Note. The nominal tightening forces of threaded connections are given at the end of each of the Sections of the Appendix, and are also included in the material of the paragraphs of the text of the Guide.
General specifications
Characteristic | Meaning |
Full length, mm | |
station wagon (Station Wagon) | 4810 |
station wagon | Ti 4890 |
hardtop (Hardtop) | 4240 |
Utilities (Van) (Utility) and mini truck (Cab Chassis) | 4970 |
Utilities (Van) and Late Years Mini Truck (since 1992) with coil spring suspension | 4700 |
Full width, mm | |
Wagon and Hardtop (without wing pads) | 1800 |
Wagon and Hardtop (with wing pads) | 1930 |
Utilities (Van) and mini truck | 1690 |
Utilities (Van) and Late Years Mini Truck (since 1992) with coil spring suspension | 1930 |
Wheel base, mm | |
Universal, Utility (Van) and mini truck | 2970 |
hardtop | 2400 |
Turning radius, m | |
Universal, Utility (Van) and mini truck | 6.7 |
hardtop | 5.5 |
Fuel tank volume, l | |
Wagon and Hardtop | 95 |
Utilities (Van) and mini truck | 90 |
Permissible weight of the towed trailer, kg | |
Models of the early years of production (until 1992) | |
| 2500 |
| 750 |
Models of later years of release (since 1992) | |
Trailer equipped with brakes | |
| 2800 |
| 2500 |
Trailer not equipped with brakes | 750 |
Maximum front overhang angle | 42° |
Maximum rear overhang angle | 30° |
Maximum flyover angle | 31° |
Maximum ground clearance, mm | 235 |
Maximum admissible water barrier depth, mm | 600 |
Types and volumes of lubricants and fluids
Note. All quantities are approximate only. Accurate data can be obtained from the readings of the dipsticks or by determination through the control / filling holes.
Engine
Characteristic | Meaning |
Lubricant type | Quality not worse than SAE 20W/50SE |
The volume of the oil pan, l | |
Engine 4.2 l | |
| 8.2 |
| 7.7 |
Engine 3.0 l | |
| 6.4 |
| 6.0 |
Cooling system
Characteristic | Meaning |
Coolant volume (including expansion tank), l | |
| 11.9 |
| 13.9 |
| 13.6 |
Type of antifreeze | Antifreeze based on ethylene glycol |
The composition of the mixture,% content of antifreeze | |
| 30 |
| 50 |
Manual transmission
Characteristic | Meaning |
Lubricant type | SAE 75W/90 GL4 |
Volume, l | |
| 3.9 |
| 3.6 |
| 5.1 |
Automatic transmission
Characteristic | Meaning |
ATF type | Matic D |
Volume, l | |
| 8.5 |
| 11.8 |
Attention! ATF Matic D is the Australian equivalent of the Japanese ATF Dexron II. Using an Australian fluid called Dexron II may result in transmission failure.
Transfer case
Characteristic | Meaning |
Lubricant type | |
| SAE 75W/90 GL4 |
| EFI Dexron II |
Volume, l | |
Release models prior to October 1994 | |
| 2.2 |
| 1.9 |
All models produced since October 1994 | 1.9 |
Front differential
Characteristic | Meaning |
Lubricant type | SAE 80W/90 GL5 |
Volume, l | |
| 5.4 |
| 4.3 |
| 5.4 |
Rear differential
Characteristic | Meaning |
Lubricant type | |
| SAE 80W/90 GL5 |
| SAE LS80W/90 GL5* |
Volume, l | |
| 2.1 |
| 3.0 |
| 4.7 |
| 2.1 |
* At ambient temperatures above 40°C, use SAE LS140 GL5
Brake fluid and hydraulic clutch fluid
Characteristic | Meaning |
Fluid type | DOT 3 |
Power steering fluid
Characteristic | Meaning |
Fluid type | Dexron II |
Volume, l | 0.9÷1.0 |
Lubrication for chassis components
Characteristic | Meaning |
Lubrication type | NLGI#2 lithium based |
Requirements for wheels and tires
Tire sizes and inflation pressure
See the information plate on the vehicle.
Note. If the tires installed on the vehicle are not listed among the permissible ones on the information plate, consult the vehicle manufacturer's dealership about the permissible operating modes and recommended inflation pressure.
Engine settings
All models except 4.2L EFI
Characteristic | Meaning |
Ignition order | 1-5-3-6-2-4 |
spark plug type | |
| NGK BKR6E |
| NGK BP5ES |
Interelectrode candle gap, mm | 0.8÷0.9 |
Ignition timing at idle | |
Models 3.0 l | |
| 3°± 2°before TDC |
| 15°± 5°before TDC |
4.2L Models with Vacuum Hose Connected | |
| 10°± 1°before TDC |
| 10°± 1°before TDC |
Idling revolutions, per minute | |
| 800 ± 50 |
| 650 ± 50 |
Gap in breaker contacts (4.2 l models), mm | 0.45÷0.55 |
Duration (by angle) closed state of the breaker contacts (4.2 l models) | 34°÷40° |
Resistive resistance of explosive wires, kOhm | no higher than 30 |
Compression pressure in cylinders, kPa | |
Standard value | |
| 1 196 |
| 1 177 |
| 883 |
| 98 |
Valve clearances, mm | |
Models 3.0 l | Zero (installed hydraulic pushers with automatic compensation) |
Models 4.2 l (engine warm but off) | 0.38 |
4.2L EFI models only
Note. When performing tuning procedures, be sure to compare the following parameters with those on the engine settings information plate located in the vehicle's engine compartment. In case of discrepancy, the last ones should be considered correct (from nameplate).
Characteristic | Meaning |
spark plug type | BPR5E |
Compression pressure in cylinders, kPa | |
| 1 187 |
| 892 |
| 98 |
Engine 4.2 l
Except later years of production equipped with fuel injection (EFI)
Common parameters
Characteristic | Meaning |
engine's type | 6-cylinder, OHV |
Model | TV42 |
Working volume, cm | 3 4 169 |
Cylinder diameter, mm | 96 |
Piston stroke, mm | 96 |
Ignition order | 1-5-3-6-2-4 |
Compression ratio | 8.3:1 |
Compression pressure in cylinders, kPa | |
| 1 177 |
| 883 |
| 98 |
cylinder head
Characteristic | Meaning |
Design | Whole |
Material | Aluminium alloy |
Permissible flatness of the mating surface, mm | 0.2 |
Head height, mm | |
| 117.19÷117.59 |
| 0.2 |
Width of the working chamfer of valve seats, mm | |
| 2.4÷2.8 |
| 1.4÷1.9 |
Valve seat bevel angle | 45° |
Valve guide type | Interchangeable |
Protrusion height of valve guides, mm | 11.7÷12.3 |
Valves and valve springs
Characteristic | Meaning |
Valve stem diameter, mm | |
| 7.965÷7.980 |
| 7.945÷7.960 |
Gap of landing of cores of valves in directing plugs, mm | |
Standard | |
| 0.020÷0.053 |
| 0.040÷0.073 |
Maximum allowable | 0.1 |
Valve length, mm | |
| 116.7÷117.0 |
| 117.0÷117.3 |
Height of the cylindrical section (girdle) valve plates, mm | |
Standard | |
| 1.3 |
| 1.5 |
Minimum allowable | 0.5 |
The angle of inclination of the chamfer of the valve plates | 45° 30' |
Free length of valve springs, mm | |
| 44.10 |
| 49.77 |
Permissible limit of trimming of valve springs, mm | |
| 1.9 |
| 2.2 |
Assembly length of valve springs, mm | |
| 35 |
| 40 |
Valve actuator assembly (rocker arms and rocker axle)
Characteristic | Meaning |
Outer Ø axis of rocker arms, mm | 19.979÷20.000 |
Internal Ø of rocker arms, mm | 20.020÷20.038 |
Gap of landing of rocker arms on an axis, mm | 0.020÷0.059 |
Camshaft
Characteristic | Meaning |
Number of bearings | 7 |
Maximum allowable bending limit, mm | 0.06 |
Maximum allowable axial play, mm | 0.5 |
Clearance in bearings, mm | |
| 0.20÷0.109 |
| 0.15 |
Diameter of bearing journals, mm | |
| 50.721÷50.740 |
| 50.521÷50.540 |
| 50.321÷50.340 |
| 50.121÷50.140 |
| 49.921÷49.940 |
| 49.721÷49.740 |
| 49.521÷49.540 |
Jaw height (along the working ledge), mm | |
| 42.311÷42.561 |
| 0.15 |
Valve lifters and push rods
Characteristic | Meaning |
Ø pushers, mm | 24.970÷24.980 |
Ø nests of pushers in the engine block, mm | 25.000÷25.033 |
Gap of landing of pushers in sockets, mm | |
| 0.020÷0.063 |
| 0.1 |
Maximum allowable bending of pusher rods, mm | 0.5 |
Cylinder block
Characteristic | Meaning |
Type | 6-cylinder in-line |
Material | Cast iron |
Permissible flatness of the mating surface, mm | 0.10 |
Cylinder diameter (standard), mm | |
| 96.00÷96.01 |
| 96.01÷96.02 |
| 96.02÷96.03 |
| 96.03÷96.04 |
| 96.04÷96.05 |
Permissible wear limit of cylinders, mm | 0.20 |
Maximum admissible ovality of cylinders, mm | 0.015 |
Maximum allowable taper of cylinders, mm | 0.010 |
Crankshaft and main bearings
Characteristic | Meaning |
Number of main bearings | 7 |
Axial play of the crankshaft | |
| 6th thrust bearing |
| 0.30 |
Standard Ø crankshaft journals, mm* | 70.907÷70.920 |
Standard Ø crankpins, mmx | 56.913÷56.926 |
Maximum allowable ovality and taper of all necks, mm | 0.0025 |
Maximum allowable bending of the crankshaft, mm |
|
Clearance in main bearings, mm | |
| 0.041÷0.087 |
| 0.09 |
Produced repair (with humiliation) dimensions (Ø) main bearings, mm | 0.25, 0.50, 0.75, 1.0 |
* To achieve the required clearance in the bearings, the shaft journals are machined
Connecting rods and connecting rod bearings
Characteristic | Meaning |
Maximum allowable bending of connecting rods, mm per 100 mm length | 0.15 |
Maximum allowable twisting of connecting rods, mm per 100 mm length | 0.3 |
The size of the connecting rods between the centers of the holes, mm | 166.45÷166.55 |
Lateral clearance of connecting rods, mm | |
| 0.20÷0.30 |
| 0.40 |
Clearance in connecting rod bearings, mm | |
| 0.027÷0.061 |
| 0.09 |
Produced repair (with humiliation) dimensions (Ø) connecting rod bearings, mm | 0.25, 0.50, 0.75, 1.0 |
Pistons and piston pins
Characteristic | Meaning |
Standard Ø pistons, mm | |
| 95.975÷95.985 |
| 95.985÷95.995 |
| 95.995÷96.005 |
| 96.005÷96.015 |
| 96.015÷96.025 |
Repair excess, mm | 0.50, 1.0 |
Measuring point 20.0 mm from piston crown Piston pin hole Ø, mm | 22.987÷22.993 |
Tight fit of the piston pin in the piston, mm | 0.004÷0.008 |
Lubrication clearance of the piston pin in the upper head of the connecting rod, mm | 0.005÷0.017 |
Piston skirt fit clearance in the cylinder, mm | 0.015÷0.035 |
Piston rings
Characteristic | Meaning |
Quantity | |
| 2 |
| 1 |
Clearance in piston ring locks, mm | |
Compression | 0.30÷0.45 |
Oil scraper | 0.20÷0.60 |
Maximum allowable | 1.5 |
Lateral clearance of piston rings in grooves, mm | |
| 0.040÷0.073 |
| 0.030÷0.063 |
| 0.015÷0.185 |
| 0.1 |
Lubrication system
Characteristic | Meaning |
Oil pressure at idle, kPa | At least 49 |
Oil pressure at 2,800 rpm, kPa | 392÷451 |
Clearances in the oil pump, mm | |
| Not more than 0.12 |
| 0.14÷0.22 |
End clearance of gears | 0.050÷0.109 |
Late Years Fuel Injection (EFI)
Common parameters
Characteristic | Meaning |
Model | TV42E |
Compression ratio | 8.5:1 |
cylinder head
Characteristic | Meaning |
Valve seat chamfer width, mm | |
| 1.08÷1.51 |
| 1.41÷1.89 |
Valves and valve springs
Length of valve springs, mm | |
| 116.7÷117.0 |
| 117.15÷117.45 |
Valve lifters and push rods
Characteristic | Meaning |
Ø pushers, mm | 24.960÷24.970 |
Ø nests of pushers in the block, mm | 24.980÷25.033 |
Gap of landing of pushers in sockets, mm | |
| 0.030÷0.073 |
| 0.1 |
Pistons and piston pins
Characteristic | Meaning |
Piston pin hole Ø, mm | 22.980÷22.999 |
Lubrication clearance of the piston pin in the connecting rod head, mm | 0.000÷0.023 |
Piston rings
Characteristic | Meaning |
Gaps in locks, mm | |
| 0.30÷0.45 |
| 0.20÷0.60 |
Engine 3.0 l
Common parameters
Characteristic | Meaning |
Type | 6-cylinder OHC |
Model | RB30S |
Working volume, cm3 | 2 962 |
Cylinder diameter, mm | 86 |
Piston stroke, mm | 85 |
Ignition order | 1-5-3-6-2-4 |
Compression ratio | 9.0:1 |
Compression pressure in cylinders, kPa | |
| 1 196 |
| 883 |
| 98 |
Cylinder head
Characteristic | Meaning |
Design | Whole |
Material | Aluminium alloy |
Permissible flatness of the mating surface, mm | 0.2 |
Width of the working chamfer of valve seats, mm | |
| 2.12 |
| 1.84 |
Valve seat bevel angle | 45° |
Valve guide type | Interchangeable |
Protrusion height of valve guides, mm | 13.20÷13.40 |
Valves and valve springs
Characteristic | Meaning |
Valve stem diameter, mm | |
| 6.965÷6.980 |
| 7.965÷7.970 |
Gap of landing of cores of valves in directing plugs, mm | |
Standard | |
| 0.020÷0.053 |
| 0.030÷0.046 |
Less limit | 0.1 |
Valve length, mm | |
| 125.3÷125.9 |
| 124.2÷124.8 |
Height of the cylindrical section (girdle) valve plates, mm | |
Standard | |
| 1.15÷1.45 |
| 1.35÷1.65 |
Minimum allowable | 0.5 |
The angle of inclination of the chamfer of the valve plates | 45° 15'÷45° 45' |
Free length of valve springs, mm | |
| 44.1 |
| 51.2 |
Permissible limit of trimming of valve springs, mm | |
| 1.9 |
| 2.2 |
Valve actuator assembly (rocker arms and rocker axles)
Characteristic | Meaning |
Outer Ø axis of rocker arms, mm | 17.979÷18.000 |
Inner Ø rocker arms | 18.007÷18.028 |
Gap of landing of rocker arms on an axis, mm | 0.007÷0.049 |
Valve lifters
Characteristic | Meaning |
Type | hydraulic |
Ø pushers, mm | 15.947÷15.957 |
Ø of landing sockets of pushers in a head, mm | 16.000÷16.013 |
Gap of landing of pushers in nests, mm | 0.043÷0.066 |
Camshaft
Characteristic | Meaning |
Number of bearings | 7 |
Maximum allowable bending limit, mm | 0.1 |
Axial play, mm | 0.03÷0.06 |
Clearance in bearings, mm | |
| 0.045÷0.090 |
| 0.065÷0.110 |
Diameter of bearing journals, mm | |
| 46.935÷46.955 |
| 46.415÷46.435 |
Jaw height (along the working ledge), mm | |
| 39.242÷39.432 |
Maximum allowable wear | 0.15 |
Cylinder block
Characteristic | Meaning |
Type | 6-cylinder in-line |
Material | Cast iron |
Permissible flatness of the mating surface, mm |
|
Cylinder diameter (standard), mm | |
| 86.000÷86.010 |
| 86.010÷86.020 |
| 86.020÷86.030 |
| 86.030÷86.040 |
| 86.040÷86.050 |
Permissible wear limit of cylinders, mm | 0.20 |
Maximum admissible ovality of cylinders, mm | 0.015 |
Maximum allowable taper of cylinders, mm |
|
Crankshaft and main bearings
Characteristic | Meaning |
Number of main bearings | 7 |
Axial backlash of a cranked shaft, mm | |
| 4th thrust bearing |
| 0.05÷0.17 |
| 0.30 |
Standard Ø crankshaft journals, mm | |
| 54.967÷54.975 |
| 54.959÷54.967 |
| 54.951÷54.959 |
Standard Ø connecting rod journals of the crankshaft, mm | |
| 49.968÷49.974 |
| 49.961÷49.968 |
Maximum allowable ovality and taper of all necks, mm | 0.005 |
Maximum allowable bending of the crankshaft, mm | 0.10 |
Clearance in main bearings, mm | |
| 0.020÷0.047 |
| 0.090 |
Produced repair (with humiliation) dimensions (Ø) main bearings, mm |
|
Connecting rods and connecting rod bearings
Characteristic | Meaning |
Maximum allowable bending and twisting of connecting rods, mm per 100 mm length | 0.025 |
Lateral clearance of connecting rods, mm | |
| 0.20÷0.30 |
| 0.40 |
Clearance in connecting rod bearings, mm | |
| 0.011÷0.035 |
| 0.090 |
Produced repair (with humiliation) dimensions (Ø) connecting rod bearings, mm | 0.08, 0.12, 0.25, 0.50 |
Pistons and piston pins
Characteristic | Meaning |
Standard Ø pistons, mm | |
| 85.975÷85.985 |
| 85.985÷85.995 |
| 85.995÷86.005 |
| 86.005÷86.015 |
| 86.015÷86.025 |
Excess dimensions, mm | 0.50, 1.00 |
Measuring point 47 mm from piston crown Ø hole for piston pin, mm | 20.987÷20.999 |
Tight fit of the piston pin in the piston, mm | 0.000÷0.004 |
Lubrication clearance of the piston pin in the upper head of the connecting rod, mm | |
| 0.005÷0.017 |
| 0.023 |
Piston skirt fit clearance in the cylinder, mm |
|
Piston rings
Characteristic | Meaning |
Quantity | |
| 2 |
| 1 |
Clearance in piston ring locks, mm | |
| 0.24÷0.31 |
| 0.18÷0.28 |
| 0.4 |
| Not specified |
Lateral clearance of piston rings in grooves, mm | |
| 0.030÷0.063 |
| 0.1 |
| 0.4 |
| Not specified |
Lubrication system
Characteristic | Meaning |
Oil pressure at idle, kPa | At least 59 |
Oil pressure at 3,200 rpm, kPa | 382÷461 |
Clearances in the oil pump, mm | |
| 0.11÷0.20 |
| 0.22÷0.33 |
| 0.05÷0.11 |
| 0.05÷0.09 |
| 0.05÷0.09 |
Cooling system
Thermostat
Characteristic | Meaning |
Type | wax-filled |
Start opening temperature | |
| 76.6°C |
| 82°C |
Full opening temperature | |
| 90°C |
| 95°С |
Valve lift, mm | 10.0 |
Radiator
Type | with corrugated plates |
Radiator fan
Drive unit | Thermostatic clutch |
Power supply system for carburetor engines
Carburetor
Characteristic | Meaning |
Manufacturer | Nikki |
Type | Double chamber, downflow |
Models | |
| 21J360-38 |
| 21J360-23 |
| 21J360-24 |
Air damper control | Automatic |
Nozzle diameter, mm | |
Primary | |
| 27 |
| 32 |
Secondary | 36 |
Ø throttle chambers, mm | |
| 36 |
| 40 |
Ø main fuel jets, mm | |
Primary | |
| 1.20 |
| 1.42 |
Secondary | |
| 2.00 |
| 2.30 |
Ø main air jets, mm | |
| 0.60 |
| 0.80 |
Ø fuel jets idling, mm | |
Primary | |
| 0.48 |
| 0.54 |
Secondary | |
| 1.10 |
| 1.30 |
Ø idle air jets, mm | |
| 1.80 |
| 0.60 |
Ø high power jet, mm | 0.75 |
Fast idle speed, per minute | |
| 1 850÷2 150 |
| 1 600÷2 000 |
| 1 800÷2 200 |
Damper clearance at fast idle, mm | |
| 0.77 ± 0.07 |
| 1.37 ± 0.14 |
| 1.64 ± 0.14 |
Air damper gap, mm | |
| 2.94 ± 0.30 |
| 5.0 ± 0.5 |
Turnovers of inclusion of a damper of a butterfly valve, in a minute | |
| 1900÷2100 |
| 1 700 ± 100 |
Idle speed with the air conditioner on, per minute | |
| 800 ± 50 |
| 1 100 ± 50 |
| 900 ± 50 |
Adjusting the fuel level in the float chamber | |
Models 3.0 l | |
| 5.0÷6.0 |
| 44.0÷45.0 |
Models 4.2 l | |
| 9.5÷10.5 |
| 47.5÷48.5 |
Idling revolutions, per minute | |
| 800 ± 50 |
| 650 ± 50 |
| 650 ± 50 |
Level of CO content in exhaust gases, % | |
| 1.0 ± 0.5 |
| 1.5 ± 0.5 |
Fuel pump
Characteristic | Meaning |
Type | |
| Electric |
| Mechanical |
Supply pressure (pressure), kPa | |
| 20.0 |
| 25.5÷32.4 |
Fuel filter
Characteristic | Meaning |
Type | Interchangeable, installed in line |
Power and engine management system for 4.2L EFI models
Fuel injection system
Characteristic | Meaning |
Type | Electronic multi-position |
Injector resistance, Ohm | 10÷14 |
Idle speed with accessories completely off, per minute | 650 ± 100 |
Fuel pump
Characteristic | Meaning |
Type | Electric, installed in the gas tank |
Pressure, kPa | |
| About 235 |
| About 294 |
Ignition system
Characteristic | Meaning |
Basic ignition timing | 10°± 1°before TDC |
Ignition timing control | Electronic |
Resistance of the primary winding of the coil at 20°С, Ohm | About 1 |
Resistance of the secondary winding of the coil at 20°C, kOhm | Around 10 |
Ignition order | 1-5-3-6-2-4 |
Engine electrical system
Battery
Characteristic | Meaning |
Type | 12V lead acid |
Ground polarity | along the negative pole |
Specific gravity of electrolyte at 20°C* | |
| Over 1.265 |
| 1.100 |
* The specific gravity of the electrolyte changes by about 0.007 for every 10°C
Generator
All models except 4.2L EFI
Characteristic | Meaning |
Manufacturer | Hitachi |
Type | 50 or 60 A |
Voltage regulator | built-in |
Regulator output voltage, V | 14.1÷14.7 |
Output current, A | 50 or 60 |
Minimum allowable length of brushes, mm | 6.0 |
Sliding ring outer Ø, mm | 30.6 |
4.2L EFI Models
Characteristic | Meaning |
Manufacturer | Hitachi |
Model | LR170-740 |
Output current, A | 70 |
Voltage regulator type | built-in |
Output voltage, V | 14.1÷14.7 |
Minimum allowable length of brushes, mm | 6 |
Sliding ring outer Ø, mm | 26 |
Starter
Characteristic | Meaning |
Manufacturer | Hitachi |
Type | geared |
Minimum allowable length of brushes, mm | 11.0 |
Force developed by brush springs, N | |
| 17.6÷21.6 |
| 15.7÷19.6 |
Minimum outer Ø of the collector, mm | |
| 32.0 |
| 29.0 |
Depth of cuts of a collector, mm | 0.5÷0.8 |
Axial play of the drive gear, mm | |
| 0.3÷1.5 |
| 0.05÷1.50 |
Ignition system
Models 3.0 l
Distributor
Characteristic | Meaning |
Ignition timing correction | Vacuum and centrifugal |
Direction of rotation of the slider | Counterclock-wise |
Ignition order | 1-5-3-6-2-4 |
Air gap of the rotor of the sensor of control pulses of ignition, mm | 0.3÷0.5 |
Setting the ignition timing (with vacuum hose disconnected and engine speed below 1000 rpm) | 3°± 2°before TDC |
Ignition coil
Characteristic | Meaning |
Primary winding resistance, Ohm | 0.8÷1.0 |
Resistance of the secondary winding, kOhm | 7.6÷11.4 |
Resistive resistance of explosive wires, kOhm | Not higher than 30 |
Models 4.2 l
Distributor
Characteristic | Meaning |
Manufacturer | Mitsubishi |
Ignition timing correction | Vacuum and centrifugal |
Direction of rotation of the slider | Counterclock-wise |
Ignition order | 1-5-3-6-2-4 |
Gap in breaker contacts, mm | 0.45÷0.55 |
Duration (by angle) closed state of the breaker contacts | 34°÷40° |
Setting the ignition timing at engine speed 650±50 per minute | 10°± 1°before TDC |
Resistive resistance of explosive wires, kOhm | Not higher than 30 |
Manual transmission
Models 4.2 l
Main characteristics
Characteristic | Meaning |
Model | FS5R50A |
Type | Fully synchronized (including reverse gear) 5-speed manual transmission |
gear ratios | |
Except 4.2L EFI models | |
| 4.556:1 |
| 2.625:1 |
| 1.519:1 |
| 1.000:1 |
| 0.836:1 |
| 4.245:1 |
4.2L EFI Models | |
| 4.262:1 |
| 2.455:1 |
| 1.422:1 |
| 1.000:1 |
| 0.850:1 |
| 3.971:1 |
Axial backlash of gears, mm | |
| 0.20÷0.48 |
| 0.20÷0.60 |
| 0.20÷0.45 |
| 0.20÷0.47 |
| 0.20÷0.44 |
Standard clearance of the synchronizer blocking ring in relation to the gear, mm | |
Except 4.2L EFI models | |
| 1.00÷1.45 |
| 1.1÷1.5 |
| 0.7 |
4.2L EFI Models | |
| 1.00÷1.45 |
| 0.7 |
Permissible limit of the lateral clearance of the retaining ring, mm | |
| 0.15 |
| 0.15 |
| 0.15 |
| 0.13 |
| 0.10 |
Permissible limit of the side clearance of the C-shaped retaining ring, mm | 0.13 |
Models 3.0 l
Main characteristics
Characteristic | Meaning |
Model | FS5R30A |
Type | Fully synchronized (including reverse gear) 5-speed manual transmission |
gear ratios | |
| 4.061:1 |
| 2.357:1 |
| 1.490:1 |
| 1.000:1 |
| 0.862:1 |
| 4.125:1 |
Axial backlash of gears, mm | |
| 0.23÷0.33 |
| 0.33÷0.43 |
| 0.10÷0.25 |
| 0.20÷0.47 |
| 0.30÷0.53 |
Clearance of the synchronizer blocking ring in relation to the gear, mm | |
| 1.05÷1.30 |
| 0.7 |
Permissible limit of the value of the clearance of the retaining ring, mm | 0.1 |
Automatic transmission
Common parameters
Characteristic | Meaning |
Model | RE4R03A |
Type | 4-speed with electronic shift control and lockable rotation converter |
gear ratios | |
| 2.784:1 |
| 1.544:1 |
| 1.000:1 |
| 0.694:1 |
| 2.275:1 |
Transfer case
Common parameters
Characteristic | Meaning |
Model | TX12A |
Type | 2-stage, constant mesh |
gear ratios | |
| 1.000:1 |
| 2.020:1 |
Axial play, mm | |
| 0.20÷0.35 |
| 0.00÷0.20 |
The limit value of the gap between the synchronizer ring and the gear, mm | 0.5 |
Limit value of a backlash of a lock ring, mm | 0.15 |
Axial play of the front drive sprocket (production models since December 1992), mm | 0.20÷0.54 |
Cardan shafts
Common parameters
Characteristic | Meaning |
Maximum allowable runout value of the cardan shaft, mm | 0.6 |
Axial play of the cross, mm | 0.02 |
Clutch
Common parameters
Characteristic | Meaning |
Type | Single disk |
Drive unit | Hydraulic with vacuum strengthening |
Pressure plate spring type | Diaphragm |
Drive hub type | spring loaded |
Release bearing type | Ball thrust, hermetic design with factory grease packing |
Driven disk
Characteristic | Meaning |
The maximum allowable radial play of the splines, measured along the outer edge of the disk, mm | |
| 1.1 |
| 1.0 |
Maximum allowable runout, mm | |
| 1.3 (measured at a distance of 132.5 from the center of the hub) |
| 0.7 (measured at a distance of 115 mm from the center of the hub) |
Minimum allowable thickness of friction linings, mm | 0.3 (over rivet heads) |
Pedal
Characteristic | Meaning |
Clutch pedal height, mm | |
| 202÷212 |
| 205÷215 |
| 210÷220 |
Clutch pedal free travel, mm | 1.0÷3.0 |
Master cylinder
Characteristic | Meaning |
Internal Ø of the main cylinder, mm | 15.87 |
Flywheel
Characteristic | Meaning |
The maximum allowable runout of the flywheel, mm | 0.1 |
Brake system
Common parameters
Characteristic | Meaning |
Type of brakes | |
Front wheels | Disc, with ventilated discs |
rear wheels | |
| drums |
| Disc, with ventilated discs |
Drive unit | |
| Hydraulic, with vacuum strengthening |
| Mechanical, affects the transmission |
Front brakes
Models of the early years of production
Characteristic | Meaning |
Brake disc thickness, mm | |
| 20.0 |
| 18.0 |
The maximum allowable runout of the brake disc, mm | 0.07 |
Thickness of friction linings of brake pads, mm | |
| 11.5 |
| 2.0 |
Caliper cylinder Ø, mm | 68.1 |
Late EFI Models
Characteristic | Meaning |
Ø brake disc, mm | 306 |
Brake disc thickness, mm | |
| 26.0 |
| 24.0 |
The maximum allowable runout of the brake disc, mm | 0.07 |
Rear disc brakes
Characteristic | Meaning |
Brake disc thickness, mm | |
| 18.0 |
| 16.0 |
Thickness of friction linings of brake pads, mm | |
| 11.0 |
| 2.0 |
Caliper cylinder Ø, mm | 51.1 |
Rear drum brakes
Characteristic | Meaning |
Drum inner Ø, mm | |
| 295.0 |
| 296.5 |
Maximum admissible ovality of a drum, mm | 0.03 |
Maximum allowable runout, mm | 0.05 |
Thickness of friction linings of shoes, mm | |
| 6.1 |
| 1.5 |
Wheel cylinder inner Ø, mm | 25.4 |
Parking brake
Characteristic | Meaning |
Internal Ø brake drum, mm | |
| 203.2 |
| 204.5 |
Maximum admissible ovality of a drum, mm | 0.03 |
Maximum allowable runout, mm | 0.05 |
Thickness of friction linings of shoes, mm | |
| 5.1 |
| 1.5 |
Lever stroke at a force of 20 kgf | 7÷9 clicks |
Foot brake pedal
Characteristic | Meaning |
Pedal free travel, mm | 1÷3 |
Pedal height, mm | |
| 202÷212 |
| 192÷202 |
Front suspension (early model years (until 1992))
Front axle
Common parameters
Characteristic | Meaning |
Type | Fully unloaded with hypoid final drive |
Final drive model | H223B |
Bridge
Characteristic | Meaning |
The limiting value of the axial play of the hub, mm | 0.08 |
Limit value of axial play of drive shafts, mm | 0.2 |
Steering knuckle turning force, kgf | 0.6÷1.75 |
Backlash of a persistent washer of a lateral gear wheel of differential, mm | 0.15÷0.20 |
Differential drive gear bearing preload, Nm |
|
Radial clearance of the driven gear of the final drive, mm | 0.15÷0.20 |
The limit value of the runout of the driven gear of the main gear, mm | 0.08 |
Total differential preload, Nm | 1.8÷2.5 |
Suspension on springs
Characteristic | Meaning |
Type | On semi-elliptical leaf springs (springs), telescopic shock absorbers and with anti-roll bar |
Type of shock absorbers | Double acting |
Coil spring suspension
Characteristic | Meaning |
Type | On coil springs with telescopic shock absorbers and anti-roll bar on some models |
Type of shock absorbers | Hydraulic, double acting |
Bridge suspension method | By means of longitudinal and transverse torque rods |
Rear suspension (early model years)
Rear axle
Common parameters
Characteristic | Meaning |
Type | Semi-floating, with hypoid final drive |
Final drive model | |
| H233B |
| H260 |
Bridge
Characteristic | Meaning |
Axial play of semiaxes, mm* | 0.02÷0.15 |
Backlash of thrust washers of side gears, mm | |
| 0.15÷0.20 |
| 0.05÷0.20 |
Pinion bearing preload, Nm | |
| 1.3÷1.6 |
| 1.5÷1.7 |
Radial play of the driven gear of the final drive, mm | 0.15÷0.20 |
The limit value of the runout of the driven gear of the main gear, mm | 0.08 |
Total differential preload, Nm | |
| 1.8÷2.5 |
| 1.7÷2.5 |
* Only for models with rear drum brakes
Suspension on springs
Characteristic | Meaning |
Type | On semi-elliptical leaf springs (springs) with telescopic shock absorbers and anti-roll bar |
Type of shock absorbers | Hydraulic, double acting |
Coil spring suspension
Characteristic | Meaning |
Type | On coil springs with telescopic shock absorbers and anti-roll bar on some models |
Type of shock absorbers | Hydraulic, double acting |
Bridge suspension method | By means of longitudinal and transverse torque rods |
Front and rear axles (late model years (since 1992) EFI)
Common parameters
Characteristic | Meaning |
Final drive ratio | |
Hardtop and Station wagon models | |
| 4.111:1 |
| 3.900:1 |
| 4.375:1 |
Utility Models (Van) and mini truck | |
| 4.375:1 |
| 4.111:1 |
Steering
Steering gear
Characteristic | Meaning |
Type | |
| РВ56SC |
| RV69K |
gear ratio | 17:1 |
Number of turns of the steering wheel (from end to end) | |
| 3.7 |
| 3.6 |
Steering wheel force (along the rim), N | |
| Less than 39 |
Steering pump
Characteristic | Meaning |
Type | vane |
Hydraulic fluid pressure at idle engine speed, kPa | |
Models of the early years of production (until 1992) | 8 630÷9 219 |
Models of later years of release (since 1992) EFI | |
| 8 140÷9 728 |
| 7 159÷7 748 |
Front wheel alignment
Models of the early years of production (before 1992)
Utilities (Van) and mini truck
Characteristic | Meaning |
Convergence, mm | |
| 0÷2 (negative) |
| 0÷2 (positive) |
collapse | 0°÷1° |
The angle of the longitudinal inclination of the axis of rotation of the wheel (run-out) | 2° 50'÷3° 50' |
The angle of the transverse inclination of the axis of rotation of the wheel | 7°÷8° |
Port angle - full turn | |
| 28°÷30° |
| 28°÷30° |
Hardtop and Wagon
Characteristic | Meaning |
Convergence, mm | |
| 0÷2 (negative) |
| 0÷2 (positive) |
collapse | 0°÷1° |
The angle of the longitudinal inclination of the axis of rotation of the wheel (run-out) | |
| 2° 5'÷3° 5' |
| 2° 20'÷3° 20' |
The angle of the transverse inclination of the axis of rotation of the wheel | 7°÷8° |
Port angle - full turn | |
| 30°÷32° |
| 27°÷29° |
Models of later years of release (since 1992) EFI
Utilities (Van) and Coil Spring Suspension Mini Truck
Characteristic | Meaning |
Convergence, mm | |
| 0÷2 (negative) |
| 0÷2 (positive) |
collapse | 0°÷1° |
The angle of the longitudinal inclination of the axis of rotation of the wheel (run-out) | 2° 5'÷3° 5' |
The angle of the transverse inclination of the axis of rotation of the wheel | 7°÷8° |
Port angle - full turn | |
| 30°÷32° |
| 27°÷29° |
Onboard electrical equipment
Lamps, W
Characteristic | Meaning |
Headlights | |
| 60/50 |
| 60/55 |
| 21 |
| 5 |
Side turn signal repeaters | |
| 21/5 |
| 21 |
| 10 |
| 5 |
| 10 |
Separately installed direction indicators (late model years) | 21 |
Tightening force of threaded connections, Nm
Engine 4.2 l
Except later years of production equipped with fuel injection (EFI)
Characteristic | Meaning |
Cylinder head bolts | |
| 29 |
| 57÷67 |
| Completely loosen the bolts |
| 29 |
| 69°÷74°by goniometer or 64÷74 |
Front cylinder head bolts | 6.4÷7.5 |
rocker axle bolts | 16÷19 |
rocker locknuts | 16÷22 |
Nuts and bolts of the inlet pipeline | 16÷19 |
Exhaust manifold nuts and bolts | 27÷31 |
Cylinder head cover bolts | 1÷3 |
Bolt of fastening of a driving gear wheel of the distributor to a camshaft | 132÷142 |
Camshaft chain guide and tensioner bolts | 7÷8 |
crankshaft pulley bolt | 142÷152 |
Nuts and bolts of the timing chain cover | 21÷26 |
Main bearing cap bolts | 162÷172 |
Connecting rod bearing cap nuts | |
| 38÷40 |
| 67÷71 or 40°÷45°by goniometer |
Oil pan bolts | 7÷8 |
Bolts of fastening of an oil intake of the oil pump | 16÷19 |
Crater pan drain plug | 29÷39 |
Bolts of the holder of a back epiploon | 21÷26 |
Oil pump bolts and nuts | 16÷19 |
Nut of a cam of a drive of the fuel pump | 16÷19 |
Oil pump rear cover bolts | 7÷8 |
Oil pump pressure reducing valve plug | 39÷69 |
Oil cooler nuts and bolts | 16÷21 |
Oil cooler pressure reducing valve plug | 29÷49 |
Water pump bolts and nuts | 16÷19 |
Late Years Fuel Injection (EFI)
Characteristic | Meaning |
Bolts and nuts of fastening of the inlet pipeline to a head of cylinders | 16÷19 |
Bolts of fastening of a delivery chamber of an air path to the inlet pipeline | 16÷19 |
Bolts of fastening of the case of a throttle to the delivery chamber | |
| 9÷11 |
| 18÷22 |
Engine 3.0 l
Characteristic | Meaning |
Cylinder head bolts | |
| 29 |
| 78 |
| Completely loosen the bolts |
| 29 |
| 78÷88 or 100°÷105°by goniometer |
Cylinder head angle bolts | 9÷12 |
Rocker axle bolts | 18÷22 |
Cylinder head cover screws | 2÷4 |
Camshaft gear bolts | 16÷22 |
Camshaft Thrust Plate Bolts | 7÷8 |
Timing belt cover bolts | 3÷5 |
Timing belt tensioner locknut | 43÷58 |
flywheel bolts | 142÷152 |
crankshaft pulley bolt | 142÷152 |
Nuts and bolts of the inlet pipeline | 18÷22 |
exhaust manifold nuts | 27÷31 |
Bolts of a common cover of main bearings | 46÷52 |
Connecting rod bearing cap nuts | |
First stage | 14÷16 |
Second stage | 38÷44 or 60°÷65°by goniometer |
Oil pan bolts | 5÷7 |
Bolts of fastening of an oil intake of the oil pump | 16÷21 |
Crater pan drain plug | 29÷39 |
Bolts of the holder of a back epiploon | 7÷8 |
Oil pump cover screws | 4÷5 |
Oil pump pressure reducing valve plug | 39÷69 |
Oil pump mounting bolts | 9÷11.8 |
Cooling system
Models 3.0 l
Characteristic | Meaning |
Bolts of fastening of a casing of the thermostat | 16÷21 |
Radiator mounting bolts | 4÷5 |
Radiator fan mounting bolts | 7÷8 |
Fan clutch nuts | 7÷8 |
Models 4.2 l
Characteristic | Meaning |
Bolts and nuts of fastening of the water pump | 16÷19 |
thermostat housing bolts | 21÷26 |
Radiator mounting bolts | 4÷5 |
Radiator fan mounting bolts | 9÷11 |
Fan clutch bolts | 9÷11 |
Power and engine management system for 4.2L EFI models
Characteristic | Meaning |
Throttle body mounting bolts | |
| 9÷11 |
| 18÷22 |
Bolts of fastening of the fuel line | 10÷12 |
Bolts of fastening of a delivery chamber of an air path | 16÷19 |
l-probe | 40÷50 |
Ignition system
Characteristic | Meaning |
Spark plug | 20÷29 |
Models 3.0 l
Characteristic | Meaning |
Bolt of fastening of the generator | 45÷60 |
Nut of fastening of a driving pulley of the generator | 39÷59 |
Starter mounting bolt | 30÷40 |
Bolt of fastening of the distributor | 9÷12 |
Models 4.2 l
Characteristic | Meaning |
Alternator adjusting bolt | 21÷26 |
Manual transmission
Models 4.2 l
Characteristic | Meaning |
Bolts of fastening of a dome of coupling to the engine | |
| 29÷39 |
| 83÷113 |
Clutch dome to transmission bolts | 54÷72 |
Nuts and bolts of fastening of a forward cardan shaft | 78÷88 |
Nuts and bolts of fastening of a back cardan shaft | 93÷108 |
Bolts of fastening of a casing of extension to transmission | 57÷72 |
Bolts of fastening of a forward cover | 16÷21 |
Holder bolts (to her) bearing (ov) | 16÷21 |
Bolt of fastening of a lock flag of an intermediate gear wheel of a reverse gear | 16÷21 |
Shift housing bolts | 16÷21 |
Selector housing bolts | 19÷21 |
Top cover bolts | 19÷21 |
Models 3.0 l
Release models prior to October 1994
Characteristic | Meaning |
Bolts of fastening of transmission to the engine | |
All except 65 mm | 29÷39 |
65 mm | 39÷49 |
Nuts and bolts of fastening of a forward cardan shaft | 78÷88 |
Nuts and bolts of fastening of a back cardan shaft | 93÷108 |
Bolts of fastening of a casing of extension to a coupling dome | 31÷42 |
Bolts of fastening of a forward cover | 16÷21 |
Bolts of the holder[s?] of the bearing[s?] | 16÷21 |
Reverse/Fifth shift rod bolt | 25÷29 |
Retainer Clutch Bolt | 31÷42 |
Retainer Coupling Plug | 19÷25 |
Shift housing bolts | 16÷21 |
Release models since October 1994
Characteristic | Meaning |
Bolts of fastening of transmission to the engine | |
| 39÷49 |
| 29÷39 |
Nuts and bolts of fastening of a forward cardan shaft | 78÷88 |
Nuts and bolts of fastening of a back cardan shaft | 93÷108 |
Automatic transmission
Characteristic | Meaning |
Bolts for fastening the drive disk to the rotation converter | 39÷49 |
Bolts of fastening of a driving disk to a cranked shaft | 147÷167 |
Transmission pan bolts | 5÷8 |
Locknut of draft of a choice of transfers | 22÷27 |
Transfer case
Characteristic | Meaning |
Transfer case mounting bolts | 32÷42 |
Parking brake shield bolts |
|
Front Drive Flange Nut | 226÷324 |
Rear Drive Flange Nut | 294÷451 |
Nuts and bolts of the front driveshaft | 78÷88 |
Nuts and bolts of the rear propeller shaft | 93÷108 |
Screws of the holder of the bearing of the driven shaft | 16÷21 |
Transfer case housing bolts | 26÷36 |
Stopper plugs | 19÷25 |
Cardan shafts
Characteristic | Meaning |
Nuts and bolts of the front driveshaft | 78÷88 |
Nuts and bolts of the rear propeller shaft | 93÷108 |
Clutch
Characteristic | Meaning |
Bolts of fastening of a basket of coupling to a flywheel | 22÷29 |
Bolts of fastening of a flywheel to a cranked shaft | |
| 147÷167 |
| 142÷152 |
Servo mounting bolts | 8÷12 |
Bolts of fastening of the main cylinder | 8÷12 |
Bolts of fastening of the executive cylinder | 30÷40 |
Nut of an axial bolt of a clutch pedal | 16÷22 |
Brake system
Models of the early years of production
Characteristic | Meaning |
GTZ mounting nuts | 8÷11 |
Nuts of fastening of the vacuum amplifier (servo) | 8÷11 |
Nut of an axial bolt of a brake pedal | 8÷11 |
Hollow caliper union bolt | 17÷20 |
Union nuts for brake pipes | 15÷18 |
Brake pressure regulator valve bolts | 8÷11 |
Bolts of fastening of an anchor bracket of a support of the forward brake mechanism | 72÷97 |
Front brake caliper guide bolts | 22÷31 |
Bolts of fastening of an anchor bracket of a support of the back disk brake mechanism | 38÷52 |
Rear disc brake caliper guide pin bolts | 31÷41 |
Bolts of fastening of a brake board | 50÷68 |
Bolts of fastening of the wheel cylinder of the back drum brake mechanism | 5.3÷7.3 |
Bolts of fastening of a brake board of the parking brake mechanism | 42÷52 |
Bolts of fastening of a brake disk of forward brake mechanisms |
|
Models of later years of release (since August 1995) EFI
Characteristic | Meaning |
Nuts of fastening of the vacuum amplifier | 13÷16 |
GTZ mounting nuts | 12÷15 |
Wheel nuts | 118÷147 |
Front suspension (early model years (until 1992))
Front axle
Characteristic | Meaning |
Shut-off hub bolts | 54÷59 |
Wheel bearing locknut | 167÷196 |
Brake shield mounting bolts | 30÷40 |
Bolts of fastening of brake disks to naves | 50÷68 |
Steering knuckle bearing cap bolts | 30÷40 |
Protective seal bolts | 9÷12 |
Steering lock bolt | 23÷26 |
Nuts of fastening of assembly of the main transfer | 54÷64 |
Pinion Flange Nut | 196÷284 |
Differential side bearing cap bolts | 93÷103 |
Bolts of fastening of a conducted gear wheel of the main transfer | 132÷152 |
Differential box bolts | 64÷74 |
Bolts and nuts of the cardan shaft | 78÷88 |
Suspension on springs
Characteristic | Meaning |
Nuts of U-shaped bolts of stepladders of springs | 108÷118 |
Nuts of anchor fingers of fastening of springs | 76÷102 |
Nuts of fingers of earrings of springs | 76÷102 |
Bolts of fastening of the stabilizer of transverse stability to the crankcase of the bridge | 25÷32 |
Nuts of fastening of the stabilizer of cross stability to the chassis | 20÷23 |
Nuts of fastening of shock-absorbers | |
| 20÷23 |
| 47÷65 |
Coil spring suspension
Characteristic | Meaning |
Rear trailing arm nut | 93÷123 |
Nuts of fastening of the trailing arm to the bridge | 157÷216 |
Nut of fastening of a cross reactive rod to the bridge | 127÷167 |
Nuts of fastening of shock-absorbers | 45÷52 |
Shock absorber bracket nuts | 39÷53 |
Nuts of racks of the stabilizer of cross stability | 25÷32 |
Stabilizer bar ball nuts | 20÷23 |
Stabilizer bar support bracket bolts | 25÷32 |
Rear suspension (early model years)
rear axle
Characteristic | Meaning |
Nuts of fastening of semiaxes | 53÷63 |
Caliper mounting bolts | 38÷52 |
axle bearing nut | 441÷490 |
Nuts and bolts of the cardan shaft | 93÷108 |
Pinion nut | |
| 196÷284 |
| 167÷245 |
Nuts of fastening of assembly of the main transfer | |
| 54÷64 |
| 27÷36 |
Differential box bolts | |
| 64÷74 |
| 39÷54 |
Limited slip differential box screws | 8÷11 |
Bolts of fastening of a conducted gear wheel of the main transfer | |
| 132÷152 |
| 196÷226 |
Side bearing cap bolts | |
| 93÷103 |
| 78÷98 |
Suspension on springs
Characteristic | Meaning |
Ladder U-bolt nuts | 108÷147 |
Nuts of anchor fingers of fastening of springs | 76÷102 |
Nuts of fingers of earrings of springs | 76÷102 |
Shock absorber nuts | |
| 47÷65 |
| 17÷23 |
Coil spring suspension
Characteristic | Meaning |
Nuts of fastening of longitudinal jet rods to the chassis | |
| 98÷137 |
| 147÷177 |
Nuts of fastening of longitudinal jet rods to the bridge | 98÷137 |
Nut of fastening of a cross jet bar to the chassis | 137÷167 |
Nut of fastening of a cross reactive rod to the bridge | 117÷158 |
shock absorber nuts | 30÷40 |
Nuts of racks of the stabilizer of cross stability | 25÷32 |
Stabilizer bar ball nuts | 32÷38 |
Stabilizer bar support bracket bolts | 25÷32 |