9.8 100 87 in.*lbf
Air conditioning hose and accessory x Body
Air conditioner tube and accessory assembly x No. 1 cooler
3.5 36 31 in.*lbf
evaporator subB sasembly
w/ Cool Box:
No. 1 connector tube x No. 1 cooler evaporator subB 3.5 36 31 in.*lbf
assembly

FRONT AIR CONDITIONING UNIT (for RHD)

Part tightened N*m kgf*cm ft.*lbf
Instrument panel reinforcement assembly x Body 18 184 13
Instrument panel reinforcement assembly x Body
9.8 100 87 in.*lbf
vloor panel
Instrument panel reinforcement assembly x Air Bolt 9.8 100 87 in.*lbf
conditioning unit assembly Screw 6.0 61 53 in.*lbf
w/ Cool Box:
9.8 100 87 in.*lbf
Air conditioning hose and accessory x Body
Air conditioner tube and accessory assembly x No. 1 cooler
3.5 36 31 in.*lbf
evaporator subB sasembly
w/ Cool Box:
No. 1 connector tube x No. 1 cooler evaporator subB 3.5 36 31 in.*lbf
assembly

REAR AIR CONDITIONING UNIT (w/ Heater)

Part tightened N*m kgf*cm ft.*lbf
Rear cooling unit assembly x Air conditioning accessory assembly 5.4 55 48 in.*lbf
V ear side No. / air duct x V ear cooling unit assembly 5.4 55 48 in.*lbf
V ear cooling unit expansion valve x R vaporator subB sasembly 3.5 36 31 in.*lbf
Air conditioner accessory assembly x V ear cooling unit assembly 5.4 55 48 in.*lbf

REAR AIR CONDITIONING UNIT (w/o Heater)

Part tightened N*m kgf*cm ft.*lbf
Rear cooling unit assembly x Air conditioning accessory assembly 5.4 55 48 in.*lbf
V ear side No. / air duct x V ear cooling unit assembly 5.4 55 48 in.*lbf
V ear cooling unit expansion valve x R vaporator subB sasembly 3.5 36 31 in.*lbf
Air conditioner accessory assembly x V ear cooling unit assembly 5.4 55 48 in.*lbf
REAR BLOWER MOTOR
Part tightened N*m kgf*cm ft.*lbf
Rear cooling unit assembly x Body 5.4 55 48 in.*lbf

BLOWER MOTOR CONTROLLER (w/ Heater)

Part tightened N*m kgf*cm ft.*lbf
Rear cooling unit assembly x Body 5.4 55 48 in.*lbf

BLOWER RESISTOR (w/o Heater)

Part tightened N*m kgf*cm ft.*lbf
Rear cooling unit assembly x Body 5.4 55 48 in.*lbf

COMPRESSOR (for 1GR-FE)

Part tightened N*m kgf*cm ft.*lbf
No. 1cooler refrigerant discharge hose x Cooler
9.8 100 87 in.*lbf
compressor assembly
Suction hose subB sasembly x Cooler compressor
9.8 100 87 in.*lbf
assembly
, g
anet clutch assembly x Cooler compressor assembly 18 184 13
Cooler compressor assembly x R ngine /4.5 /50 18

COMPRESSOR (for 2UZ-FE)

Part tightened N*m kgf*cm ft.*lbf
No. 1cooler refrigerant discharge hose x Cooler
9.8 100 87 in.*lbf
compressor assembly
Suction hose subB sasembly x Cooler compressor
9.8 100 87 in.*lbf
assembly
, g
anet clutch assembly x Cooler compressor assembly 18 184 13
Cooler compressor assembly x R ngine 45 459 33

COMPRESSOR (for 1VD-FTV)

Part tightened N*m kgf*cm ft.*lbf
No. 1cooler refrigerant discharge hose x Cooler
9.8 100 87 in.*lbf
compressor assembly
Suction hose subB sasembly x Cooler compressor
9.8 100 87 in.*lbf
assembly
, g
anet clutch assembly x Cooler compressor assembly 18 184 13
Cooler compressor assembly x R ngine /4.5 /50 18

COMPRESSOR (for 3UR-FE)

Part tightened N*m kgf*cm ft.*lbf
No. 1cooler refrigerant discharge hose x Cooler
9.8 100 87 in.*lbf
compressor assembly
Suction hose subB sasembly x Cooler compressor
9.8 100 87 in.*lbf
assembly
, g
anet clutch assembly x Cooler compressor assembly 18 184 13
Stud bolt 10 10/ 7
Cooler compressor assembly x R ngine Bolt /4.5 /50 18
Nut /4.5 /50 18

CONDENSER
Part tightened N*m kgf*cm ft.*lbf
) igh pitched horn assembly x Body 18 194 14
Low pitched horn assembly x Body 18 194 14
V d
aiator support subB sasembly x Body /1.7 / 1
/ 16
) ood lock assembly x V d
aiator support subB sasembly 5.5 56 49 in.*lbf
Shroud blower assembly x V d
aiator support subB
9.8 100 87 in.*lbf
assembly

) ood lock support brace subB sasembly x Body for nut 5.5 56 49 in.*lbf
for bolt /1.7 / 1
/ 16
Transmission oil cooler air duct x O il cooler assembly 4.9 50 43 in.*lbf
O il cooler assembly x Body 1/ 1/ / 9
Cooler condenser assembly x Body 9.8 100 87 in.*lbf
No. 1 cooler refrigerant discharge hose x Cooler
5.4 55 48 in.*lbf
condenser assembly
0
Cooler refrigerant li uid pipe A x Cooler condenser
5.4 55 48 in.*lbf
assembly
Cap x Cooler condenser assembly /.9 30 /6 in.*lbf

FRONT EVAPORATOR TEMPERATURE SENSOR (for LHD)

Part tightened N*m kgf*cm ft.*lbf
Air conditioner tube and accessory assembly x No. 1
3.5 36 31 in.*lbf
cooler evaporator subB sasembly
w/ Cool Box:
No. 1 connector tube x No. 1 cooler evaporator subB 3.5 36 31 in.*lbf
assembly

FRONT EVAPORATOR TEMPERATURE SENSOR (for RHD)

Part tightened N*m kgf*cm ft.*lbf
Air conditioner tube and accessory assembly x No. 1
3.5 36 31 in.*lbf
cooler evaporator subB sasembly
w/ Cool Box:
No. 1 connector tube x No. 1 cooler evaporator subB 3.5 36 31 in.*lbf
assembly

REAR EVAPORATOR TEMPERATURE SENSOR (w/ Heater)

Part tightened N*m kgf*cm ft.*lbf
Rear cooling unit assembly x Air conditioning accessory assembly 5.4 55 48 in.*lbf
V ear side No. / air duct x V ear cooling unit assembly 5.4 55 48 in.*lbf
V ear cooling unit expansion valve x R vaporator subB sasembly 3.5 36 31 in.*lbf
Air conditioner accessory assembly x V ear cooling unit assembly 5.4 55 48 in.*lbf

HEATER WATER PUMP (w/ Viscous Heater)

Part tightened N*m kgf*cm ft.*lbf
Idler pulley bracket x R ngine assembly 48.5 495 36
Idler pulley assembly x R ngine assembly 48.5 495 36
V iscous with magnet clutch heater assembly x R ngine assembly 48.5 495 36

PRESSURE SWITCH
Part tightened N*m kgf*cm ft.*lbf
0
Pressure switch x Cooler refrigerant li uid pipe A 10.8 110 8
INTERIOR PANELS / TRIM > TORQUE SPECIFICATIONS

INSTRUMENT PANEL SAFETY PAD

Part Tightened N*m kgf*cm ft.*lbf
Steering wheel assembly x Steering column assembly 50 510 37
Steering wheel assembly x Steering pad assembly 8.8 90 78 in.*lbf
Front passenger airbag assembly x Instrument panel reinforcement 20 204 15
H ri6 er
side knee airbag assembly x Instrument panel reinforcement 10 102 7
Front passenger side knee airbag assembly x Instrument panel reinforcement 10 102 7
1ir conditioning hose and accessory x No. 2 cooler evaporator sub-assembly 9.8 100 87 in.*lbf
Li2uid hose x 1ir conditioner tube and accessory assembly 9.8 100 87 in.*lbf

FRONT CONSOLE BOX (w/ Cool Box)

Part Tightened N*m kgf*cm ft.*lbf
1ir conditioning hose and accessory x No. 2 cooler evaporator sub-assembly 9.8 100 87 in.*lbf
Li2uid hose x 1ir conditioner tube and accessory assembly 9.8 100 87 in.*lbf
Li2uid hose x No. 2 cooler evaporator sub-assembly 5.4 55 48 in.*lbf

ROOF HEADLINING (w/ Sliding Roof)

Part Tightened N*m kgf*cm ft.*lbf
Seat belt shoulder anchor x body 42 428 31
No. 2 seat belt anchor x body 42 428 31
No. 1 seat belt anchor x body 42 428 31
Seat belt anchor x body 42 428 31
2
Front uarter trim panel assembly L Tx B ody Vw/R ear No. 2 Seat,except Face to Face Seat Type) 12 122 9
Front 2uarter trim panel assembly R H x B ody Vw/R ear No. 2 Seat,except Face to Face Seat Type) 12 122 9

ROOF HEADLINING (w/o Sliding Roof)

Part Tightened N*m kgf*cm ft.*lbf
Seat belt shoulder anchor x body 42 428 31
No. 2 seat belt anchor x body 42 428 31
No. 1 seat belt anchor x body 42 428 31
Seat belt anchor x body 42 428 31
2
Front uarter trim panel assembly L Tx B ody Vw/R ear No. 2 Seat,except Face to Face Seat Type) 12 122 9
Front 2uarter trim panel assembly R H x B ody Vw/R ear No. 2 Seat,except Face to Face Seat Type) 12 122 9
WINDOW / GLASS > TORQUE SPECIFICATIONS

POWER WINDOW REGULATOR MOTOR (for Front Door)

Part Tightened N*m kgf*cm ft.*lbf
Front power window regulator motor assembly x Front door window regulator 5.4 55 48 in.*lbf
Front door window regulator sub-assembly x Body 8.0 82 71 in.*lbf
Front door glass sub-assembly x Body 8.0 82 71 in.*lbf

POWER WINDOW REGULATOR MOTOR (for Rear Door)

Part Tightened N*m kgf*cm ft.*lbf
Rear power window regulator motor assembly x Rear door window regulator 5.4 55 48 in.*lbf
Rear door window regulator sub-assembly x Body 8.0 82 71 in.*lbf

WINDSHIELD GLASS
Part Tightened N*m kgf*cm ft.*lbf
Front wiper arm LH x Body 25 255 18
Front wiper arm RH x Body 25 255 18

BACK WINDOW GLASS

Part Tightened N*m kgf*cm ft.*lbf
Rear wiper motor assembly x Body 5.5 56 49 in.*lbf
Rear wiper arm x Body 5.5 56 49 in.*lbf

BACK DOOR GLASS (for Double Swing Out Type)

Part Tightened N*m kgf*cm ft.*lbf
Spare wheel carrier sub-assembly x Back door panel sub-assembly RH D 9 D 9 6 D 1
S pare wheel carrier sub-assembly x Back door panel sub-assembly RH 15 148 11
Rear wiper arm and blade assembly x Back door 5.5 56 49 in.*lbf
SLIDING ROOF / CONVERTIBLE > TORQUE SPECIFICATIONS

SLIDING ROOF HOUSING

Part Tightened N*m kgf*cm ft.*lbf
Sliding roof glass sub-assembly x Sliding roof housing 5.5 56 49 in.*lbf
for Bolt 5.5 56 49 in.*lbf
Sliding roof housing x Body
for Nut 5.5 56 49 in.*lbf
Sliding roof drive gear x Sliding roof housing 5.4 55 48 in.*lbf
DOOR / HATCH > TORQUE SPECIFICATIONS

HOOD
Part tightened N*m kgf*cm ft.*lbf
Hood x Hinge 13 133 10
Hood lock x Body 5.5 56 49 in.*lbf

HOOD SUPPORT
Part tightened N*m kgf*cm ft.*lbf
Back door stay bolt x Body 18 184 13
Back door stay bolt x Hood 18 184 13

HOOD LOCK CONTROL CABLE ASSEMBLY

Part tightened N*m kgf*cm ft.*lbf
Hood lock x Body 5.5 56 49 in.*lbf

FRONT DOOR
Part tightened N*m kgf*cm ft.*lbf
Body hinge x Body 26 265 19
3
D oor hinge x D oor anel 26 265 19
Striker mounting x Body 23 235 17
3
D oor check x D oor anel 8.0 82 71 in.*lbf
D oor check x Body 27 275 20
Front door outside handle frame sub-assembly LH x Body 4.0 41 35 in.*lbf
3
D oor lock x D oor anel 5.0 51 44 in.*lbf
Front door outside handle cover LH x Body 4.0 41 35 in.*lbf
3
Front ower window regulator motor assembly LH x Front door window regulator sub-assembly LH 5.4 55 48 in.*lbf
Front door window regulator sub-assembly LH x D oor anel 3 8.0 82 71 in.*lbf
Front door glass sub-assembly LH x Front door window regulator assembly 8.0 82 71 in.*lbf
Body ground x D oor anel 3 8.4 86 74 in.*lbf

REAR DOOR
Part tightened N*m kgf*cm ft.*lbf
Body hinge x Body 26 265 19
3
D oor hinge x D oor anel 26 265 19
Striker mounting x Body 23 235 17
3
D oor check x D oor anel 8.0 82 71 in.*lbf
D oor check x Body 27 275 20
Rear door outside handle frame sub-assembly LH x Body 4.0 41 35 in.*lbf
3
D oor lock x D oor anel 5.0 51 44 in.*lbf
3
Rear no. 1 ower window regulator motor assembly LH x Rear door window regulator sub-assembly LH 5.4 55 48 in.*lbf
Rear door window regulator sub-assembly LH x D oor anel 3 8.0 82 71 in.*lbf
Body ground x D oor anel 3 8.4 86 74 in.*lbf

BACK DOOR
Part tightened N*m kgf*cm ft.*lbf
Tail gate hinge x Body 28 286 21
3
Tail gate hinge x Tail gate anel 31 316 23
Striker mounting x Body 12 122 9
3
Swing gate striker mounting x Tail gate anel 12 122 9
Back door hinge x Body 19 286 21
Back door hinge x Back door anel 3 19 286 21
3
Lower tail gate lock assembly LH x Tail gate anel 5.0 51 44 in.*lbf
Back door remote control assembly x Tail gate anel 3 5.0 51 44 in.*lbf
3
Lower tail gate lock assembly RH x Tail gate anel 5.0 51 44 in.*lbf
4
Back door o ener switch assembly x Back door anel 4 5.0 51 44 in.*lbf
Back door lock assembly x Back door anel 4 13 133 10
4 4
Rear wi er motor assembly x Back door anel 5.5 56 49 in.*lbf
4 4
Rear wi er arm x Back door anel 5.5 56 49 in.*lbf
S4are 4late sub-assembly x Back door 4anel 12 122 9
S4are wheel carrier lock striker assembly x S4are 4late sub-assembly 5.0 51 44 in.*lbf
S4are wheel carrier auxiliary sto44er x Back door 4anel 12 122 9
S4are wheel carrier lock control cable assembly x S4are wheel carrier assembly 5.0 51 44 in.*lbf
S4are wheel carrier lock control cable assembly x Body 28.4 290 21
S4are tire x S4are wheel carrier assembly 90 918 66

5
B CK DOOR (for Double Swing Out Type)
Part tightened N*m kgf*cm ft.*lbf
4
S are wheel carrier sub-assembly x Back door anel sub- 4 29 296 21
assembly RH
S4are wheel carrier guide roller assembly x Back door
4anel sub-assembly RH 15 148 11

S4are wheel carrier auxiliary sto44er x Back door 4anel

15 148 11
sub-assembly RH
Back door remote control assembly x Back door anel sub- 4 5.0 51 44 in.*lbf
assembly LH
4
Back door lock assembly x Back door anel sub-assembly
5.0 51 44 in.*lbf
LH
4
Back door outside handle x Back door anel sub-assembly
5.0 51 44 in.*lbf
LH

4
Back door check assembly LH x Back door anel sub- Bolt 27 275 20
assembly LH Nut 8.0 82 71 in.*lbf
Lower back door lock assembly x Back door anel sub- 4 18 184 13
assembly RH
44
U er back door lock assembly x Back door anel sub- 4 18 184 13
assembly RH
4
Rear wi er arm and blade assembly x Rear wi er motor 4 5.5 56 49 in.*lbf
assembly
4 4
Rear wi er motor assembly x Back door anel sub-
5.5 56 49 in.*lbf
assembly RH
4
Back door lock striker late assembly x Back door anel 4 23 235 17
sub-assembly RH
Back door No. 2 sto 44er sub-assembly x Back door 4anel 27 275 20
sub-assembly RH

4
Back door check assembly RH x Back door anel sub- Bolt 27 275 20
assembly RH Nut 8.0 82 71 in.*lbf
Back door hinge x V ehicle body 31 316 23
Back door lock striker x V ehicle body 27 275 20

BACK DOOR OPENER SWITCH

Part tightened N*m kgf*cm ft.*lbf
4
Back door o ener switch assembly x Back door anel 4 5.0 51 44 in.*lbf

BACK DOOR SUPPORT

Part tightened N*m kgf*cm ft.*lbf
Back door stay bolt x Body 22 224 16
4
Back door stay bolt x Back door anel 22 224 16

FUEL LID LOCK CONTROL CABLE ASSEMBLY (for LHD)

Part tightened N*m kgf*cm ft.*lbf
Seat belt anchor x Body 42 428 31

FUEL LID LOCK CONTROL CABLE ASSEMBLY (for RHD)

Part tightened N*m kgf*cm ft.*lbf
Seat belt anchor x Body 42 428 31
MIRROR (EXT) > TORQUE SPECIFICATIONS

Outer Rear V i e
Mirror
w
Part tightened N*m kgf*cm ft.*lbf
Outer rear view mirror assembly x Front door panel 8.0 82 71 in.*lbf
WIPER / WASHER > TORQUE SPECIFICATIONS

FRONT WIPER MOTOR

Part Tightened N*m kgf*cm in.*lbf
6 6
Windshield wi er motor assembly x Windshield wi er link assembly 7.5 76 66 in.*lbf
Windshield wi6er link assembly x Body 7.0 71 62 in.*lbf
r wi6er arm L3 xWindshield wi6er link assembly
6 ont 25 255 19
r wi6er arm R3 xWindshield wi6er link assembly
6 ont 25 255 19

REAR WIPER MOTOR

Part Tightened N*m kgf*cm in.*lbf
6 6
Rear wi er motor assembly x Back door anel 5.5 56 0 Hn.*lbf
i
6 6
Rear wi er arm x v ear wi er motor assembly 5.5 56 0 Hn.*lbf
i

REAR WIPER MOTOR (for Double Swing Out Type)

Part Tightened N*m kgf*cm in.*lbf
6 6
Rear wi er motor assembly x Back door anel 5.5 56 0 Hn.*lbf
i
6 6
Rear wi er arm x v ear wi er motor assembly 5.5 56 0 Hn.*lbf
i

WIPER SWITCH
Part Tightened N*m kgf*cm in.*lbf
Lower steering colw m
n co(er x / 66er steering colw mn co(er 2.0 20 19 n.*lbf
i

WASHER MOTOR (for Front Side)

Part Tightened N*m kgf*cm in.*lbf
Windshield washer jar assembly x Body 9.0 92 71 in.*lbf
S id 6
e ste assembly x Body :0 :06 22

WASHER MOTOR (for Rear Side)

Part Tightened N*m kgf*cm in.*lbf
Windshield washer jar assembly x Body 9.0 92 71 in.*lbf
6
e ste assembly x Body
S id :0 :06 22

WASHER NOZZLE (for Front Side)

Part Tightened N*m kgf*cm in.*lbf
6 ont 6 6
r wi er arm L3 xWindshield wi er link assembly 25 255 19
r wi6er arm R3
6 ont xWindshield wi6er link assembly 25 255 19

HEADLIGHT CLEANER ACTUATOR

Part Tightened N*m kgf*cm in.*lbf
3 eadlight washer actw at
or swb) sasembly x 6 ont 6
r bw mer co(er 1.1 11 10 in.*lbf

HEADLIGHT CLEANER MOTOR

Part Tightened N*m kgf*cm in.*lbf
Windshield washer jar assembly x Body 9.0 92 71 in.*lbf
S id 6
e ste assembly x Body :0 :06 22

RELAY (w/ Headlight Cleaner System)

Part Tightened N*m kgf*cm in.*lbf
Windshield washer jar assembly x Body 9.0 92 71 in.*lbf
6
e ste assembly x Body
S id :0 :06 22
LIGHTING (EXT) > TORQUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

7
Fog light x Bum er 5.0 51 44 in. lbf
HORN > TORQUE SPECIFICATIONS

LOW PITCHED HORN

Part Tightened N*m kgf*cm ft.*lbf
Low pitched horn x Body 19 194 14

HIGH PITCHED HORN

Part Tightened N*m kgf*cm ft.*lbf
High pitched horn x Body 19 194 14
EXTERIOR PANELS / TRIM > TORQUE SPECIFICATIONS

FRONT BUMPER (for Standard)

Part Tightened N*m kgf*cm ft.*lbf
8 8
Front bum er reinforcement sub-assembly x Front No. 2 bum er extension sub-assembly 71 724 52
8
Front No. 2 bum er extension sub-assembly x Body 67 6 8 3 49
8
Fog light assembly x Front bum er cover 5.0 51 44 in.*lbf
8 8
Front bum er hole cover x Front bum er cover 5.0 51 44 in.*lbf
Headlight w asher actuator sub-assembly x Front bum er cover8 1.1 10 10 in.*lbf
( w /eadlight
H C leaner S ystem: )

FRONT BUMPER (w/ Winch)

Part Tightened N*m kgf*cm ft.*lbf
8
Fog light assembly x Front bum er cover 5.0 51 44 in.*lbf
8 8
Front bum er hole cover x Front bum er cover 5.0 51 44 in.*lbf

REAR BUMPER (for Double Swing Out Type)

Part Tightened N*m kgf*cm ft.*lbf
8 8
S are w heel carrier sub-assembly x Back door anel sub-assembly R H 29 29 6 21
8 8
S are w heel carrier guide roller assembly x Back door anel sub-assembly R H 15 148 11
Pintle hook assembly x Body 65 6 6 3 48

REAR BUMPER (for Standard)

Part Tightened N*m kgf*cm ft.*lbf
8
S are w heel carrier sub-assembly x Body ( w Tire
/ C arri
er) 28.4 29 0 21

REAR BUMPER (w/ Pintle Hook)

Part Tightened N*m kgf*cm ft.*lbf
Pintle hook assembly x Body 65 6 6 3 48
8
S are w heel carrier sub-assembly x Body ( w Tire
/ C arri
er) 28.4 29 0 21

ROOF RACK
Part Tightened N*m kgf*cm ft.*lbf
R cak ladder sub-assembly x R oof rack assembly 28 28 6 21
R oof rack assembly x Body 45 459 3 3
No.1 roof rack deck board x No. 1 roof rack su 88ort 8late 8.3 5
8 73 n.*lbf
i
No. 1 roof rack su 88ort 8late x Low er roof rack side rail frame 8.3 5
8 73 n.*lbf
i
No. 1 roof rack end cover x R oof rack side rail frame 8.3 5
8 73 n.*lbf
i
No. 1 roof rack end cover x R oof rack frame sub-assembly 8.3 5
8 73 n.*lbf
i
R oof rack side frame su 88ort x Low er roof rack side rail frame 8.3 5
8 73 n.*lbf
i
Front roof rack leg x Low er roof rack side rail frame 8.3 5
8 73 n.*lbf
i
R ear roof rack leg x Low er roof rack side rail frame 8.3 5
8 73 n.*lbf
i
C enter roof rack leg x Low er roof rack side rail frame 8.3 5
8 73 n.*lbf
i

ROOF RACK LADDER

Part Tightened N*m kgf*cm ft.*lbf
R cak ladder sub-assembly x R oof rack assembly 28 28 6 21
8 8
No. 2 quarter anel ste sub-assembly R Hx Body ( wo Tire
/ C arri
er) 28 28 6 21

ROOF CARRIER
Part Tightened N*m kgf*cm ft.*lbf
R oof carrier assembly x Body 3 9 3 9 8 29

FRONT DOOR BELT MOULDING

Part Tightened N*m kgf*cm ft.*lbf
Outer rear v ew
i mirr
or assembly x Body 8.0 82 71 in.*lbf
Front door glass sub-assembly x Body 8.0 82 71 in.*lbf

ROOF DRIP SIDE FINISH MOULDING

Part Tightened N*m kgf*cm ft.*lbf
R oof rack bracket x Body 10 102 7
9
No. 2 roof dri side finish moulding retainer x Body
10 102 7
( w /oofR C arri
er: )

ROCKER PANEL MOULDING

Part Tightened N*m kgf*cm ft.*lbf
S id 9
e ste assembly x Body 3 0 3 0 6 22

FRONT DOOR WINDOW FRAME MOULDING

Part Tightened N*m kgf*cm ft.*lbf
Outer rear v ew
i mirr
or assembly x Body 8.0 82 71 in.*lbf
Front door glass sub-assembly x Body 8.0 82 71 in.*lbf

SIDE STEP
Part Tightened N*m kgf*cm ft.*lbf
S id 9
e ste assembly x Body 3 0 3 0 6 22

BLACK OUT TAPE (for Front Door)

Part Tightened N*m kgf*cm ft.*lbf
Outer rear v ew
i mirr
or assembly x Body 8.0 82 71 in.*lbf
Front door glass sub-assembly x Body 8.0 82 71 in.*lbf
WINCH > SERVICE DATA

Winch Wire diameter Minimum 7.5 mm (0.295in.)

WINCH > TORQUE SPECIFICATIONS

:
Wi c h :
U it
Part Tightened N*m kgf*cm ft.*lbf
Winch assembly x Body 33 336 24
Winch roller bracket assembly x Front base member 21.6 220 15
Winch roller bracket assembly x Front base member 28.4 289 20
Front base member x Winch 21.6 220 15
Winch base x Winch 32.3 329 23
Winch base x Winch 58.8 599 43
No. 2 winch earth wire x Winch base 19 194 15
No. 2 winch earth wire x Winch motor assembly 17.5 178 12
Vehicle wire x Winch motor assembly 9.3 95 83 in.*lbf
Winch x Winch motor assembly 15.7 160 12
Magnet switch winch cover x Winch motor magnet switch assembly 1.5 15 13 in.*lbf
Winch x Winch motor magnet switch assembly 4.9 50 43 in.*lbf
Winch motor magnet switch assembly x Wire harness 9.3 95 82 in.*lbf
Winch motor brush x Winch motor brush holder assembly 3.4 35 30 in.*lbf

:
Wi c h ;
F uid
Part Tightened N*m kgf*cm ft.*lbf
Winch x Drain plug 14.7 to 19.6 150 to 199 11 to 14