SS–1 SERVICE SPECIFICATIONS – STANDARD BOLT STANDARD BOLT HOW TO DETERMINE BOLT STRENGTH Bolt Type Hexagon Head Bolt Stud Bolt Normal Recess Bolt Weld Bolt Class Deep Recess Bolt No Mark No Mark No Mark 4T 5T w/ Washer w/ Washer 6T 7T 8T 9T 10T 11T SS SS–2 SERVICE SPECIFICATIONS – STANDARD BOLT SPECIFIED TORQUE FOR STANDARD BOLTS Class 4T SS 5T 6T 7T 8T 9T 10T 11T Diameter (mm) Pitch (mm) Specified torque N*m kgf*cm ft.*lbf N*m kgf*cm ft.*lbf 6 1 5 55 48 in.*lbf 6 60 52 in.*lbf 8 1.25 12.5 130 9 14 145 10 10 1.25 26 260 19 29 290 21 12 1.25 47 480 35 53 540 39 14 1.5 74 760 55 84 850 61 Hexagon head bolt Hexagon flange bolt 16 1.5 115 1,150 83 - - - 6 1 6.5 65 56 in.*lbf 7.5 75 65 in.*lbf 8 1.25 15.5 160 12 17.5 175 13 10 1.25 32 330 24 36 360 26 12 1.25 59 600 43 65 670 48 14 1.5 91 930 67 100 1,050 76 16 1.5 140 1,400 101 - - - 6 1 8 80 69 in.*lbf 9 90 78 in.*lbf 8 1.25 19 195 14 21 210 15 10 1.25 39 400 29 44 440 32 12 1.25 71 730 53 80 810 59 14 1.5 110 1,100 80 125 1,250 90 16 1.5 170 1,750 127 - - - 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 12 1.25 95 970 70 105 1,050 76 14 1.5 145 1,500 108 165 1,700 123 16 1.5 230 2,300 166 - - - 8 1.25 29 300 22 33 330 24 10 1.25 61 620 45 68 690 50 12 1.25 110 1,100 80 120 1,250 90 8 1.25 34 340 25 37 380 27 10 1.25 70 710 51 78 790 57 12 1.25 125 1,300 94 140 1,450 105 8 1.25 38 390 28 42 430 31 10 1.25 78 800 58 88 890 64 12 1.25 140 1,450 105 155 1,600 116 8 1.25 42 430 31 47 480 35 10 1.25 87 890 64 97 990 72 12 1.25 155 1,600 116 175 1,800 130 SS–3 SERVICE SPECIFICATIONS – STANDARD BOLT HOW TO DETERMINE NUT STRENGTH Nut Type Present Standard Hexagon Nut Old Standard Hexagon Nut Cold Forging Nut Class Cutting Processed Nut No Mark No Mark (w/ Washer) 4N No Mark (w/ Washer) No Mark 5N (4T) 6N 7N (5T) 8N No Mark 10N (7T) 11N 12N HINT: • *: Nut with 1 or more marks on one side surface of the nut. • Use the nut with the same number of the nut strength classification or greater than the bolt strength classification number when tightening parts with a bolt and nut. Example: • Bolt = 4T • Nut = 4N or more SS SS–4 SERVICE SPECIFICATIONS – 1NZ-FXE ENGINE CONTROL SYSTEM 1NZ-FXE ENGINE CONTROL SYSTEM SERVICE DATA SS Camshaft timing oil control valve - Standard resistance Terminals 1 - 2 at 20°C (68°F) - 6.9 to 7.9 Ω Camshaft position sensor - Standard resistance Terminals 1 - 2 Cold The terms "Cold" and "Hot" refer to the temperature of the sensor. "Cold" means approximately -10 to 50°C (14 to 122°F). "Hot" means approximately 50 to 100°C (122 to 212°F). 1,630 to 2,740 Ω The terms "Cold" and "Hot" refer to the temperature of the sensor. "Cold" means approximately -10 to 50°C (14 to 122°F). "Hot" means approximately 50 to 100°C (122 to 212°F). 985 to 1,600 Ω Terminals 1 - 2 Hot Crankshaft position sensor - Standard resistance Terminals 1 - 2 Cold Terminals 1 - 2 Hot 2,065 to 3,225 Ω 1,265 to 1,890 Ω Engine coolant temperature sensor - Standard resistance Terminals 1 - 2 at 20°C (68°F) - 2.32 to 2.59 Ω Terminals 1 - 2 at 80°C (176°F) - 0.310 to 0.326 Ω Throttle body (throttle control motor) - Standard resistance Terminals 1 - 2 at 25 °C (77°F) - 50 MΩ or more Throttle body (throttle position sensor) - Standard resistance Terminals 1 - 4 at 25 °C (77°F) - 1.2 to 3.5 kΩ Knock sensor - Standard resistance Terminals 1 - 2 at 20°C (68°F) - 120 to 280 kΩ EFI relay - Standard resistance Terminals 3I-5 - 3I-8 - 10 kΩor higher Terminals 3I-5 - 3I-8 When battery voltage is applied to terminals 3I-6 and 3I-7) Below 1 Ω Terminals 3G-5 - 3G-8 - 10 kΩ or higher Terminals 3G-5 - 3G-8 When battery voltage is applied to terminals 3G-6 and 3G-7) Below 1 Ω Circuit opening relay - Standard resistance SERVICE SPECIFICATIONS – 1NZ-FXE ENGINE CONTROL SYSTEM SS–5 TORQUE SPECIFICATIONS Camshaft timing oil control valve Part Tightened N*m kgf*cm ft.*lbf Camshaft timing oil control valve x Cylinder head 7.5 76 66 in.*lbf Camshaft position sensor Part Tightened N*m kgf*cm ft.*lbf Camshaft position sensor x Cylinder head 7.5 76 66 in.*lbf Crankshaft position sensor Part Tightened N*m kgf*cm ft.*lbf Crankshaft position sensor x Cylinder block 7.5 76 66 in.*lbf Engine coolant temperature sensor Part Tightened N*m kgf*cm ft.*lbf Engine coolant temperature sensor x Cylinder head 20 204 15 Throttle body Part Tightened N*m kgf*cm ft.*lbf Throttle with motor body x Intake manifold 20 204 15 Air cleaner x Cylinder head cover 7.0 71 62 in.*lbf Air cleaner x Throttle with motor 3.0 31 27 in.*lbf No. 1 air cleaner inlet x Air cleaner 3.0 31 27 in.*lbf Part Tightened N*m kgf*cm ft.*lbf knock sensor x Cylinder block 20 204 15 Intake manifold x Cylinder head 20 204 15 Harness clamp x Intake manifold 9.0 92 80 in.*lbf Oil dipstick guide x Intake manifold 9.0 92 80 in.*lbf Knock sensor ECM Part Tightened N*m kgf*cm ft.*lbf ECM x Hybrid vehicle control ECU 3.0 31 80 in.*lbf ECM x Body 3.0 31 80 in.*lbf SS SS–6 SERVICE SPECIFICATIONS – 1NZ-FXE ENGINE MECHANICAL 1NZ-FXE ENGINE MECHANICAL SERVICE DATA Drive belt SS New drive belt deflection : Pressing force: 98 N (10 kgf, 22lbf) 9.0 to 12.0 mm (0.35 to 0.47 in.) Used drive belt deflection : Pressing force: 98 N (10 kgf, 22lbf) 11.0 to 15.0 mm (0.43 to 0.59 in.) New drive belt tension 392 to 588 N (40 to 60 kgf, 88 to 132 lb) Used drive belt tension 196 to 392 N (20 to 40 kgf, 44 to 88 lb) Ignition timing 8 to 12° BTDC Idle speed 950 to 1050 rpm Compression Valve clearance (cold) Standard pressure 882 kPa (9.0 kgf/cm2 128 psi) Minimum pressure 686 kPa (7.0 kgf/cm2 99 psi) Difference between each cylinder Within 98 kPa (1.0kgf/cm2 14 psi) Intake 0.17 to 0.23 mm (0.007 to 0.009 in.) Exhaust 0.27 to 0.33 mm (0.011 to 0.013 in.) Chain Maximum elongation chain length at 16 links 124.2 mm (4.890 in.) Camshaft timing gear Minimum diameter (w / chain) 96.2 mm (3.787 in.) Camshaft timing sprocket Minimum diameter (w / chain) 96.2 mm (3.787 in.) Chain tensioner slipper Maximum wear 1.0 mm (0.039 in.) Chain vibration damper Maximum wear 1.0 mm (0.039 in.) Cylinder head bolt Standard length 142.8 to 144.2 mm (5.622 to 5.677 in.) Maximum length 147.1 mm (5.791 in.) Maximum Cylinder block side warpage 0.05 mm (0.0020 in.) Cylinder head Intake valve Exhaust valve Valve spring Intake manifold side warpage 0.10 mm (0.0039 in.) Exhaust manifold side warpage 0.10 mm (0.0039 in.) Camshaft bearing cap setting ring pin protrusion height 8.5 to 9.5 mm (0.335 to 0.374 in.) Standard overall length 89.25 mm (3.5138 in.) Minimum overall length 88.95 mm (3.5020 in.) Standard valve stem diameter 4.970 to 4.985 mm (0.1957 to 0.1963 in.) Standard valve margin thickness 1.0 mm (0.039 in.) Minimum valve margin thickness 0.7 mm (0.028 in.) Standard overall length 87.90 mm (3.4606 in.) Minimum overall length 87.60 mm (3.4488 in.) Standard valve stem diameter 4.965 to 4.980 mm (0.1955 to 0.1961 in.) Standard valve margin thickness 1.15 mm (0.0453 in.) Minimum valve margin thickness 0.85 mm (0.0335 in.) Standard free length 59.77 mm (2.3531 in.) Maximum spring deviation 1.6 mm (0.063 in.) Maximum spring angle (reference) 2° Standard spring installed tension at 32.5 mm (1.280 in.) 140 to 154 N (14.2 to 15.7 kgf, 31.5 to 34.6 lbf) Maximum spring working tension at 25.1 mm (0.988 in.) 180 to 198 N (18.4 to 20.2 kgf, 40.5 to 44.5 lbf) SERVICE SPECIFICATIONS – 1NZ-FXE ENGINE MECHANICAL Valve guide bushing Valve lifter Camshaft No. 2 camshaft Cylinder block Connecting rod SS–7 Standard inside diameter 5.010 to 5.030 mm (0.1972 to 0.1980 in.) Intake: Standard oil clearance 0.025 to 0.060 mm ( 0.0010 to 0.0024 in.) Intake: Maximum oil clearance 0.08 mm (0.0031 in.) Exhaust: Standard oil clearance 0.030 to 0.065 mm (0.0012 to 0.0026 in.) Exhaust: Maximum oil clearance 0.10 mm (0.0039 in.) Standard: Standard guide bush diameter 9.685 to 9.706 mm (0.3813 to 0.3821 in.) O/S: Standard guide bush diameter 9.735 to 9.755 mm (0.3833 to 0.3841 in.) Protrusion height 9.0 to 9.4 mm (0.354 to 0.370 in.) Lifter diameter 30.966 to 30.976 mm (1.2191 to 1.2195 in.) Lifter bore diameter 31.009 to 31.025 mm (1.2208 to 1.2215 in.) Standard oil clearance 0.033 to 0.059 mm (0.0013 to 0.0023 in.) Maximum oil clearance 0.10 mm (0.0039 in.) Maximum circle runout 0.03 mm (0.0012 in.) Standard cam lobe height 42.310 to 42.410 mm (1.6657 to 1.6697 in.) Minimum cam lobe height 42.16 mm (1.6598 in.) No. 1 journal diameter 34.449 to 34.465 mm (1.3563 to 1.3569 in.) Other journals diameter 22.949 to 22.965 mm (0.9035 to 0.9041 in.) Standard thrust clearance 0.040 to 0.095 mm (0.0016 to 0.0037 in.) Maximum thrust clearance 0.11 mm (0.0043 in.) Standard oil clearance 0.040 to 0.095 mm (0.0016 to 0.0037 in.) Maximum oil clearance 0.115 mm (0.0045 in.) Maximum circle runout 0.03 mm (0.0012 in.) Standard cam lobe height 44.046 to 44.146 mm (1.7341 to 1.7380 in.) Minimum cam lobe height 43.90 mm (1.7283 in.) No. 1 journal diameter 34.449 to 34.465 mm (1.3563 to 1.3569 in.) Other journals diameter 22.949 to 22.965 mm (0.9035 to 0.9041 in.) Standard thrust clearance 0.040 to 0.095 mm (0.0016 to 0.0037 in.) Maximum thrust clearance 0.11 mm (0.0043 in.) Standard oil clearance 0.040 to 0.095 mm (0.0016 to 0.0037 in.) Maximum oil clearance 0.115 mm (0.0045 in.) Maximum warpage 0.05 mm (0.0020 in.) Standard bore diameter 75.000 to 75.133 mm (2.9528 to 2.9580 in.) End plate straight pin protrusion 11.5 to 12.5 mm (0.453 to 0.492 in.) Oil pan straight pin protrusion 8.5 to 9.5 mm (0.335 to 0.374 in.) Cylinder head set straight pin protrusion 8.5 to 9.5 mm (0.335 to 0.374 in.) Chain tensioner straight pin protrusion 18.5 to 19.5 mm (0.728 to 0.768 in.) Oil pump set ring pin protrusion 3.5 to 4.5 mm (0.138 to 0.177 in.) Standard thrust clearance 0.16 to 0.36 mm (0.0063 to 0.0142 in.) Maximum thrust clearance 0.36 mm (0.0142 in.) Standard oil clearance 0.016 to 0.040 mm (0.0006 to 0.0016 in.) Maximum oil clearance 0.06 mm (0.0024 in.) Maximum out-of alignment 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) Maximum twist 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) Inside diameter 17.965 to 17.985 mm (0.7073 to 0.7081 in.) SS SS–8 SERVICE SPECIFICATIONS – 1NZ-FXE ENGINE MECHANICAL Piston Piston ring SS Connecting rod bolt Crankshaft Crankshaft bearing cap set bolt Diameter 74.941 to 74.979 mm (2.9504 to 2.9519 in.) Pin hole diameter at 20 °C (68°F) 18.013 to 18.016 mm (0.7092 to 0.7093 in.) Pin diameter 18.001 to 18.004 mm (0.7087 to 0.7088 in.) Standard pin oil clearance 0.009 to 0.015 mm (0.0004 to 0.0006 in.) Maximum pin oil clearance 0.050 mm (0.0020 in.) Standard piston clearance 0.045 to 0.068 mm (0.0018 to 0.0027 in.) Maximum piston clearance 0.08 mm (0.0032 in.) No. 1: Groove clearance 0.02 to 0.07 mm (0.0008 to 0.0028 in.) No. 2: Groove clearance 0.02 to 0.06 mm (0.0008 to 0.0024 in.) Oil: Groove clearance 0.02 to 0.06 mm (0.0008 to 0.0024 in.) No. 1: Standard end gap 0.20 to 0.30 mm (0.0079 to 0.0118 in.) No. 1: Maximum end gap 0.61 mm (0.0240 in.) No. 2: Standard end gap 0.30 to 0.45 mm (0.0118 to 0.0177 in.) No. 2: Maximum end gap 1.20 mm (0.0472 in.) Oil: Standard end gap 0.10 to 0.40 mm (0.0039 to 0.0158 in.) Oil: Maximum end gap 1.15 mm (0.0453 in.) Standard diameter 6.6 to 6.7 mm (0.260 to 0.264 in.) Maximum diameter 6.4 mm (0.252 in.) Maximum circle runout 0.03 mm (0.0012 in.) Main journal diameter 45.988 to 46.000 mm (1.8106 to 1.8110 in.) Main journal taper and out-of-round 0.02 mm (0.0008 in.) Crank pin diameter 39.992 to 40.000 mm (1.5745 to 1.5748 in.) Maximum crank pin taper and out-of-round 0.02 mm (0.0008 in.) Standard: Crankshaft timing sprocket diameter (w/ chain) 51.72 mm (2.0362 in.) Maximum: Crankshaft timing sprocket diameter (w/ chain) 50.5 mm (1.988 in.) Standard oil clearance 0.01 to 0.023 mm (0.0004 to 0.0009 in.) Maximum oil clearance 0.07 mm (0.0028 in.) Standard diameter 7.3 to 7.5 mm (0.287 to 0.295 in.) Minimum diameter 7.3 mm (0.287 in.) SS–9 SERVICE SPECIFICATIONS – 1NZ-FXE ENGINE MECHANICAL TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Spark plug x Cylinder head 18 184 13 Ignition coil x Cylinder head cover 9.0 92 80 in.*lbf Idler pulley x Adjust bolt 40 408 30 No. 1 air cleaner inlet x Clamp 3.0 31 27 No. 2 camshaft bearing cap x Cylinder head 13 130 9.6 No. 1 camshaft bearing cap x Cylinder head 23 235 17 Camshaft timing sprocket x No. 2 camshaft 64 653 47 Screw plug x Timing chain cover 15 153 11 Chain vibration damper x Cylinder block 9.0 92 80 in.*lbf Chain tensioner slipper x Cylinder block 9.0 92 80in.*lbf Chain tensioner x Cylinder block 9.0 92 80 in.*lbf Engine mounting bracket x Timing chain cover 55 561 41 Engine mounting spacer x Body 55 561 41 Engine mounting insulator RH x Engine mounting bracket 52 530 38 Crankshaft pulley x Crankshaft 128 1,305 95 Cylinder head cover x Cylinder head 10 102 74 Wire harness x Cylinder head cover 9.0 92 80 in.*lbf Windshield washer jar x Body Bolt A: 4.9 50 43 in.*lbf Windshield washer jar x Body Bolt B: 14 143 10 Windshield washer jar x Body Nut: 5.5 56 49 in.*lbf Reservoir bracket x Body 8.5 87 75 in.*lbf Brake master cylinder reservoir x Reservoir bracket 8.5 87 75 in.*lbf Air cleaner assembly x Cylinder head cover Bolt: 7.0 71 62 in.*lbf Air cleaner assembly x Cylinder head cover Clamp: 3.0 31 27 in.*lbf Oil control valve filter x Cylinder head 30 306 22 No. 1 taper screw plug x Cylinder head 44 449 33 Cylinder head x Cylinder block 1st: 29 2nd: 90° 3rd: 90° 1st: 296 2nd: 90° 3rd: 90° 1st: 21 2nd: 90° 3rd: 90° Oil dipstick guide x Intake manifold 9.0 92 80 in.*lbf Water bypass pipe x Cylinder head 9.0 92 80 in.*lbf Engine coolant temperature sensor x Cylinder head 20 204 15 Noise filter x Cylinder head 9.0 92 80 in.*lbf Exhaust manifold x Cylinder head 27 275 20 No. 1 exhaust manifold heat insulator x Exhaust manifold 8.0 82 71 in.*lbf Knock sensor wire bracket x Cylinder head 9.0 92 80 Flywheel x Crankshaft 49 500 36 Transmission input damper x Flywheel 20 204 15 Starter hole insulator x Hybrid vehicle transaxle 32 326 24 Engine mounting insulator bracket LH x Engine mounting insulator LH 80 816 59 Front suspension crossmember x Body Bolt A: 113 1,152 83 Front suspension crossmember x Body Bolt B: 157 1,602 116 SS SS–10 SERVICE SPECIFICATIONS – 1NZ-FXE ENGINE MECHANICAL Part Tightened SS N*m kgf*cm ft.*lbf Engine moving control rod x Front suspension crossmember 56 571 41 Engine moving control rod x Hybrid vehicle transaxle 100 1,020 74 Steering sliding yoke x Steering gear 35 357 26 Compressor x Cylinder block 25 255 18 Purge VSV x Engine mounting insulator RH 7.5 76 5.5 in.*lbf Front wheel x Front axle 103 1,050 76 Connecting rod cap x Connecting rod 1st: 15 2nd: 90° 1st: 153 2nd: 90° 1st: 11 2nd: 90° Crankshaft bearing cap x Cylinder block 1st: 22 2nd: 90° 1st: 224 2nd: 90° 1st: 16 2nd: 90° Stud bolt x Cylinder block 5.0 51 44 Oil pan x Cylinder block 24 245 18 Oil strainer x Oil pan 11 112 8.1 No. 2 oil pan x Oil pan 9.0 92 80 in.*lbf Drain plug x No. 2 oil pan 37.5 382 28 Oil filter union x Oil pan 30 306 22 Oil filter x Oil filter union 17.5 178 13 Camshaft timing gear x Camshaft 64 653 47 Camshaft position sensor x Cylinder head 8.0 82 71 in.*lbf Timing chain cover x Cylinder head and cylinder block Bolt A: 24 Bolt B: 11 Bolt C: 11 Nut D: 24 Bolt E: 24 Bolt A: 245 Bolt B: 112 Bolt C: 112 Nut D: 245 Bolt E: 245 Bolt A: 18 Bolt B: 8.1 Bolt C: 8.1 Nut D: 18 Bolt E: 18 Water pump x Timing chain cover 11 112 8 Engine mounting bracket x Timing chain cover 55 561 41 Water pump pulley x Water pump 15 153 11 Fuel delivery pipe x Cylinder head Bolt A: 19 Bolt B: 9.0 Bolt A: 194 Bolt B: 92 Bolt A: 14 Bolt B: 80 in.*lbf Camshaft timing control valve x Cylinder head 7.5 76 66 Cylinder head cover x Cylinder head 10 102 7 Ventilation valve x Cylinder head cover 27 275 20 Crankshaft position sensor x Timing chain cover 7.5 76 20 Water inlet x Cylinder block 9.0 92 80 SERVICE SPECIFICATIONS – 1NZ-FXE FUEL SS–11 1NZ-FXE FUEL SERVICE DATA Fuel injector Standard resistance 13.45 to 14.15 Ω at 21°C (68°F) Standard injection volume Difference between each fuel injector (Injection volume: 36 to 46 cm3 (2.1 to 2.8 cu in.)) 10 cm3 (0.6 cu in.) or less SS SS–12 SERVICE SPECIFICATIONS – 1NZ-FXE FUEL TORQUE SPECIFICATIONS Fuel injector Part Tightened Fuel delivery pipe x Cylinder head SS Bolt A Bolt B N*m kgf*cm ft.*lbf 19 194 14 9.0 92 80 in.*lbf Reservoir bracket x Body 8.5 87 75 in.*lbf Brake master cylinder reservoir x Reservoir bracket 8.5 87 75 in.*lbf Front outer cowl top panel x Body 6.4 65 57 in.*lbf No. 2 engine room relay block x Body 8.4 86 74 in.*lbf Fuel tank Part Tightened N*m kgf*cm ft.*lbf Canister x Fuel tank 6.0 61 53 in.*lbf Trap canister with pump module x Fuel tank 6.0 61 53 in.*lbf Fuel tank bracket x Fuel tank 6.0 61 53 in.*lbf Fuel tank x Body 39 400 29 SS–12 SERVICE SPECIFICATIONS – 1NZ-FXE EMISSION CONTROL 1NZ-FXE EMISSION CONTROL SERVICE DATA Air fuel ratio sensor Fuel tank pressure sensor SS Voltage E5-23 (A1A+) - E5-28 (E1) E5-23 (A1A+) - E5-28 (E1) 3.0 to 3.6 V 2.7 to 3.3 V Resistance at 20°C(68°F) 1 (HT) - 2 (+B) 2 (+B) - 4 (AF-) 1.8 to 3.4 Ω 10 KΩ or higher Voltage 1-3 4.5 to 5.5 V 2-3 3.0 to 3.6 V Purge VSV Resistance 1-2 26 to 30 Ω at 20°C(68°F) Heated oxygen sensor Resistance 1 (HT) - 2 (+B) 1 (HT) - 4 (E) 11 to 16 Ω at 20°C(68°F) 10 KΩ or higher Canister pressure switching valve Resistance 1-2 36 to 42 Ω at 20°C(68°F) 1 - body 10 KΩ or higher 2 - body 10 KΩ or higher SS–13 SERVICE SPECIFICATIONS – 1NZ-FXE EMISSION CONTROL TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Canister x Fuel tank sub-assembly 6.0 61 53 in.*lbf Trap canister x Fuel tank sub-assembly 6.0 61 53 in.*lbf Purge VSV x Engine mounting insulator sub-assembly RH 7.5 76 66 in.*lbf Canister pressure switching valve x Canister 2.9 30 26 in.*lbf Ventilation valve x Cylinder head cover 27 275 20 Air fuel ratio sensor x Exhaust manifold : for use with SST 44 449 32 Air fuel ratio sensor x Exhaust manifold : for use without SST 40 408 30 Heated oxygen sensor x Exhaust manifold : for use with SST 44 449 32 Heated oxygen sensor x Exhaust manifold : for use without SST 40 408 30 SS SERVICE SPECIFICATIONS – 1NZ-FXE EXHAUST SS–13 1NZ-FXE EXHAUST SERVICE DATA Compression spring minimum length Front exhaust pipe assembly x Exhaust manifold 40.5 mm (1.594 in.) Tailpipe assembly x Front exhaust pipe assembly 38.5 mm (1.516 in.) SS SS–14 SERVICE SPECIFICATIONS – 1NZ-FXE EXHAUST TORQUE SPECIFICATIONS Part tightened SS N*m kgf*cm ft.*lbf Front exhaust pipe x Exhaust manifold 43 440 32 Tail pipe x Front exhaust pipe 43 440 32 Front floor panel brace x Body 30 302 22 SS–14 SERVICE SPECIFICATIONS – 1NZ-FXE COOLING 1NZ-FXE COOLING SERVICE DATA Thermostat Valve opening temperature Valve lift Radiator cap 80 to 84°C (176 to 183°F) at 95°C (203°F) Standard opening pressure 8.5 mm (0.33 in.) or more 74 to 103 kPa (0.75 to 1.05 kgf*cm2, 10.7 to 14.9 psi) Minimum opening pressure SS 59 kPa (0.6 kgf*cm2, 8.5 psi) Fan Standard amperage at 20°C (68°F) 9.2 to 11.0 A Integration relay Resistance B1 - B4 10 kΩ or higher Below 1 Ω (when battery voltage is applied to terminals 2 and 3) No. 1 Cooling fan relay No. 2 cooling fan relay Resistance Resistance 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 3-4 Below 1 Ω 3-5 10 kΩ or higher 3-4 10 kΩ or higher (when battery voltage is applied to terminals 1 and 2) 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) SS–15 SERVICE SPECIFICATIONS – 1NZ-FXE COOLING TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Fan x Fan motor 6.2 63 55 in.*lbf Fan shroud x Radiator 7.5 76 66 in.*lbf Radiator support x body 5.0 51 44 in.*lbf Water pump x Cylinder block 11 112 8 Water pump pulley x Water pump 15 153 11 Cooler bracket x Radiator support Bolt A 20 204 15 Cooler bracket x Suction hose Bolt B 8.5 87 75 in.*lbf Inverter bracket x Radiator support Bolt A 21 214 16 Inverter bracket x Inverter Bolt B 25 255 18 Radiator temperature switch x Radiator 7.0 71 62 in.*lbf Radiator support lower LH x Radiator Bolt A 5.0 51 44 in.*lbf Bolt B 3.9 40 35 in.*lbf Radiator support lower RH x Radiator Bolt A 5.0 51 44 in.*lbf Bolt B 3.9 40 35 in.*lbf Radiator support upper LH x Radiator Bolt A 5.0 51 44 in.*lbf Bolt B 3.9 40 35 in.*lbf Radiator support upper RH x Radiator Bolt A 5.0 51 44 in.*lbf Bolt B Radiator Drain Plug sub-assembly x Radiator 3.9 40 35 in.*lbf 13 129 9.4 Radiator bleeder plug x Radiator 1.5 15 13 in.*lbf Coolant heat storage tank x Body 19 194 14 Coolant heat storage tank x Coolant heat storage water pump 6.0 61 53 in.*lbf SS SERVICE SPECIFICATIONS – 1NZ-FXE LUBRICATION SS–15 1NZ-FXE LUBRICATION SERVICE DATA Oil pressure Oil pump tip clearance Oil body tip clearance at idle speed at 2,500 rpm 59 kPa (0.6 kgf/cm2, 4.2 psi) Standard 0.060 to 0.180 mm (0.0024 to 0.0071 in.) Maximum 0.28 mm (0.0110 in.) Standard 0.250 to 0.325 mm (0.0098 to 0.0128 in.) Maximum 0.425 mm (0.0167 in.) 150 to 550 kPa (1.5 to 56 kgf/cm2, 22 to 80 psi) SS SS–16 SERVICE SPECIFICATIONS – 1NZ-FXE LUBRICATION TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Oil pressure switch x Cylinder block 15 153 11 Stud bolt x Cylinder head 10 102 7 32 11 11 24 24 326 112 112 245 245 24 8 8 18 18 Camshaft timing oil control valve assembly x Cylinder head 7.5 76 66 in.*lbf Engine mounting bracket x Cylinder block 55 561 41 Engine mounting bracket x Engine mounting insulator sub-assembly RH 52 530 38 Crankshaft pulley x Crankshaft 128 1,305 95 Cylinder head cover x Cylinder head 10 102 7 Ignition coil x Cylinder head cover 9.0 92 80 in.*lbf Brake master cylinder reservoir cover x Cylinder head cover 9.0 92 80 in.*lbf Oil pan drain plug x No. 2 oil pan 38 387 28 Oil pump cover x Oil pump assembly Bolt Screw 8.8 10 90 102 78 in.*lbf 7 Windshield washer jar assembly x Body Bolt A Bolt B Nut 4.9 14 5.5 50 143 56 43 in.*lbf 10 49 in.*lbf Brake master cylinder reservoir cover x Reservoir bracket and reservoir 8.5 87 75 in.*lbf Reservoir bracket x Body 8.5 87 75 in.*lbf 7.0 3.0 71 31 62 in.*lbf 27 in.*lbf 103 1,050 76 Oil pump assembly x Cylinder head and block SS Air cleaner assembly x Cylinder head cover Front wheel RH x Front axle Bolt A Bolt B Bolt C Nut D Bolt E Bolt Clamp SS–16 SERVICE SPECIFICATIONS – 1NZ-FXE IGNITION 1NZ-FXE IGNITION SERVICE DATA Spark plug SS Standard electrode gap 1.0 to 1.1 mm (0.039 to 0.043 in.) Maximum electrode gap 1.2 mm (0.047 in.) DENSO SK16R11 NGK IFR5A11 SS–17 SERVICE SPECIFICATIONS – 1NZ-FXE IGNITION TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Engine No. 2 relay block x Cowl top panel sub assembly 8.4 86 74 in.*lbf Ignition coil assembly x Cylinder head cover 9.0 92 80 in.*lbf SS SERVICE SPECIFICATIONS – 1NZ-FXE STARTING SS–17 1NZ-FXE STARTING SERVICE DATA Power switch ( Indicator condition) Power switch Key slot OFF OFF ON (ACC) Green illumination ON (IG) Amber illumination Hybrid system ON OFF Push button start system malfunctioning Flashes continuously in amber Pushed: 7 (SS2) - 6 (GND) Below 1 Ω Pushed: 5 (SS1) - 6 (GND) Below 1 Ω Released: 7 (SS2) - 6 (GND) 10 kΩ or higher Released: 5 (SS1) - 6 (GND) 10 kΩ or higher Key is in key slot: 3(KSW2) - 2(COM) 10 kΩ or higher SS SS–18 SERVICE SPECIFICATIONS – 1NZ-FXE CHARGING 1NZ-FXE CHARGING TORQUE SPECIFICATIONS Part Tightened SS N*m kgf*cm ft.*lbf Battery hold down clamp x Body 5.4 55 48 in.*lbf Battery hold down clamp x Battery tray 5.4 55 48 in.*lbf Fusible link block x Battery 6.0 61 53 in.*lbf No. 2 quarter vent duct x Body 4.0 41 35 in.*lbf Battery negative terminal x Battery 6.0 61 53 in.*lbf SERVICE SPECIFICATIONS – P112 HYBRID VEHICLE CONTROL SS–19 P112 HYBRID VEHICLE CONTROL SERVICE DATA Inverter Converter operation Water pump with motor A-2 (GIVA) - A-16 (GINV) HV Approximately 0 V A-3 (GIVB) - A-16 (GINV) Approximately 0 V A-4 (GUU) - A-16 (GINV) Approximately 14 to 16 V A-5 (GVU) - A-16 (GINV) Approximately 14 to 16 V A-6 (GWU) - A-16 (GINV) Approximately14 to 16 V A-7 (MIVA) - A-16 (GINV) Approximately 0 V A-8 (MIVB) - A-16 (GINV) Approximately 0 V A-9 (MUU) - A-16 (GINV) Approximately 14 to 16 V A-10 (MVU) - A-16 (GINV) Approximately 14 to 16 V A-11 (MWU) - A-16 (GINV) Approximately 14 to 16 V A-12 (VH) - A-16 (GINV) Approximately 0.5 V A-13 (CPWM) - A-32 (GCNV) Approximately 0 V A-14 (GSDN) - A-32 (GCNV) Approximately 2 to 4.5 V A-15 (VL) - A-32 (GCNV) Approximately 0.5 V A-16 (GINV) - C-2 (GND) Approximately 0 V A-18 (GIWA) - A-16 (GINV) Approximately 0 V A-19 (GIWB) - A-16 (GINV) Approximately 0 V A-20 (CT) - A-16 (GINV) Approximately 0 V A-21 (GIVT) - A-16 (GINV) Approximately 2 to 4.5 V A-22 (GFIV) - A-16 (GINV) Approximately 5 to 8 V A-23 (MIWA) - A-16 (GINV) Approximately 0 V A-24 (MIWB) - A-16 (GINV) Approximately 0 V A-25 (MSDN) - A-16 (GINV) Approximately 0 V A-26 (MIVT) - A-16 (GINV) Approximately 2 to 4.5 V A-27 (MFIV) - A-16 (GINV) Approximately 5 to 8 V A-28 (OVH) - A-16 (GINV) Approximately 5 to 8 V A-29 (CSDN) - A-32 (GCNV) Approximately 0 V A-30 (FCV) - A-32 (GCNV) Approximately 13.5 to 16.5 V A-31 (OVL) - A-32 (GCNV) Approximately 13.5 to 16.5 V A-32 (GCNV) - C-2 (GND) Approximately 0 V B-1 (ILK) - Body ground After installing the probe to the terminal, temporarily install the inverter cover. It does not have to be tightened with the bolts at this point. Below 1 Ω C-1 (IGCT) - C-2 (GND) Approximately 8 to 16 V C-2 (GND) - Body ground Below 1 Ω Auxiliary battery voltage : READY light ON 14 V Auxiliary battery voltage : READY light OFF 12 V Output current : READY light ON Approximately 80 A or less Battery positive terminal to terminal 1 and the battery negative terminal to terminal 2 Water pump motor operates properly SS SS–20 IGCT relay SS SERVICE SPECIFICATIONS – P112 HYBRID VEHICLE CONTROL 7J-1 - 7J-4 HV 10 kΩ or higher 7J-1 - 7K-4 Below 1 Ω 7J-2 - 7J-3 Below 1 Ω 7J-4 - 7K-1 10 kΩ or higher 7J-1 - 7J-4 : When battery voltage is applied to terminals 7J-2 and 7J-3 Below 1 Ω 7J-1 - 7K-1 : When battery voltage is applied to terminals 7J-2 and 7J-3 Below 1 Ω SS–21 SERVICE SPECIFICATIONS – P112 HYBRID VEHICLE CONTROL TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf MG 1 power cable x MG 1 power cable terminal 8.0 82 71 in.*lbf MG 2 power cable x MG 2 power cable terminal 8.0 82 71 in.*lbf No. 1 circuit breaker sensor x Inverter with converter assembly 8.0 82 71 in.*lbf No. 2 inverter bracket x Inverter with converter assembly 25 255 18 No. 1 inverter bracket x Inverter with converter assembly 25 255 18 Connector bracket x Inverter with converter assembly 8.0 82 71 in.*lbf Inverter with converter assembly x Body 21 214 16 Inverter cover x Inverter with converter 11 112 8.1 Hybrid control ECU x ECM 5.5 56 49 in.*lbf Water pump with motor assembly x Body 7.0 71 62 in.*lbf Frame wire x Floor panel 9.0 92 80 in.*lbf Suspension crossmember x Body Bolt A: 113 1,152 83 Bolt B: 157 1,601 116 9.0 92 80 in.*lbf No. 1 wire harness protector x Body Frame wire x Engine room relay block 9.0 92 80 in.*lbf Frame wire x No. 2 system main relay 5.6 57 50 in.*lbf Frame wire x No. 3 system main relay 5.6 57 50 in.*lbf Accelerator pedal rod x Body 7.5 77 66 in.*lbf SS SERVICE SPECIFICATIONS – P112 HYBRID BATTERY CONTROL SS–21 P112 HYBRID BATTERY CONTROL SERVICE DATA Battery plug No. 1 system main relay No. 2 system main relay No. 3 system main relay Resistance between terminals 10 kΩ or higher Install the service grip: Resistance between terminals Below 1 Ω Positive terminal - Negative terminal 10 kΩ or higher A-2 (CONT2) - B-2 (CONT2) Below 1 Ω A-3 (CONT3) - C-2 (CONT3) Below 1 Ω B-1 (GND) - GND Below 1 Ω C-1 (GND) - GND Below 1 Ω Apply battery voltage between the GND terminal and CONT1 terminal of the connector A: Positive terminal - Negative terminal Below 1 Ω A-1 (CONT1) - GND 70 to 160 kΩ Positive terminal - Negative terminal 10 kΩ or higher Apply battery voltage between the connector terminals: Positive terminal - Negative terminal Below 1 Ω Resistance between the connector terminals 20 to 50 kΩ Positive terminal - Negative terminal 10 kΩ or higher Apply battery voltage between the connector terminals: Positive terminal - Negative terminal Below 1 Ω Resistance between the connector terminals 20 to 50 kΩ System main resistor Resistance between terminals 18 to 22 Ω Battery blower relay 3-5 10 kΩ or higher When battery voltage is applied to terminals 1 and 2: 3-5 Below 1 Ω Positive probe to terminal 1 (VIB) Negative probe to terminal 2 (GIB) 3.5 to 4.5 kΩ Positive probe to terminal 2 (GIB) Negative probe to terminal 1 (VIB) 5 to 7 kΩ Positive probe to terminal 1 (VIB) Negative probe to terminal 3 (IB) A083579E02 3.5 to 4.5 kΩ Positive probe to terminal 1 (VIB) Negative probe to terminal 3 (IB) 5 to 7 kΩ Battery current sensor SS SS–22 SERVICE SPECIFICATIONS – P112 HYBRID BATTERY CONTROL TORQUE SPECIFICATIONS SS Part Tightened N*m kgf*cm ft.*lbf Upper battery carrier x HV battery 5.5 56 49 in.*lbf Battery cover x HV battery 8.0 82 71 in.*lbf HV battery x Body 19 194 14 Frame wire x No. 2 system main relay 5.6 57 50 in.*lbf Frame wire x No. 3 system main relay 5.6 57 50 in.*lbf No. 6 battery carrier panel x HV battery assembly 7.5 76 66 in.*lbf Quarter vent duct x Body 4.0 41 35 in.*lbf Battery bracket reinforcement x Body 28 286 21 Battery bracket reinforcement x HV battery assembly 28 286 21 Battery carrier bracket x Body 28 286 21 Battery carrier bracket x HV battery assembly 28 286 21 No. 2 main battery cable x No. 2 frame wire 5.4 55 48 in.*lbf No. 2 main battery cable x No. 2 system main relay 5.6 57 50 in.*lbf Main battery cable x No. 2 frame wire 5.4 55 48 in.*lbf Main battery cable x No. 3 system main relay 5.6 57 50 in.*lbf Aluminum shield wire x HV battery 3.3 34 29 in.*lbf No. 2 frame wire x HV battery 5.4 55 48 in.*lbf Battery plug x Upper battery carrier 5.4 55 48 in.*lbf Junction block x HV battery 5.4 55 48 in.*lbf No. 1 system main relay x Upper battery carrier 3.4 35 30 in.*lbf Ground terminal x Upper battery carrier 5.6 57 50 in.*lbf No. 3 system main relay x Upper battery carrier 3.4 35 30 in.*lbf No. 2 system main relay x Upper battery carrier 3.4 35 30 in.*lbf System main resistor x Upper battery carrier 3.4 35 30 in.*lbf Battery current sensor x Upper battery carrier 1.4 14 12 in.*lbf Battery ECU x Upper battery carrier 3.3 34 29 in.*lbf Electric vehicle fuse x Service grip 5.4 55 48 in.*lbf Battery blower x Body 5.0 51 44 in.*lbf SERVICE SPECIFICATIONS – HYBRID TRANSAXLE SS–23 HYBRID TRANSAXLE SERVICE DATA Differential case side bearing preload (Starting torque) New bearing 0.98 to 1.57 N*m (9.99 to 16.01 kgf*cm, 8.67 to 13.90 in.*lbf) Reused bearing 0.49 to 0.78 N*m (5.00 to 7.95 kgf*cm, 4.43 to 6.90 in.*lbf) Differential case side bearing preload (Turning torque 20 rpm) Differential preload adjusting shim thickness 0.61 to 1.35 N*m (6.2 to 13.77 kgf*cm, 5.4 to 11.95 in.*lbf) Mark 1 1.80 mm (0.0709 in.) Mark 2 1.83 mm (0.0720 in.) Mark 3 1.86 mm (0.0732 in.) Mark 4 1.89 mm (0.0744 in.) Mark 50 1.92 mm (0.0756 in.) Mark 51 1.94 mm (0.0764 in.) Mark 52 1.96 mm (0.0772 in.) Mark 53 1.98 mm (0.0780 in.) Mark 54 2.00 mm (0.0787 in.) Mark 55 2.02 mm (0.0795 in.) Mark 56 2.04 mm (0.0803 in.) Mark 57 2.06 mm (0.0811 in.) Mark 58 2.08 mm (0.0819 in.) Mark 59 2.10 mm (0.0827 in.) Mark 60 2.12 mm (0.0835 in.) Mark 61 2.14 mm (0.0843 in.) Mark 62 2.16 mm (0.0850 in.) Mark 63 2.18 mm (0.0858 in.) Mark 64 2.20 mm (0.0866 in.) Mark 65 2.22 mm (0.0874 in.) Mark 66 2.24 mm (0.0882 in.) Mark 67 2.26 mm (0.0890 in.) Mark 68 2.28 mm (0.0898 in.) Mark 69 2.30 mm (0.0906 in.) Mark 70 2.32 mm (0.0913 in.) Mark 19 2.34 mm (0.0921 in.) Mark 20 2.37 mm (0.0933 in.) - 2.40 mm (0.0945 in.) Mark 22 2.43 mm (0.0957 in.) Mark 23 2.46 mm (0.0969 in.) SS SS–24 SERVICE SPECIFICATIONS – HYBRID TRANSAXLE Input shaft shim thickness SS Counter drive gear shim thickness Mark 1 1.00 mm (0.0394 in.) Mark 2 1.20 mm (0.0472 in.) Mark 3 1.40 mm (0.0551 in.) Mark 4 1.60 mm (0.0630 in.) Mark 5 1.80 mm (0.0709 in.) Mark 6 2.00 mm (0.0787 in.) Mark 7 2.20 mm (0.0866 in.) Mark 8 2.40 mm (0.0945 in.) Mark 9 2.60 mm (0.1024 in.) Mark 10 2.80 mm (0.1102 in.) Mark 11 3.00 mm (0.1181 in.) Mark 12 3.20 mm (0.1260 in.) Mark A 2.20 mm (0.0866 in.) Mark B 2.25 mm (0.0886 in.) Mark C 2.30 mm (0.0906 in.) Mark D 2.35 mm (0.0925 in.) Mark E 2.40 mm (0.0945 in.) Mark F 2.45 mm (0.0965 in.) Mark G 2.50 mm (0.0984 in.) Mark H 2.55 mm (0.1003 in.) Mark J 2.60 mm (0.1024 in.) Mark K 2.65 mm (0.1043 in.) Mark L 2.70 mm (0.1063 in.) Mark M 2.75 mm (0.1083 in.) Mark N 2.80 mm (0.1102 in.) Differential oil seal LH and RH drive in depth 2.7 +-0.5 mm (0.11 +-0.02 in.) Oil pressure 9.8 kPa (0.1 kgf/cm2, 1.4 pst) Differential side gear backlash Standard Differential side gear washer thickness 0.05 to 0.20 mm (0.0020 to 0.0079 in.) 0.95 mm (0.0374 in.) 1.00 mm (0.0394 in.) 1.05 mm (0.0414 in.) 1.10 mm (0.0433 in.) 1.15 mm (0.0453 in.) 1.20 mm (0.0472 in.) Sun gear bush diameter Standard 25.525 to 25.546 mm (1.00492 to 1.00575 in.) Maximum 25.596 mm (1.00771 in.) SS–25 SERVICE SPECIFICATIONS – HYBRID TRANSAXLE TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Oil pump cover x MG2 assembly 5.5 56 49 in.*lbf Transaxle oil drain plug 39 400 29 Hybrid transaxle assembly x Engine 33 332 24 Coolant drain plug x MG1 assembly 39 400 29 Screw plug x MG1 assembly 55 561 41 Set plug x MG2 assembly 39 400 29 Filler plug x MG2 assembly 39 400 29 MG1 assembly x MG2 assembly 25 250 18 Oil strainer x MG2 assembly 7.9 81 70 in.*lbf Motor water jacket cover x MG2 assembly 5.5 56 49 Housing tube x MG1 assembly 15 155 11 Detent spring set bolt 9.8 100 86 in.*lbf Parking cover x MG2 assembly 5.5 56 49 in.*lbf Parking shaft cover x MG2 assembly 5.5 56 49 in.*lbf Oil pump cover x plug 7.4 75 65 in.*lbf Power cable cover x MG1 assembly 4.8 48 42 in.*lbf Mounting bracket x MG2 assembly 52 530 38 Shift lever assembly x Steering column 8 80 71 in.*lbf Generator cable x Converter and inverter 5.5 56 49 in.*lbf Generator cable x MG1 cable cover 5.8 59 51 in.*lbf Generator cable x MG1 assembly 8.5 87 75 in.*lbf Connector x MG1 assembly 5.8 59 51 in.*lbf Connector x MG2 assembly 5.8 59 51 in.*lbf Transmission case cover x MG2 assembly 7.0 71 62 in.*lbf Shift control actuator x MG2 assembly 16 160 12 Shift lever assembly x Body 12 122 9 Engine hanger x Hybrid transaxle assembly 38 387 28 Stay x Hybrid transaxle assembly 9.0 92 80 in.*lbf Engine mounting bracket No.3 x Hybrid transaxle assembly 52 530 38 Housing side cover x Hybrid transaxle assembly 32 326 23 Engine mounting insulator x Hybrid transaxle assembly 80 816 59 Earth wire x Hybrid transaxle assembly 9.0 92 80 in.*lbf Set plug x MG2 assembly 39 400 29 Screw plug x MG2 assembly 13 130 9 Nut x Baring 280 2860 207 SS SS–26 SERVICE SPECIFICATIONS – DRIVE SHAFT DRIVE SHAFT TORQUE SPECIFICATIONS SS Part Tightened N.m kgf.cm ft.lbf Front axle hub nut 216 2200 159 Front wheel set nut 103 1050 76 transaxle x drain plug 39 398 29 Flexible hose and speed sensor front x Shock absorber assembly front 29 300 22 Speed sensor front x Steering knuckle 8.0 82 71 in.lbf Tie rod end sub-assembly x Steering knuckle 49 500 36 Suspension arm sub-assembly lower No.1 x Steering knuckle 89 908 66 SERVICE SPECIFICATIONS – AXLE SS–27 AXLE SERVICE DATA Front axle hub bearing: Backlash Maximum: 0.05 mm (0.0020 in.) Front axle hub sub-assembly: Deviation Maximum: 0.05 mm (0.0020 in.) Rear axle hub & bearing assembly: Backlash Maximum: 0.05 mm (0.0020 in.) Rear axle hub & bearing assembly: Deviation Maximum: 0.07 mm (0.0028 in.) SS SS–28 SERVICE SPECIFICATIONS – AXLE TORQUE SPECIFICATIONS SS Part Tightened N.m kgf.cm ft.lbf Front axle hub nut 216 2200 159 Front wheel set nut 103 1050 76 Rear wheel set nut 103 1050 76 Front axle assembly x Shock absorber assembly front 153 1560 113 Speed sensor front x Steering knuckle 8.0 82 71 in.lbf Tie rod end sub-assembly x Steering knuckle 49 500 36 Suspension arm sub-assembly lower No.1 x Steering knuckle 89 908 66 Front disc brake caliper assembly x Steering knuckle 109 1114 81 Rear axle hub & bearing assembly x Rear axle beam 61 622 45 Steering knuckle x Lower ball joint assembly 71 724 52 Steering knuckle x Front axle hub 56 571 41 SS–28 SERVICE SPECIFICATIONS – SUSPENSION SUSPENSION SERVICE DATA Front wheel alignment SS Vehicle height A-B: D-C: 95 mm (3.74 in.) 62 mm (2.40 in.) Toe-in (total) Rack end length difference 0° +-12' (0° +-0.2°, 0 +-2 mm, 0 +0.08 in.) 1.5 mm (0.059 in.) or less Wheel angle Inside wheel 40° 35' +-2° (40.58° +-2°) Outside wheel: Reference Rear wheel alignment Front suspension 34°15' (34.25°) Camber Right-left error -0° 35' +-45' (-0.58° +-0.75°) 45' (0.75°) or less Caster Right-left error 3°10' +-45' (3.17° +-0.75°) 45' (0.75°) or less Steering axis inclination Right-left error 12°35' +-45' (12.58° +-0.75°) 45' (0.75°) or less Toe-in (total) 0°18' +-15' (0.30° +-0.25°, 3.0 +2.5 mm, 0.12 +-0.10 in.) Camber Right-left error -1°30' +-30' (-1.50 +-0.5°) 30' (0.5°) or less Lower ball joint turning torque 0.98 to 4.90 N*m (10 to 50 kgf*cm, 8.7 to 43 in.*lbf) Stabilizer link turning torque 0.05 to 1.96 N*m (0.5 to 20 kgf*cm, 0.4 to 17.4 in.*lbf) A: Ground clearance of front wheel center B: Ground clearance of lower arm No.1 set bolt center C: Ground clearance of rear axle carrier bush set bolt center D: Ground clearance of rear wheel center SS–29 SERVICE SPECIFICATIONS – SUSPENSION TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Tie rod end lock nut 74 755 55 Steering knuckle x Shock absorber 153 1,560 113 Front wheel hub nut 103 1,050 76 Suspension support x Piston rod 47 479 35 Suspension support x Body 39 398 29 ABS speed sensor wire harness bracket set bolt 19 192 14 Steering gear x Suspension cross member 58 591 43 Stabilizer link x Shock absorber with coil spring 74 755 55 Steering knuckle x Lower ball joint 71 724 52 Lower suspension arm x Suspension cross member 137 1,400 101 Stabilizer bracket No.1 x Suspension cross member 19 194 14 Rear wheel hub nut 103 1,050 76 Piston rod set nut 56 571 41 Shock absorber with coil spring x Body 80 816 59 Shock absorber with coil spring x Rear axle beam 80 816 59 Parking brake cable set bolt 5.4 55 48 in.*lbf Rear axle hub set bolt 61 622 45 Skid control sensor wire set bolt 5.0 51 44 in.*lbf Rear axle beam x Body 85 867 63 Stabilizer bar x Rear axle beam 149 1,520 110 SS SS–30 SERVICE SPECIFICATIONS – TIRE AND WHEEL TIRE AND WHEEL SERVICE DATA Cold tire inflation pressure 185/65R15 86S Front: Rear: SS 240 kPa (2.4 kgf/cm2, 35 psi) 230 kPa (2.3 kgf/cm2, 33 psi) Tire runout 1.4 mm (0.055 in.) or less Imbalance after adjustment 8.0 g (0.018 lb) or less SS–31 SERVICE SPECIFICATIONS – TIRE AND WHEEL TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Tire pressure warning receiver x Body 7.5 76 66 in.*lbf Tire pressure warning valve set nut 4.0 41 35 in.*lbf Tire pressure warning ECU set bolt 7.5 76 66 in.*lbf SS SERVICE SPECIFICATIONS – BRAKE CONTROL SS–31 BRAKE CONTROL SERVICE DATA Brake pedal stroke sensor 0.8 to 1.2 V SS SS–32 SERVICE SPECIFICATIONS – BRAKE CONTROL TORQUE SPECIFICATIONS Brake actuator SS Part Tightened N*m kgf*cm ft.*lbf Brake line union nut 15 155 11 Brake actuator x No. 2 brake actuator bracket 18 184 13 Brake actuator x Gusset 7.5 76 66 in.*lbf Brake actuator x bracket 18 184 13 Brake actuator x Brake actuator damper 18 184 13 Brake actuator w/ gusset x Body 20 200 15 Brake actuator x Brake tube clamp bracket 5.0 51 44 in.*lbf Brake actuator tube set nut 8.5 87 75 in.*lbf No. 1 front brake tube set bolt 5.0 51 44 in.*lbf Brake actuator bracket x No. 5 front brake tube bracket 5.0 51 44 in.*lbf Brake actuator resistor set nut 5.0 51 44 in.*lbf Front speed sensor Part Tightened N*m kgf*cm ft.*lbf Front speed sensor set bolt 8.0 82 71 in.*lbf Front speed sensor wire clamp x Body 8.0 82 71 in.*lbf Front speed sensor wire clamp x Shock absorber 19 192 14 Wheel nut 103 1,050 76 Yaw rate sensor Part Tightened N*m kgf*cm ft.*lbf Yaw rate sensor set bolt 19 194 14 Skid control ECU Part Tightened N*m kgf*cm ft.*lbf Skid control ECU set nut 5.0 51 44 in.*lbf Brake control power supply Part Tightened N*m kgf*cm ft.*lbf Brake control power supply assembly set bolt 19 194 14 Brake pedal stroke sensor Part Tightened N*m kgf*cm ft.*lbf Brake pedal stroke sensor set bolt 9.3 95 82 in.*lbf SS–32 SERVICE SPECIFICATIONS – BRAKE BRAKE SERVICE DATA SS Brake pedal height from asphalt sheet 138 to 148 mm (5.433 to 5.827 in.) Brake pedal stroke sensor 0.8 to 1.2 V Brake pedal free play 0.5 to 4 mm (0.02 to 0.16 in.) Stop light switch clearance 0.5 to 2.4 mm (0.020 to 0.095 in.) Brake pedal reserve distance from asphalt sheet at 196 N (20 kgf, 44.1 lbf) More than 104 mm (4.1 in.) Front brake pad lining thickness Standard 11.0 mm (0.433 in.) Minimum 1.0 mm (0.039 in.) Front brake disc thickness Standard 22.0 mm (0.866 in.) Minimum 20.0 mm (0.787 in.) Front brake disc runout Maximum 0.05 mm (0.0020 in.) Rear brake drum inside diameter Standard 200.0 mm (7.874 in.) Maximum 201.0 mm (7.913 in.) Standard 4.0 mm (0.157 in.) Minimum 1.0 mm (0.039 in.) Rear drum brake shoe lining thickness Rear brake drum and rear brake shoe clearance 0.6 mm (0.024 in.) SS–33 SERVICE SPECIFICATIONS – BRAKE TORQUE SPECIFICATIONS Brake pedal Part tightened N*m kgf*cm ft.*lbf Brake pedal support x Body 13 130 9 Brake pedal support x Instrument panel reinforcement 24 241 18 Brake pedal shaft nut 37 375 27 Stop light switch lock nut 26 265 19 Brake pedal stroke sensor set bolt 9.3 95 82 in.*lbf Brake master cylinder Part tightened N*m kgf*cm ft.*lbf Brake line union nut 15 155 11 No. 1 front brake tube set bolt 5.0 51 44 in.*lbf No. 5 front brake tube set bolt 5.0 51 44 in.*lbf No. 1 brake master cylinder union set screw 1.8 18 16 in.*lbf Push rod clevis lock nut 26 265 19 Brake master cylinder subassembly set nut 13 127 9 Brake stroke simulator cylinder Part tightened N*m kgf*cm ft.*lbf Brake stroke simulator stud bolt 5.0 51 44 in.*lbf Brake stroke simulator x Bracket 6.0 61 53 in.*lbf Brake stroke simulator bracket x Body 8.5 87 75 in.*lbf Brake stroke simulator x Brake actuator tube assembly 8.5 87 75 in.*lbf Brake line union nut 15 155 11 Front brake Part tightened N*m kgf*cm ft.*lbf Front disc brake cylinder mounting set bolt 109 1,114 81 Front disc brake cylinder x Front disc brake cylinder mounting 34 347 25 Flexible hose union bolt 33 337 24 Bleeder plug 8.4 86 74 in.*lbf Wheel nut 103 1,050 76 Part tightened N*m kgf*cm ft.*lbf Rear wheel brake cylinder x Backing plate 9.8 100 87 in.*lbf Brake line union nut 15 155 11 Bleeder plug 8.5 85 73 in.*lbf Wheel nut 103 1,050 76 Rear drum brake SS SS–34 SERVICE SPECIFICATIONS – PARKING BRAKE PARKING BRAKE SERVICE DATA Parking brake pedal travel at 300 N (31 kgf, 68.3 lbf) SS 6 to 9 clicks SS–35 SERVICE SPECIFICATIONS – PARKING BRAKE TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Parking brake control pedal set bolt and nut 20 204 15 No. 1 parking brake cable lock nut 5.4 55 48 in.*lbf No. 1 parking brake cable set bolt and nut 14 143 10 No. 2 parking brake cable clamp bolt 5.4 55 48 in.*lbf No. 2 parking brake cable retainer bolt 6.0 61 53 in.*lbf No. 2 parking brake cable x Backing plate 8.0 82 71 in.*lbf No. 3 parking brake cable clamp bolt 5.4 55 48 in.*lbf No. 3 parking brake cable retainer bolt 6.0 61 53 in.*lbf No. 3 parking brake cable x Backing plate 8.0 82 71 in.*lbf Parking brake cable heat insulator set nut 5.4 55 48 in.*lbf Parking brake intermediate lever adjusting nut 12.5 127 9 Wheel nut 103 1,050 76 SS SERVICE SPECIFICATIONS – STEERING COLUMN SS–35 STEERING COLUMN SERVICE DATA Steering wheel free play Maximum 30 mm (1.18 in.) SS SS–36 SERVICE SPECIFICATIONS – STEERING COLUMN TORQUE SPECIFICATIONS SS Part tightened N*m kgf*cm ft.*lbf Steering column assembly set bolt 25 255 18 Power steering motor set bolt 18 185 13 Steering intermediate shaft assembly No. 2 x Steering column assembly 35 360 26 Steering intermediate shaft assembly No. 2 x Steering sliding yoke sub-assembly 35 360 26 Steering sliding yoke subassembly x Steering intermediate shaft assembly 35 360 26 Steering wheel set nut 50 510 37 Tilt lever bracket set screw 2.0 20 37 Steering wheel pad set screw (Torx screw) 8.8 90 78 in.*lbf Power steering motor assembly x Steering column assembly 18 185 18 in.*lbf Power steering ECU assembly 5 50 44 in.*lbf Tie rod end lock nut 74 750 54 SS–36 SERVICE SPECIFICATIONS – POWER STEERING POWER STEERING SERVICE DATA STEERING WHEEL SS Steering effort (Reference) 5.5 N*m (56 kgf*cm, 49 in.*lbf) Steering wheel free play Maximum 30 mm (1.18 in.) POWER STEERING GEAR Tie rod end sub-assembly total preload (Turning) 2.0 N*m (20.4 kgf*cm, 18 in.*lbf) or less Steering gear assembly total preload (Turning) 0.6 - 1.2 N*m (6.1 - 12.2 kgf*cm, 5 - 11 in.*lbf) Steering rack boot clamp clearance 3.0 mm (0.12 in.) or less SS–37 SERVICE SPECIFICATIONS – POWER STEERING TORQUE SPECIFICATIONS Part tightened N*m kgf*cm ft.*lbf 50 510 37 Power steering rack x Steering rack end sub-assembly 60 (83) 612 (846) 44 (61) Tie rod assembly lock nut 74 749 54 Steering gear assembly set bolt 58 591 43 Steering intermediate shaft x Steering gear assembly 35 360 26 Front stabilizer bracket No. 1 19 194 14 Front stabilizer link assembly set nut 74 755 55 Steering sliding yoke subassembly set bolt 35 360 26 STEERING WHEEL Steering wheel set nut POWER STEERING GEAR Tie rod end sub-assembly set nut 74 749 54 Hub nut 103 1,050 76 ( ): For use without SST SS SERVICE SPECIFICATIONS – AIR CONDITIONING SS–37 AIR CONDITIONING SERVICE DATA Refrigerant charge volume Standard: 450 +- 50 g (15.87 +- 1.76 oz.) SS SS–38 SERVICE SPECIFICATIONS – AIR CONDITIONING TORQUE SPECIFICATIONS REFRIGERANT LINE SS Part Tightened N*m kgf*cm ft.*lbf Suction hose sub-assembly x Electric inverter compressor assembly 9.8 100 87 in.*lbf Discharge hose sub-assembly x Electric inverter compressor assembly 9.8 100 87 in.*lbf Discharge hose sub-assembly x Condenser assembly 5.4 55 49 in.*lbf Cooler refrigerant liquid pipe Ex Condenser assembly 5.4 55 49 in.*lbf AIR CONDITIONING UNIT Part Tightened N*m kgf*cm ft.*lbf Air conditioning tube and accessory assembly x Air conditioning unit assembly 3.5 35 30 in.*lbf ELECTRIC INVERTER COMPRESSOR Part Tightened N*m kgf*cm ft.*lbf Electric inverter compressor assembly x Engine 25 255 18 Suction hose sub-assembly x Electric inverter compressor assembly 9.8 100 87 in.*lbf Discharge hose sub-assembly x Electric inverter compressor assembly 9.8 100 87 in.*lbf CONDENSER Part Tightened N*m kgf*cm ft.*lbf Discharge hose sub-assembly x Condenser assembly 5.4 55 49 in.*lbf Cooler refrigerant liquid pipe Ex Condenser assembly 5.4 55 49 in.*lbf Radiator support bracket sub-assembly upper RH Bolt A 5.0 51 44 in.*lbf Bolt B 3.9 40 35 in.*lbf Bolt C 7.5 76 66 in.*lbf Bolt A 5.0 51 44 in.*lbf Radiator support bracket sub-assembly upper RH Bolt B 3.9 40 35 in.*lbf Bolt C 7.5 76 66 in.*lbf SS–38 SERVICE SPECIFICATIONS – SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM TORQUE SPECIFICATIONS Part Tightened Steering pad x Steering wheel assembly SS N*m kgf*cm ft.*lbf 8.8 90 78 in.*lbf Curtain shield airbag assembly set bolt 11 110 8 Front passenger airbag assembly x Body 20 204 15 Center airbag sensor x Body Front airbag sensor x Body 17.5 178 13 RH Side: 9.0 92 80 in.*lbf LH Side: 17.5 178 13 Side airbag sensor x Body 9.0 92 80 in.*lbf Rear airbag sensor x Body 17.5 178 13 Seat position sensor x Front seat assembly 8.0 82 71 in.*lbf SS–39 SERVICE SPECIFICATIONS – SEAT BELT SEAT BELT TORQUE SPECIFICATIONS FRONT SEAT BELT Part Tightened N*m kgf*cm ft.*lbf Front seat inner belt assembly x Front seat 42 428 31 Front seat outer belt assembly (Upper part of retractor) x Body 5.0 51 44 in.*lbf Front seat outer belt assembly (Lower part of retractor) x Body 42 428 31 Front seat outer belt assembly (shoulder anchor) x Body 42 428 31 Front seat outer belt assembly (floor anchor) x Body 42 428 31 Front shoulder belt anchor adjuster assembly x Body 42 428 31 REAR SEAT BELT Part Tightened N*m kgf*cm ft.*lbf Child restraint seat anchor bracket sub-assembly x Body 42 428 31 Rear seat inner belt assembly center x Body 42 428 31 Rear seat inner Belt Assembly RH x Body 42 428 31 Rear seat belt assembly outer center (retractor side.) x Body 42 428 31 Rear seat belt assembly outer center (for Floor Anchor) x Body 42 428 31 Rear seat outer belt assembly RH (retractor) x Body 42 428 31 Rear seat outer belt assembly RH (floor anchor side) x Body 42 428 31 Rear seat outer belt RH (floor anchor side.) x Body 42 428 31 SS SS–40 SERVICE SPECIFICATIONS – WIPER AND WASHER WIPER AND WASHER TORQUE SPECIFICATIONS SS Part Tightened N*m kgf*cm ft*lbf Wiper motor x Wiper link 5.4 5.5 48 in. lbf Wiper motor x Crank arm 17 175 13 Wiper link x Body 5.5 56 49 in. lbf Wiper arm x Wiper link 21 214 15 Rear wiper motor x Body 5.5 56 49 in. lbf Rear wiper motor x Rear wiper arm 5.5 56 49 in. lbf SS–41 SERVICE SPECIFICATIONS – AUDIO / VISUAL AUDIO / VISUAL TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft*lbf Antenna holder assembly x antenna nut 5.0 51 44 in. lbf Antenna cord x bolt 7.0 71 62 in. lbf SS SS–42 SERVICE SPECIFICATIONS – HORN HORN TORQUE SPECIFICATIONS HORN SS Part Tightened N*m kgf*cm ft.*lbf Low pitched horn x Body 20 204 15 High pitched horn x Body 20 204 15 SERVICE SPECIFICATIONS – WINDSHIELD / WINDOWGLASS SS–43 WINDSHIELD / WINDOWGLASS TORQUE SPECIFICATIONS WINDSHIELD/WINDOWGLASS Part Tightened N*m kgf*cm ft.*lbf Wiper arm x Body 21 214 15 w/ Rear Wiper Rear wiper arm x Body 5.5 56 49 in.*lbf SS SS–44 SERVICE SPECIFICATIONS – MIRROR MIRROR TORQUE SPECIFICATIONS MIRROR SS Part Tightened N*m kgf*cm ft.*lbf Outer rear view mirror assembly x Door panel 5.5 56 49 in.*lbf SS–45 SERVICE SPECIFICATIONS – INSTRUMENT PANEL INSTRUMENT PANEL TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Instrument panel reinforcement x Passenger airbag 20 204 15 SS SS–46 SERVICE SPECIFICATIONS – SEAT SEAT TORQUE SPECIFICATIONS Front Seat Assembly SS Part Tightened N*m kgf*cm ft.*lbf Airbag sensor x Seat adjuster frame 8.0 82 71 in.*lbf Seatback cover bracket x Seat adjuster frame (w/ front seat side airbag) 5.5 56 49 in.*lbf Inner belt x Seat adjuster frame 42 428 31 Seat x Body 37 377 27 Part Tightened N*m kgf*cm ft.*lbf Seatback hinge x Seatback frame 36.8 375 27 Seatback center hinge x Seatback frame 36.8 375 27 Seatback hinge x Body 18.1 185 13 Seatback center hinge x Body 18.1 185 13 Seatback lock x Seatback frame 18.1 185 13 Rear seat outer belt center x Seatback frame 42 428 31 Rear seat outer belt center (floor anchor) x Body 42 428 31 Rear Seat Assembly SS–47 SERVICE SPECIFICATIONS – ENGINE HOOD / DOOR ENGINE HOOD / DOOR TORQUE SPECIFICATIONS Part tightened N*m kgf*cm ft.*lbf HOOD Hood hinge x Hood 13 133 10 Hood hinge x Body 5.5 56 49 in.*lbf Hood lock x Hood 8.0 82 71 in.*lbf Door check x Body 30 306 22 Door check x Door panel 5.5 56 49 in.*lbf Door frame sub-assembly rear lower x Door panel 8.0 82 71 in.*lbf Door glass x Front door window regulator 5.5 56 49 in.*lbf Door hinge x Body 26 265 19 Door hinge x Door panel 26 265 19 FRONT DOOR Door lock x Door panel 5.0 51 44 in.*lbf Door lock striker x Body 23 235 17 Door outside handle cover x Door panel 7.0 71 62 in.*lbf Door outside handle frame x Door panel 4.0 41 35 in.*lbf Outer view mirror x Door panel 10 102 7 Window regulator x Door panel 8.0 82 71 in.*lbf Door check x Body 30 306 22 Door check x Door panel 5.5 56 49 in.*lbf Door hinge x Body 26 265 19 REAR DOOR Door hinge x Door panel 26 265 19 Door lock x Door panel 5.0 51 44 in.*lbf Door lock striker x Body 23 235 17 Door outside handle cover x Door panel 4.0 41 35 in.*lbf Door outside handle frame x Door panel 7.0 71 62 in.*lbf Window division bar subassembly x Door panel 5.5 56 49 in.*lbf Back door femaie stopper x Door panel 5.5 56 49 in.*lbf Back door hinge assembly x Body 19.5 200 14 Back door hinge assembly x Door panel 19.5 200 14 Back door lock assembly x Door panel 8.0 82 71 in.*lbf Back door lock striker x Body 11.5 120 8.0 Back door stay sub-assembly x Body 7.0 71 62 in.*lbf Back door stay sub-assembly x Door panel 22 224 16 Center stop light assembly x Door panel 5.5 56 49 in.*lbf BACK DOOR (LIFTBACK MODEL) SS SS–48 SERVICE SPECIFICATIONS – EXTERIOR EXTERIOR TORQUE SPECIFICATIONS Front Bumper SS Part tightened N*m kgf*cm ft.*lbf Front bumper reinforcement x Body 67 683 49 Radiator grille protector x Body 5.0 51 44 in.*lbf SS–49 SERVICE SPECIFICATIONS – INTERIOR INTERIOR TORQUE SPECIFICATIONS Roof Headlining Part tightened N*m kgf*cm ft.*lbf Front seat outer belt (floor anchor) x Body 42 430 31 Rear seat 3 point type belt (floor anchor) x Body 42 430 31 SS