td-01 02 Ps

TECHNICAL DATA
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . .
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . .
FUEL AND EMISSION CONTROL
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE ELECTRICAL SYSTEM . . . . . . . . .
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL TRANSMISSION . . . . . . . . . . . . . . .
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . .
FRONT AND REAR AXLES (VEHICLES
BUILT UP TO 07/2002) . . . . . . . . . . . . . . . . .
FRONT AND REAR AXLES (VEHICLES
BUILT FROM 08/2002) . . . . . . . . . . . . . . . . .
TD
TD
TD
TD
1
1
4
4
TD 5
TD 6
TD10
TD10
TD11
TD11
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . .
BRAKING SYSTEM (VEHICLES
BUILT UP TO 07/2002) . . . . . . . . . . . . . . . . .
BRAKING SYSTEM (VEHICLES
BUILT FROM 08/2002) . . . . . . . . . . . . . . . . .
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . .
WHEELS AND TIRES (VEHICLES
BUILT UP TO 07/2002) . . . . . . . . . . . . . . . . .
WHEELS AND TIRES (VEHICLES
BUILT FROM 08/2002) . . . . . . . . . . . . . . . . .
BODY ELECTRICAL SYSTEM . . . . . . . . . . .
HEATER AND AIR
CONDITIONER SYSTEMS . . . . . . . . . . . . .
TD12
TECHNICAL DATA
ENGINE
Engine
Item
Generator
Drive belt deflection
[Applied pressure
98 N {10 kgf, 22 lbf}]
(mm {in})
P/S
A/C
Generator
Drive belt tension

(N {kgf, lbf})
P/S
A/C
Compression
(kPa {kgf/cm2, psi} [rpm])
Pushing distance of the front oil seal

(from the edge of the chain cover)
Pushing distance of the rear oil seal
(from the edge of the rear cover)
G6
New
10.012.0 {0.400.47}
Used
12.014.0 {0.480.55}
New
6.67.2 {0.260.28}
Used
7.28.0 {0.290.31}
New
8.510.0 {0.340.39}
Used
10.011.5 {0.400.45}
New
491588 {5060, 110132}
Used
393490 {4050, 88110}
New
412470 {4248, 93105}
Used
354402 {3641, 8090}
New
557641 {56.765.4, 125143}
Used
471556 {48.056.7, 106124}
Standard
1255 {12.8, 182} [270]
Minimum
882.6 {9.0, 128} [270]
(mm {in})
(mm {in})
TD1
00.7 {00.027}
00.5 {00.019}
TD13
TD13
TD14
TD15
TD15
TD17
TD18
TD18
TECHNICAL DATA
Specification
Item
WL
WL Turbo
Type
WLT3
Diesel, 4-cycle
Cylinder arrangement and number
Inline, 4-cylinder
Combustion chamber
Swirl type
Valve system
OHC, timing gear and belt driven,12 valves
Displacement
Bore
WL3
(ml {cc, cu in})
stroke
2,499 {2,499, 152.4}
(mm {in})
Generator
93.0
92.0 {3.66
3.62}
New
7.09.0 {0.280.35}
Used
8.010.0 {0.320.39}
Limit
16.0 {0.63}
A/C (measuring
[Applied pressure 98 N {10 kgf, point a)
22 lbf}]
(mm {in})
New
5.06.2 {0.200.24}
Used
6.06.5 {0.240.25}
Limit
11.3 {0.44}
A/C (measuring
point b)
New
9.511.8 {0.380.46}
Used
11.012.5 {0.440.49}
Limit
18.0 {0.71}
New
442637 {4565, 99143}
Used
383539 {3955, 86121}
Limit
177 {18, 40}
New
403519 {4153, 91116}
Used
354431 {3644, 8096}
Limit
181 {18.5, 41}
Generator
Drive belt tension

(N {kgf, lbf})
A/C
Timing belt deflection

[Applied pressure 98 N {10 kgf, 22 lbf}]
(mm {in})
Bolt head mark W

Cylinder head bolt length
(mm {in})
Bolt head mark N
Standard
9.010.0 {0.360.39}
Standard
101.2101.8 {3.9854.007}
Minimum
102.5 {4.035}
Standard
113.2113.8 {4.4574.480}
Minimum
114.5 {4.508}
Camshaft oil seal tapping amount
(mm {in})
0.51.0 {0.020.03}
Front oil seal tapping amount
(mm {in})
00.4 {00.01}
Rear oil seal tapping amount
(mm {in})
Compression ratio
21.9,
Compression pressure
IN
Valve timing
EX
(kPa
{kgf/cm2,
psi} [rpm])
20.1, 19.8*1
21.6
19.9
2,942 {30, 427} [200]
Open
BTDC ()
10
Close
ABDC ()
28
24
23
Open
BBDC ()
61
Close
ATDC ()
IN
Valve
clearance
00.5 {00.01}
21.6*1
(mm {in})
EX
Engine cold
0.050.15 {0.00200.0059}
(0.10 0.05 {0.0039 0.0019})
Engine hot
(Reference)
0.15 {0.0059}
Engine cold
0.150.25 {0.00600.0098}
(0.20 0.05 {0.0078 0.0019})
Engine hot
(Reference)
0.25 {0.0098}
TD2
TECHNICAL DATA
Engine
Item
Generator
[Applied pressure
98 N {10 kgf, 22 lbf}]
(mm {in})
P/S
A/C
Generator
Drive belt tension

(N {kgf, lbf})
P/S
A/C
Compression
(kPa {kgf/cm2, psi} [rpm])
Timing belt deflection

[Applied pressure 98 N {10 kgf, 22 lbf}] (mm {in})
Pushing distance of the front oil seal
(from the edge of the chain cover)
Pushing distance of the rear oil seal
(from the edge of the rear cover)
F2 CARB
F2 CIS
New
7.08.0 {0.280.31}
Used
8.09.0 {0.320.35}
New
5.06.0 {0.200.23}
Used
5.56.5 {0.220.25}
New
10.012.0 {0.400.47}
Used
12.014.0 {0.480.55}
New
510588 {5260, 115132}
Used
432509 {4452, 97114}
New
393490 {4050, 88110}
Used
344441 {3545, 7799}
New
373490 {3850, 84110}
Used
275372 {2838, 6283}
Standard
1196 {12.2, 173} [300]
1226 {12.5, 178} [300]
Minimum
837 {8.54, 121} [300]
858 {8.75, 124} [300]
New
8.09.0 {0.320.35}
Used
9.010.0 {0.360.39}
(mm {in})
(mm {in})
TD3
0 {0}
00.5 {00.019}
TECHNICAL DATA
LUBRICATION SYSTEM
Engine
Item
F2
G6
WL
WL Turbo
295392
{3.04.0,
4356}
[3000]
305402
{3.14.1,
4558}
[3000]
452529
{4.65.4,
6676}
[3000]
402480
{4.14.9,
5969}
[3000]
Oil replacement
3.9 {4.1, 3.4}
4.5 {4.8, 4.0}
5.6 {5.9, 4.9}
Oil and oil filter replacement
4.2 {4.4, 3.7}
4.7 {5.0, 4.4}
6.3 {6.7, 5.5}
Total (dry engine)
4.6 {4.9, 4.0}
5.5 {5.8, 4.8}
Oil pressure
(kPa
Oil capacity
(L {US qt, lmp qt})
{kgf/cm2,
psi} [rpm])
Engine oil
API service CD
SAE 40
0C40_C {32_F104F}
SAE 30
10C20_C {14_F68F}
SAE 20W-20
Above 30_C {86F}
Above 25_C {13F}

Viscosity
6.7 {7.1, 5.9}
API service SG
SAE
10W-30*,
10W-40, 10W-50
Above 10_C {14F)
SAE 20W-40, 20W-50
Below 20_C {4_F}
SAE 5W-20
Below 0_C {32_F}
SAE
15C40_C {5_F104F}
5W-30*
SAE 10W-30
Below 10_C {50_F}
D European specification vehicles use only those oils marked with an asterisk
SAE 5W-30
COOLING SYSTEM
Engine
Item
F2
G6
Cooling system
Coolant capacity (Approximate
quantity)
(L {US qt, lmp qt})
Water
pump
WL
7.5 {7.9, 6.6}
9.4 {9.9,8.3}
Without
heater
6.9 {7.3, 6.1}
8.8 {9.3, 7.7}
Type
Centrifugal,
timing belt
driven
Type
Wax, flow
control
Wax,
twostage
Wax, bottom bypass
83.589.5
{183193}
Sub:
83.589.5
{183193}
Main:
86.589.5
{188193}
8084 {176183}
Opening
temperature
(_C {_F})
Full-open
temperature
(_C {_F})
WLT3
Centrifugal, Vbelt driven
100 {212}
8.5 {0.33}
min
Full-open lift
(mm {in})
95 {203}
Sub: 1.5
{0.06} min
Main: 8.0
{0.31} min
Type
8.5 {0.33} min.

Corrugated fin
Cap valve opening pressure

(kPa {kgf/cm2, psi})
74102
{0.751.05, 10.714.9}
Type
Cooling
fan
WL turbo
With
heater
Thermo
stat
Radiator
WL3
Water-cooled, force circulation
94122 {0.951.25, 13.617.7}

Thermo-modulation
Outer diameter
Blade
(mm {in})
Number
380 {15.0}
410 {16.1}
440 {17.3}
10
TD4
TECHNICAL DATA
FUEL AND EMISSION CONTROL SYSTEMS
CIS vehicles
Engine
Item
Idle speed
(rpm)
F2
730770 (750"20)
730770 (750"20)
46/750
57/750
(BTDC /rpm)
Injection timing
Idle speed*1
G6
(rpm)
A/C
ON*2
700800 (750"50)
P/S ON*3
780880 (830"50)
700800 (750"50)
CO concentration
Within the regulation
HC concentration
Fuel pressure
Hold pressure
More than 340 {3.5, 50}
Fuel pump maximum pressure
500630 {5.06.5, 7292}
Fuel leakage
Less than 1
(drop/2 minutes)
Injection volume
(ml {cc, fl oz}/15 sec.)
Fuel injector
5571 {5571, 1.92.3}
Resistance
1216
() [20C {68F}]
Pressure regulator
*1:
*2:
*3:
*4:
4660 {4660, 1.62.0}
Fuel pressure (at vacuum ON)

210250 {2.12.6, 3036}
Fuel pressure (at vacuum OFF*4)

270310 {2.73.2, 3945}
Excludes temporary idle speed drop just after the loads (A/C, P/S) are turned on.
A/C switch and fan switch are turned on.
Steering wheel is fully turned.
Hot condition at start.
DIESEL vehicles
Engine
Item
WL Turbo
WL
(780"20)*1
(rpm)
760800
700740 (720"20)*2
107115 {1.091.18,
15.516.8}
When A/C is operated
825875 (850"25)
805855 (830"25)
825875 (850"25)*3
When P/S is operated
Idle speed
Injection timing
ATDC 10
Boost relief pressure
Idle-up speed
(rpm)
When engine is cold

Injection pump
Injection nozzle
Cam lift
12001500 (1350"150)
(mm {in})
Diesel smoke
2.48 {0.098}
Injection starting pressure

(MPa {kgf/cm2, psi})
New: 11.412.2 {116124, 16501760}

Inspection: More than 10.0 {102, 1450}
No leakage when pressure of 8.8 MPa {90 kgf/cm2, 1280 psi})
is applied.
Nozzle leakage
*1:
*2:
*3:
700740 (720"20)
(%)
General (L.H.D.)
Europe and UK
Europe
TD5
TECHNICAL DATA
CARB vehicles
Engine
Item
F2 CARB
Idle speed
800850 (800 +50

0 )
(rpm)
Injection timing
(BTDC)
Idle-up speed
(rpm)
57 (6"1)
A/C Operated
14001600 (1500"100)
P/S Operated
D/P Operated
19002100 (2000"100)
T/P Operated
CO concentration
HC concentration
Fuel pump
Carburetor
(ppm)
Discharge pressure
(kPa
Discharge amount
Float level
(mm {in})
{kgf/cm2,
psi})
2025 {0.20.25, 2.83.6}
cc {cu in} min.
1150 {70.2}
89 {0.3150.354}
Primary throttle opening angle

*1:
*2:
10501250 (1150"100)
1
2
2.02.5 (2.0 +0.5
0 )* , 2.03.0 (2.5"0.5)*
(%)
4445 {1.7321.772}
()
4852 {50"2}
GULF
General
ENGINE ELECTRICAL SYSTEM

Engine
Item
G6
Electrolyte gravity
1.271.29
Back-up current *1
Test load chart
(mA)
Max. 20
Battery type
80D26R
(A)
Battery type
(5-hour rate)
80D26R (55)
5.56.5
Quick charge
(A/30 min.)
Battery type
(5-hour rate)
80D26R (55)
35
(A)
Battery
Slow charge
195
Rotor resistance (Between slip rings)
()
Standard
Brush length
Brush spring force
(mm {in})
Standard
(N {kgf, lbf})
4.86.0 {0.480.62, 1.061.36}
Minimum
(N {kgf, lbf})
2.2 {0.22, 0.48}
Terminal
Standard voltage
(V)
Idle
[20_C {68_F}]
Generated current*2
(Reference)
(A)
18.5 {0.73}
Minimum
Ignition switch
ON
Generator
(mm {in})
3.74.4
Engine speed
Terminal
5.0 {0.20}
B+
Approx. 1
B+
14.114.7
13.014.0
14.114.7
1000
Approx. 043
2000
Approx. 062
(rpm)
*1:
Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the ignition
switch is at OFF position and the ignition key is removed.
*2: Must not be 0 A.
TD6
TECHNICAL DATA
Engine
Item
Ignition
coil
G6
Primary coil
Resistance
[20_C {68_F}]
()
Secondary coil
(k)
NGK
DENSO
KJ16CR11*3, *5, KJ20CR11*4, *5

K16PRU*3, K20PRU*4
Plug gap
(mm {in})
(k)
)
Resistance
Tightening torque
Hightension
lead
) [20 _C {68 _F}]

(k
Commutator
diameter
Brush length
Starter
Brush spring force
1.01.1 {0.0400.043}*5,
0.70.8 {0.0280.031}
3.07.5
DENSO
1522 {1.52.3, 1116}
No.1 lead
2.97.7
No.2 lead
4.310.8
No.3 lead
5.413.5
No.4 lead
6.616.2
Center lead
4.511.2
Standard
(mm {in})
29.4 {1.16}
Minimum
(mm {in})
28.8 {1.14}
Standard
(mm {in})
12.3 {0.48}
Minimum
(mm {in})
Standard
(N {kgf, lbf})
180243 {18.324.8, 40.354.5}
Minimum
(N {kgf, lbf})
57.7 {5.88, 12.9}
Pinion gap
No load test
NGK
(Nm {kgfm, ftlbf})
Resistance
1016
ZFR5F11*3, *5, ZFR6F11*4, *5,
BKR5E*3, BKR6E*4
Type
Spark
plug
0.810.99
(mm {in})
7.0 {0.28}
3.0 {1.118}
Voltage
(V)
11.5
Current
(A)
Below 100
*3:
Standard plug
*4: Cold type plug
*5: Europe
TD7
TECHNICAL DATA
Engine
Item
F2 CARB
F2 CIS
Electrolyte gravity
Back-up current
Test load chart
(A)
Battery
1.271.29
*1
(mA)
Battery type
34B19R
180
(A)
Battery type
(5-hour rate)
Quick charge
(A/30 min.)
Battery type
(5-hour rate)
34B19R (27)
3.04.0
Brush spring force
4.55.5
20
30
()
18.5 {0.73}
Minimum
(mm {in})
5.0 {0.20}
Standard
(N {kgf, lbf})
4.86.0 {0.480.62, 1.061.36}
Minimum
(N {kgf, lbf})
2.2 {0.22, 0.48}
B+
Approx. 1
B+
14.114.7
13.014.0
14.114.7
Terminal
(V)
Idle
[20_C {68_F}]
Ignition
coil
Engine speed
Terminal
1000
Approx. 043
2000
Approx. 062
(rpm)
Primary coil
Resistance
[20_C {68_F}]
()
Secondary coil
02/1200, 913/2200,
1923/6000
/kPa {mmHg, inHg}
02/20 {150, 5.9},

1115/53.3 {400, 15.7}
BKR5E*5
BKR6E*3
BKR7E*4
BPR5ES11*3
BPR6ES11*4
K16PRU*5
K20PRU*3
K22PRU*4
W16EXRU11*3
W20EXRU11*4
0.70.8 {0.0280.031}
1.01.1 {0.0400.043}
NGK
Type
DENSO
Spark
plug
Plug gap
(mm {in})
(k)
)
Tightening torque
Hightension
lead
Resistance
(k
) [20 _C {68 _F}]
NGK
*2:
*3:
*4:
*5:
3.07.5
DENSO
(Nm {kgfm, ftlbf})
1522 {1.52.3, 1116}
No.1 lead
2.757.07
No.2 lead
4.1910.43
No.3 lead
4.3810.88
No.4 lead
Center lead
*1:
0.810.99
1016
/rpm
Distributor
Vacuum spark advance
1.0351.265
(k)
Centrifugal spark advance
Resistance
3.74.4
(mm {in})
Standard voltage
Generated current*2
(Reference)
(A)
55D23R (48)
Standard
Ignition switch
ON
Generator
55D23R (48)

Brush length
55D23R
34B19R (27)
Slow charge
Max. 20
110
5.7314.08
2.005.33
3.99.9
Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the ignition
switch is at OFF position and the ignition key is removed.
Must not be 0 A.
Standard plug
Cold type plug
Hot type plug
TD8
TECHNICAL DATA
Engine
Item
Commutator
diameter
Brush length
Starter
Brush spring force
F2 CARB
Standard
(mm {in})
32.0 {1.26}
Minimum
(mm {in})
31.4 {1.24}
Standard
(mm {in})
17.0 {0.67}
Minimum
(mm {in})
Standard
(N {kgf, lbf})
19.2 {1.95, 4.25}
Minimum
(N {kgf, lbf})
8.83 {0.90, 1.98}
Pinion gap
11.5 {0.46}
(mm {in})
No load test
0.52.0 {0.0200.078}
Voltage
(V)
11.5
Current
(A)
Below 60
Engine
Item
WL, WL Turbo
Electrolyte gravity
1.271.29
Back-up current *1
Test load chart
(A)
(mA)
Battery type
Battery
Slow charge
(A)
Quick charge
(A/30 min.)
Battery type
(5-hour rate)
Battery type
(5-hour rate)
195
75D26R
195
95D31R
250
75D26L (52)
5.56.5
75D26R (52)
5.56.5
95D31R (64)
6.58.0
75D26L (52)
35
75D26R (52)
35
95D31R (64)
Brush spring force
40
()
(mm {in})
17.9 {0.70}
Minimum
(mm {in})
5.0 {0.20}
Standard
(N {kgf, lbf})
2.65 {0.27, 0.59}
(N {kgf, lbf})
1.18 {0.12, 0.26}
Minimum
B+
B+
2.04.0
14.0514.85
14.0514.85
7.0257.425
13.0014.85
1000
Terminal B
current
Approx. 058
2000
Terminal B
current
Approx. 074
Terminal
Standard voltage
(V)
Idle
[20_C {68_F}]
Generated current*2
(Reference)
(A)
2.50
Standard
Engine switch
ON
Generator
20 max.
75D26L

Brush length
F2 CIS
Engine speed
(rpm)
Terminal
*1: Back-up
current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the engine
switch is at OFF position and the engine key is removed.
*2: Must not be 0 A.
TD9
TECHNICAL DATA
Engine
Item
Commutator
diameter
Brush length
Starter
Brush spring force
WL, WL Turbo
Standard
(mm {in})
29.5 {1.16}
Minimum
(mm {in})
27.3 {1.07}
Standard
(mm {in})
17.7 {0.70}
Minimum
(mm {in})
Standard
(N {kgf, lbf})
27.033.0 {2.753.37, 6.057.41}
Minimum
(N {kgf, lbf})
Pinion gap
(mm {in})
No load test
8.7 {0.34}
3.0 {0.12}
Voltage
(V)
11
Current
(A)
Below 130
CLUTCH
Item
Specification
Clutch pedal
Height
(mm {in})
241.6246.6 {9.529.70}
Pedal free play
(mm {in})
3.08.0 {0.120.31}
(mm {in})
0.7 {0.027} max.
Clutch disc
Runout limit
Clutch fluid
Type
SAE J1703 or FMVSS116 DOT-3 or DOT-4
MANUAL TRANSMISSION
M15M-D
Item
Specification
Type
Transmission oil
Viscosity
Capacity
API service GL-4 or GL-5

All-season
SAE 75W-90
Above
10 _C {50 _F}
SAE 80W-90
(L {US qt, lmp qt})
2.0 {2.1, 1.8}
M15MX-D
Item
Specification
Type
Transmission oil
Viscosity
Capacity

All-season
SAE 75W-90
Above
10 _C {50 _F}
SAE 80W-90
(L {US qt, lmp qt})
Type
Transfer oil
Viscosity
Capacity
2.5 {2.6, 2.2}

All-season
SAE 75W-90
Above
10 _C {50 _F}
SAE 80W-90
(L {US qt, lmp qt})
2.0 {2.1, 1.8}
R15M-D
Item
Specification
Type
Transmission oil
Viscosity
Capacity

All-season
SAE 75W-90
Above
10 _C {50 _F}
SAE 80W-90
(L {US qt, lmp qt})
TD10
2.8 {3.0, 2.5}
TECHNICAL DATA
R15MX-D
Item
Specification
Type
Transmission oil
Viscosity
All-season
SAE 75W-90
Above
10 _C {50 _F}
SAE 80W-90
Capacity
(L {US qt, lmp qt})
3.2 {3.4, 2.8}
Type
Transfer oil
Viscosity
All-season
SAE 75W-90
Above
10 _C {50 _F}
SAE 80W-90
Capacity
(L {US qt, lmp qt})
2.0 {2.1, 1.8}
PROPELLER SHAFT
Item
Front propeller shaft

(4 4)
Rear propeller shaft

(4 4)
0.4 {0.016}
0.4 {0.016}
0.4 {0.016}
0.31.1
{3.012.0, 2.710.4}
0.30.7
{3.08.0, 2.76.9}
0.31.1
{3.012.0, 2.710.4}
Propeller shaft (4
Runout limit
(mm {in})
Starting torque of universal

(Nm {kgfcm, inlbf})
2)
FRONT AND REAR AXLES (VEHICLES BUILT UP TO 07/2002)

Item
4 2
Play
0 {0}
Preload
Front axle
Wheel bearing
0.40.7 {4.08.0, 3.56.9}
(Nm {kgfcm, inlbf})

Pull scale reading
5.910.7 {0.61.1, 1.42.4}
(N {kgf, lbf})
Rear axle
Wheel bearing play
Drive shaft
Shaft length
(mm {in})
(mm {in})
0.050.25 {0.0020.010}
Left side
551.0561.0 {21.722.0}
Right side
619.0629.0 {24.424.7}
Pinion height
(mm {in})
Backlash of side gear and differential

pinion
(mm {in})
Drive pinion preload (Nm {kgfcm, inlbf})
Backlash of drive
pinion and ring
gear
(mm {in})
Front
0.0320.032 {0.0010.001}
Rear
0.2540.254 {0.0100.010}
Front
00.1 {00.003}
Rear
Front
0.91.3 {9.014.0, 7.912.1}
Rear
1.82.6 {18.027.0, 15.723.4}
Standard
0.090.11 {0.00360.0043} [Front]

0.120.20 {0.0050.008} [Rear]
Minimum
0.05 {0.002} [Front], 0.12 {0.008} [Rear]
Allowance variation
0.07 {0.003} [Front], 0.08 {0.005} [Rear]

3.909
Differential
Final gear ratio
4.444
4.100
WL3
F2 CIS
F2 CARB
WL
Grade
Front
Viscosity
SAE 90
1.20 {1.27, 1.06} [MFW]
1.50 {1.59, 1.32} [RFW]
Front
Rear
1.40 {1.48, 1.23}
Grade
1.85 {1.96, 1.63}
API service GL-6
Viscosity
Capacity
4.777
WLT3
WL TURBO
G6
WL
Above-18_C {0_F}: SAE 90

Below-18_C {0_F}: SAE 80
Rear
Capacity
(L {US qt, lmp qt})
LSD
4.444
API service GL-5
Standard
Oil
4 4
(mm {in})
SAE 90
(L {US qt, lmp qt})
TD11
1.40 {1.48, 1.23}
1.85 {1.96, 1.63}
TECHNICAL DATA
FRONT AND REAR AXLES (VEHICLES BUILT FROM 08/2002)
Item
Specification
Drive type
Play
(mm {in})
Preload
Front axle
Wheel bearing
Drive shaft
Shaft length (Air

in boot at
atmospheric
pressure)
(mm {in})
(mm {in})
0.050.25 {0.0020.010}
525.5535.5
{20.6921.08}
Right side
593.5603.5
{23.3723.75}
(mm {in})
Backlash of side gear and differential

pinion
(mm {in})
Drive pinion preload (Nm {kgfcm, inlbf})
Front
0.0320.032 {0.0010.001}
Rear
0.2540.254 {0.0100.010}
Front
00.1 {00.003}
Rear
Front
0.91.3 {9.014.0, 7.912.1}
Rear
1.82.6 {18.027.0, 15.723.4}
Standard
0.090.11 {0.00360.0043} [Front]

0.120.20 {0.0050.008} [Rear]
Minimum
0.05 {0.002} [Front], 0.12 {0.008} [Rear]
Allowance variation
0.07 {0.003} [Front], 0.08 {0.005} [Rear]

3.909
Differential
0.05 {0.002}
Left side
Pinion height
Backlash of drive
pinion and ring
gear
(mm {in})
0 {0}
5.910.7 {0.61.1, 1.42.4}
(N {kgf, lbf})
Wheel bearing play
4x4
0.40.7 {4.08.0, 3.56.9}
(Nm {kgfcm, inlbf})

Pull scale reading
Rear axle
4x2
Final gear ratio
4.444
4.100
WL3
F2 CIS
F2 CARB
WL
Grade
Front
Standard
Above-18_C {0_F}: SAE 90

Below-18_C {0_F}: SAE 80
Rear
Capacity
(L {US qt, lmp qt})
SAE 90
1.20 {1.27, 1.06} [MFW]
1.50 {1.59, 1.32} [RFW]
Front
Rear
1.40 {1.48, 1.23}
Grade
LSD
1.85 {1.96, 1.63}
API service GL-6
Viscosity
Capacity
4.777
WLT3
WL TURBO
G6
WL
API service GL-5
Viscosity
Oil
4.444
SAE 90
(L {US qt, lmp qt})
TD12
1.40 {1.48, 1.23}
1.85 {1.96, 1.63}
TECHNICAL DATA
STEERING SYSTEM
Item
Play
Steering wheel
(mm {in})
Effort
030 {01.18}
(Nm {kgfcm, inlbf})
Backlash
45 {460, 399} max.
(mm {in})
Worm shaft preload
Steering gear
(Nm {kgfcm, inlbf})
Grade
Capacity
Power steering
oil pump
7.8 {80, 69} max.

0 {0}
1.01.3
{1014, 8.712.1}
0.71.2
{6.512.5, 5.710.8}
8.99.3
{9095, 12801350}
API service GL-4, SAE 90
ATF M-III or equivalent

(e.g. DexronRII)
0.34 {0.36, 0.30}
1.1 {1.2, 1.0}
8.99.3
{9095, 12801350}
Gear housing pressure

Oil
Engine speed sensing

power steering
Manual steering
(L {US qt, lmp qt})
Oil pump fluid pressure

BRAKING SYSTEM (VEHICLES BUILT UP TO 07/2002)

4 2
Item
F2, G6
4 4
WL, WL Turbo
Brake pedal
Brake pedal height
(mm {in})
L.H.D.: 214219 {8.438.81}

R.H.D.: 219224 {8.638.81}
Brake pedal play
(mm {in})
38 {0.120.31}
Brake pedal-to-floor clearance
(mm {in})
105 {4.2} min.
Power brake unit

Fluid pressure when
pedal depressed at
196 N {20 kgf ,44 lbf})
Power brake unit

at 0 kPa {0 mmHg,
0 in Hg}
790 {8, 114} min.
Power brake unit at

66.7 kPa {500
mmHg, 19.7 in Hg}
8,240 {84, 1,200} min.
Vacuum pump
Vacuum specification [In 20 seconds]
[When engine speed 1,500 rpm]
(kPa {mmHg, in Hg})
73.3 {550, 21.7}
Maximum vacuum
(kPa {mmHg, in Hg})
93.3 {700, 27.6}
Braking force control device

Type
LSPV
Rear fluid pressure when front pressure is

4,900 kPa {50 kgf/cm2, 711 psi}
2,550 {26, 370}
Front disc brake

Disc pad thickness limit
(mm {in})
2.0 {0.08}
Thickness limit
(mm {in})
22 {0.87}
Runout limit
(mm {in})
0.05 {0.002}
Brake lining thickness limit
(mm {in})
1.0 {0.04}
Drum maximum diameter
(mm {in})
Disc plate
Rear drum brake

271.5 {10.68}
296.5 {11.67}
Parking brake
Parking brake lever stroke
[When pulled at 98 N {10 kgf, 22 lbf}]
(notches)
17
Brake fluid
Type
TD13
TECHNICAL DATA
BRAKING SYSTEM (VEHICLES BUILT FROM 08/2002)
Item
Specification
Drive type
4x2
4x4
Brake pedal
Brake pedal height
(mm {in})
L.H.D.: 214219 {8.438.81}

R.H.D.: 219224 {8.638.81}
Brake pedal play
(mm {in})
38 {0.120.31}
Brake pedal-to-floor clearance
(mm {in})
105 {4.2} min.
Power brake unit

Fluid pressure when
pedal depressed at
196 N {20 kgf ,44 lbf})
Power brake unit

at 0 kPa {0 mmHg,
0 in Hg}
790 {8, 114} min.
Power brake unit at

66.7 kPa {500
mmHg, 19.7 in Hg}
8,040 {82, 1,166} min.
Vacuum pump
Vacuum specification [In 20 seconds]
(kPa {mmHg, in Hg})
73.3 {550, 21.7}
Maximum vacuum
(kPa {mmHg, in Hg})
93.3 {700, 27.6}
Load sensing proportioning valve (LSPV)
Fluid pressure
When front
pressure is 4,900
kPa {50 kgf/cm2,
711 psi}
Without ABS: 2,2502,850

{22.9529.06, 327413}
With ABS: 2,9103,710
{29.6837.83, 423538}

{22.9529.06, 327413}
With ABS: 2,6503,450
{27.0335.18, 385500}
When front
pressure is 9,800
kPa {100 mmHg,
19.7 in Hg}

{31.9240.07, 454569}
With ABS: 4,9706,170
{50.6862.91, 721894}

{31.9240.07, 454569}
With ABS: 47005,900
{47.9360.16, 682855}
Front disc brake

Disc pad thickness limit
(mm {in})
2.0 {0.08}
Thickness limit
(mm {in})
Runout limit
(mm {in})
0.05 {0.002}
Brake lining thickness limit
(mm {in})
1.0 {0.04}
Drum maximum diameter
(mm {in})
271.5 {10.68}
Disc plate
22 {0.87}
26 {1.02}
Rear drum brake
Parking brake
Parking brake lever stroke
[When pulled at 98 N {10 kgf, 22 lbf}]
(notches)
17
Brake fluid
Type
TD14
TECHNICAL DATA
SUSPENSION
Suspension
Item
4 2
(mm {in})
Total toe-in
Front wheel
alignment
[unloaded*1]
4 4
3"3 {0.12"0.12}
0_16 "16
(Degree)
0_14 "14
Camber angle
+2_
35_00 3_
33_00 +2_
3_
0_56"30
33_30 +2_
3_
30_00 +2_
3_
1_ 06"30
Caster angle*2
1_37"45
2_02"45
Inner
Maximum
steering angle
Outer
Exposed thread of shock absorber piston
(mm {in})
Lower arm ball joint rotation torque

(Pull scale reading)
(N {kgf, lbf})
Upper arm ball joint rotation torque

(Pull scale reading)
(N {kgf, lbf})
Exposed thread of stabilizer control link bolt
68 {0.240.31}
1444 {0.74.5, 1.69.9}
3.432.5 {0.43.2, 0.97.0}
(mm {in})
1821 {0.710.82}
*1:
Fuel tank is full. Engine coolant and engine oil are at specified levels. Spare tire, jack, and tools are in
designated positions.
Adjust to the median when carrying out wheel alignment.
*2: Difference between left and right must not exceed 45.
Wheels and Tires
(Vehicles built up to 07/2002)
Europe
Item
4 2
Front
Size
Front
Tire
195R14C-8PR
Rear
Air pressure
Rear
Wear limit
Up to full
passenger
Full
loaded
Up to full
passenger
Full
loaded
Offset
(mm {in})
Pitch circle diameter
(mm {in})
(Nm {kgfcm, inlbf})

Runout limit (mm {in})
235/75R15 105S
200 {2.0, 28}

180 {1.8, 26}
180 {1.8, 26}
205R16C-8PR
180 {1.8, 26}
180 {1.8, 26}

220 {2.2, 31}
200 {2.0, 28}
450 {4.5, 63}
200 {2.0, 28}

180 {1.8, 26}
180 {1.8, 26}
250 {2.5, 35}
450 {4.5, 63}
1.6 {0.06}
14 5J
14 5 1/2J
Tightening torque
Wheel
and tire
205/75R14C
(mm {in})
Size
Wheel
4 4
14 5 1/2J
40 {1.57}
15 6 1/2JJ
16 6JJ
25 {0.98}
35 {1.38}
139.7 {5.45}
Standard wheel: 89117 {912, 6586}
Styled wheel (16 6JJ): 118147 {1215, 87108}
Horizontal
2.0 {0.078}
Vertical
1.5 {0.059}
Imbalance limit
(g {oz})
10 {0.35}
D One balance weight: max. 60 g {2.1 oz}.
D If the total weight exceeds 100 g {3.5 oz} on one side, rebalance after moving the tire around on the rim.
D Do not use more than two balance weights on either side of the wheel.
TD15
TECHNICAL DATA
General
Item
4 2
Front
Size
185R14C8PR
Rear
Unloaded
(Up to
full
passenger
Front )
Tire
Air pressure
Loaded
(Full
loaded)
200
{2.0, 28}
180
{1.8, 26}
180 {1.8, 26}
200
{2.0, 28}
180 {1.8, 26}
Size
(mm {in})
(mm {in})
Tightening torque
(Nm {kgfcm, inlbf})
240
{2.4, 34}
260
{2.6, 36}
1.6 {0.06}
14 5J
Offset
250
{2.5, 35}
450 {4.5, 63}
(mm {in})
(mm
205R16C- 235/75R15 P235/75R1 P235/75R1

8PR
105S
5 105S
5 106S
Unloaded
(Up to
full
passenger
Rear )
Wheel
Wheel
and tire Runout limit
{in})
195R14C8PR
180
{1.8, 26}
Loaded
(Full
loaded)
Wear limit
4 4
14 5J
14 5
1/2J
40 {1.57}
16 6JJ
15 6 1/2JJ
35 {1.38}
25 {0.98}
139.7 {5.45}
Standard wheel: 89117 {912, 6586}
Styled wheel (16 6JJ): 118147 {1215, 87108}
Horizontal
2.0 {0.078}
Vertical
1.5 {0.059}
Imbalance limit
(g {oz})
10 {0.35}
D If the total weight exceeds 100 g {3.5 oz} on one side, rebalance after moving the tire around on the rim.
D Do not use more than two balance weights on the inner or outer side of the wheel.
TD16
TECHNICAL DATA
Wheels and Tires
(Vehicles built from 08/2002)
L.H.D
Item
Specification
Drive type
4x2
Front
195R14
C8PR
Size
Rear
Air Pressure
Front
Tire
(kPa {kgf/cm2,
psi})
Wheel
Wheel
and
tire
4x4
205/75
R14C
235/75
R15
105S
205R16
C8PR
P235/7
5R15
108S
265/70
R15
110S
Unloaded
Loaded
210 {2.1, 30}

210 {2.1, 30}
Unloaded
Rear
Loaded
Wear limit
(mm {in})
Size
(mm {in})
Offset
(mm {in})
(mm {in})
240
{2.4, 35}
1.6 {0.06}
14x5
1/2JJ
14x5J
40 {1.57}
16x6JJ
15x6 1/2JJ
16x7JJ
35
{1.38}
25 {0.98}
10 {0.39}
139.7 {5.50}
Standard wheel: 89117 {912, 6586}
Styled wheel (16x6JJ): 118147 {1215, 87108}
Vertical: 1.5 {0.059} max.
Horizontal: 2.0 {0.079} max.
(mm {in})
imbalance limit
250
{2.5, 36}
450 {4.6, 65}
Tightening torque
(Nm {kgfcm, ftlbf})
Runout limit
265/70
R15
112S
(g {oz})
10 {0.35} max.

D If the total weight exceeds 100 g {3.5 oz} on each side, rebalance after moving the tire around the rim.
R.H.D
Item
Specification
Drive type
Size
Air Pressure
4x2
Front
Tire
(kPa {kgf/cm2,
psi})
Wheel
and
tire
235/75
R15 105S
P235/75
R15 108S
265/70
R15 110S
Rear
265/70
R15 112S
Unloaded
Loaded
210 {2.1, 30}

210 {2.1, 30}
Unloaded
Wear limit
Wheel
205/75
R14C
Rear
Front
4x4
Loaded
450
{4.6, 65}
250
{2.5, 36}
(mm {in})
240
{2.4, 35}
1.6 {0.06}
Size
(mm {in})
14x5 1/2JJ
15x6 1/2JJ
15x7JJ
Offset
(mm {in})
40 {1.57}
25 {0.98}
10 {0.39}
(mm {in})
139.7 {5.50}
Tightening torque
(Nm {kgfcm, ftlbf})
Runout limit
imbalance limit
89117 {912, 6586}

Vertical: 1.5 {0.059} max.
Horizontal: 2.0 {0.079} max.
(mm {in})
(g {oz})
10 {0.35} max.

D If the total weight exceeds 100 g {3.5 oz} on each side, rebalance after moving the tire around the rim.
TD17
TECHNICAL DATA
BODY ELECTRICAL SYSTEM
Item
Specification
Headlight
Exterior light bulb capacity
Interior light bulb capacity
Warning and indicator light

bulb capacity
(W)
(W)
(W)
High beam/Low beam*
60/55 2
Parking light
5 2
Front turn light
21 2
Brake light/taillight
21/5 2
Rear turn light
21 2
Back-up light
21 2
Rear fog light
21 1
License plate light
5 2
Stretch cab, Double cab
Interior light
10 1
Regular cab
8 1
Instrument cluster illumination
3.4 4
Oil pressure warning light
1.4 1
Generator warning light
1.4 1
Sedimentor warning light
1.4 1
Brake system warning light
1.4 1
Rear window defroster indicator light
1.4 1
Glow indicator light
1.4 1
High beam indicator light
1.4 1
Turn indicator light
1.4 2
Air bag system warning light
1.4 1
4 4 indicator light
1.4 1
LOCK indicator light
1.4 1
*: Also remains illuminated when high beam turned on.

HEATER AND AIR CONDITIONER SYSTEMS
Specification
Item
Refrigerant
Regular amount
Lubricating oil
A/C compressor
G6, WL
(g {oz})
Sealed volume
(ml {cc, fl oz})
Magnetic clutch clearance

(mm {in})
F2
550 {19.4}
180 {180, 6.08}
0.350.75 {0.0140.029}
TD18
0.30.6 {0.0120.023}

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TECHNICAL DATA

Drive belt tension

(kPa {kgf/cm2, psi} [rpm])

Pushing distance of the front oil seal

491588 {5060, 110132}

393490 {4050, 88110}

412470 {4248, 93105}

354402 {3641, 8090}

557641 {56.765.4, 125143}

471556 {48.056.7, 106124}

1255 {12.8, 182} [270]

882.6 {9.0, 128} [270]

Cylinder arrangement and number

OHC, timing gear and belt driven,12 valves

(ml {cc, cu in})

2,499 {2,499, 152.4}

442637 {4565, 99143}

383539 {3955, 86121}

177 {18, 40}

403519 {4153, 91116}

354431 {3644, 8096}

181 {18.5, 41}

Drive belt tension

Timing belt deflection

Bolt head mark W

Camshaft oil seal tapping amount

Front oil seal tapping amount

Rear oil seal tapping amount

2,942 {30, 427} [200]

Drive belt tension

(kPa {kgf/cm2, psi} [rpm])

Timing belt deflection

510588 {5260, 115132}

432509 {4452, 97114}

393490 {4050, 88110}

344441 {3545, 7799}

373490 {3850, 84110}

275372 {2838, 6283}

1196 {12.2, 173} [300]

1226 {12.5, 178} [300]

837 {8.54, 121} [300]

858 {8.75, 124} [300]

3.9 {4.1, 3.4}

4.5 {4.8, 4.0}

5.6 {5.9, 4.9}

Oil and oil filter replacement

4.2 {4.4, 3.7}

4.7 {5.0, 4.4}

6.3 {6.7, 5.5}

Total (dry engine)

4.6 {4.9, 4.0}

5.5 {5.8, 4.8}

Above 30_C {86F}

Above 25_C {13F}

6.7 {7.1, 5.9}

Above 10_C {14F)

SAE 20W-40, 20W-50

Below 20_C {4_F}

Below 0_C {32_F}

Below 10_C {50_F}

7.5 {7.9, 6.6}

6.9 {7.3, 6.1}

8.8 {9.3, 7.7}

KJ16CR113, 5, KJ20CR114, 5