Rocky Notes
-----------
Air Conditioning
----------------
Compressor:
- pulley: 5 groove, 126.00 OD x ??.?? ID x 26.70 W
- cover: steel
- cover bolt: 12 mm hex / M8-1.25 x 14 "8" + LW (x2) [T:18 ft-lb]
- compressor bolt: 12 mm hex / M8-1.25 x 86 (22) "8" + W (x4) [T:18 ft-lb]
- comp. hose bolt: 12 mm hex / M8-1.25 x ?? (??) "8" + LW + W (x2) [T:18 ft-lb]
- bracket bolt: 14 mm hex / M10-1.25 x 30 "6" + LW (x4) [T:27 ft-lb]
- bracket: iron
Condenser:
- fan motor
- fan relay
- fusible link
Receiver dryer:
- liquid tubes [T:4 ft-lb]
Expansion valve:
- on evaporator [T:4 ft-lb]
Evaporator:
- A/C amplifier
- A/C switch
- dual pressure switch
- thermistor
- wire harness
- A/C VSV
- A/C SV
- A/C cut-off amplifier
- accelerating cut switch
- water temperature switch
Blower:
- blower motor
- blower resistor
- blower switch
- heater relay
Fusible link & Fuses:
- CDS FAN , A/C, HEATER
Axle & Suspension: Front
------------------------
Quantity per side
Hub body:
- center cap: plastic
- cover bolt: 5 mm BHCS / M6-1.00 x 13 + W (x5) - replaced w/ SHCS [T:8 ft-lb]
- cover
* gasket: fiber
- axle snap ring - remove
- body bolt: 8 mm SHCS / M10-1.25 x 32 (x5) [T:47 ft-lb]
* sealant: Daihatsu Bond No. 4
Axle hub:
- wheel lug nut: 21 mm hex / M12-1.50 x 29 (20) (x5) [T:76 ft-lb]
- brake hose clamp - upper arm
- brake mount bolt: 17 mm hex / M12-1.25 x 27 "9" + LW (x2) [T:58 ft-lb]
* brake mount washer: M12 x 2.0 mm (x2)
- brake caliper bolt: 14 mm hex / M10-1.25 x 67 (27) "9" + LW [T:27 ft-lb]
* rubber grease: brake mounting support pin
- axle: 25 mm OD, Groove 22 mm x 2.2 mm, 24-spline
* axle snap ring: 22.3 mm ID
- axle nut, outer: 49.2 mm hex / M35-1.50 x 6.0 [T:90 ft-lb]
* axle washer: 35 x 62 x 1.2 mm - 5 tabs
- axle nut, inner: 54.0 mm hex / M35-1.50 x 9.5 flanged [T:90 ft-lb]
- bearing, outer: 35 x 62 x 18.0 x 14.0 mm NTN 32007X / Timken X32007X
Brakes:
- brake bolt: 14 mm hex / M12-1.25 x ?? "11" + LW (x5) - rotor [T:47 ft-lb]
- hub bolt: flat knurl / M12-1.50 x ?? (x5) - wheel Pressed In
- brake disc (rotor)
- bearing, inner: 40 x 68 x 19.0 mm Koyo 32008XM - driver - normal
- bearing, inner: 40 x 68 x 22.3 mm Koyo 32008JR-3 - pass - raised 3 mm
* oil seal, outer: 55 x 72 x 10.5 mm National 225535 - nitrile
Steering knuckle:
- brake disc dust cover
- dust cover bolt: 12 mm hex / M8-1.25 x ?? "6" + LW [T:6 ft-lb]
- stopper bolt: 14 mm hex / M12-1.25 x 40 rounded
- stopper nut: 21 mm hex / M12-1.25 x 12 flanged [T:65 ft-lb]
* oil seal, inner: 42 x 55 x 7.0 mm National 224200 - nitrile (7.5 mm ?)
* oil seal, inner: 42 x 55 x 6.0 mm Timken 224200S - nitrile, metal
- bush: brass, 26.? mm ID
- upper ball joint
- upper ball joint castle nut + cotter pin [T:76 ft-lb]
- upper bolt: 12 mm hex / M8-1.25 x 30 "?" (x4) - replaced w/ flanged
- upper nut: 12 mm hex / M8-1.25 x ? + LW (x4) - replaced w/ new [T:24 ft-lb]
- lower ball joint
- lower ball joint castle nut + cotter pin [T:76 ft-lb]
- lower bolt: 14 mm hex / M10-1.25 x ?? "?" (x4)
- lower nut: 14 mm hex / M10-1.25 x ? + LW (x4) [T:49 ft-lb]
CV drive shaft:
- bearing, outer: ?? x ?? x ??.? mm ?
- boot, outer + clips (2)
- boot, inner + clips (2)
- bearing, inner: ?? x ?? x ??.? mm ?
- c ring: ?? x ?.? mm
Stabilizer bar:
- brackets
- bushings
- cushions
- washers
- nuts
- link rods
Torsion spring:
- bolt: 22 mm hex / M12-1.25 x ?? - adjust
- nut: 22 mm hex / M12-1.25 x ?? - lock (x2)
Axle & Suspension: Rear
-----------------------
Quantity per side
Parking brake:
- cable
- bracket (x2)
- bolt: 10 mm hex / M6-1.00 x ?? "?" + LW (x1)
- bolt: 12 mm hex / M8-1.25 x ?? "?" + LW (x2)
Brakes:
- center cap: plastic
- wheel lug nut: 21 mm hex / M12-1.50 x 29 (20) (x5) [T:76 ft-lb]
- drum: M10-1.25 threaded bolt holes (x2) - for removal
- shoes (2)
- parking brake shoe lever - attached to shoe w/ "C" washer
- springs (4)
- spring clips (2)
- spring pins (2)
- adjuster
- adjusting lever
- hole plug, rubber: 24 x 8 x 4.0 mm
Wheel cylinder:
- boots, pistons, cup, spring: ??.? mm
- flare nut: 10 mm hex / M10-fine x ? (x2 passenger, x1 driver) [T:12 ft-lb]
- bleeder plug: driver rear - end of line [T:8 ft-lb]
- plate bolt: 10 mm hex / M6-1.00 x ?? "?" + LW (x2) [T:8 ft-lb]
* sealant: TB 1105B
Backing plate:
- nut: 14 mm hex / M10-1.25 x ?? (x4) [T:35 ft-lb]
- lock washer (x4)
- bolt: flat knurl / M10-1.25 x ?? (x4) Pressed In
* sealant: TB 1104
- shim
Axle shaft:
- axle: 30 mm OD x 722 mm long (L), 776 mm long (R), 27-spline
- hub bolt: flat knurl / M12-1.50 x ?? (x5) - wheel Pressed In
* oil seal, end: 80.5 x 95.5 x ?? mm NOK ? - axle housing end gasket
* oil seal, outer: 50 x 62 x 7 mm Timken 225005 - nitrile, bi-directional lip
* oil seal, outer: 50 x 62 x 9 mm Timken 225008 - nitrile, metal
* retainer, inner: 35 x 52 x 18 mm Daihatsu 42423-87601 (Feroza Rocky) ?
* retainer, inner: 35 x 52 x 18 mm Daihatsu 42423-87602 (F70 Taft) ?
- bearing, rear: 35 x 80 x 21 mm Koyo DG358021W / Timken 511022
* oil seal, inner: 52 x 65 x 9 mm NOK AB29551 - rubber
* oil seal, inner: 52 x 65 x 9 mm Timken 225208 - nitrile
- retainer, outer
- brake drum oil deflector
Leaf springs:
- leaf 1: 1170 x 70 x 6
- leaf 2: 1010 x 70 x 6
- leaf 3: 785 x 70 x 6
- leaf 4: 590 x 70 x 12
Axle & Suspension: Shocks
-------------------------
Front: (2)
- nut, upper: 14 mm hex / M10-1.25 x ? + flange (2) + bushings (2) [T:18 ft-lb]
- bolt, lower: 17 mm hex / M12-1.25 x ?? "5" + LW [T:44 ft-lb]
- Upper Mount: Stud S1
- Lower Mount: Eye E2 (12x32)
- Economy: Gabriel 81872 Guardian $18.20 ea (Red twin-tube)
- extended: 14.95"
- compressed: 9.59"
- stroke: 5.36"
- Original: KYB 344098 Excel-G $19.37 ea (Black twin-tube)
- extended: 14.57"
- compressed: 9.45"
- stroke: 5.12"
- Increased: KYB KG5476 Gas-A-Just $27.79 ea (Silver monotube)
- extended: 14.57"
- compressed: 9.45"
- stroke: 5.12"
Rear: (2)
- nut, upper: 14 mm hex / M10-1.25 x ? + flange (2) + bushings (2) [T:18 ft-lb]
- nut, lower: 14 mm hex / M10-1.25 x ? + flange (2) + bushings (2) [T:18 ft-lb]
- Upper Mount: Stud S1
- Lower Mount: Stud S1
- Economy: Gabriel 81870 Gaurdian $17.48 ea (Red twin-tube)
- extended: 17.67"
- compressed: 10.56"
- stroke: 7.11"
- Original: KYB 343219 Excel-G $16.51 ea (Black twin-tube)
- extended: 17.40"
- compressed: 10.31"
- stroke: 7.09"
- Increased: KYB KG5517 Gas-A-Just $31.79 ea (Silver monotube)
- extended: 17.87"
- compressed: 10.91"
- stroke: 6.97"
Axle & Suspension: Tires
------------------------
Wheels:
- bolt pattern: 5 x 139.7 mm (5 x 5.5") - same as Jeep CJ '76-'86
- center bore: 108.1 mm
- thread size: M12 x 1.5
- size: 15" diameter, 6" width
- weight: ?.? kg wheel + BFG All Terrain T/A KO2 (main)
- weight: ?.? kg wheel + Phantom A/P 225/70R15 (spare)
Wid/AR Wh = Diam X Wid Wh
---------- = ---------------
P215/70R15 = 26.9 X 8.5 R 15 -1.8% - Blue Rocky
P205/75R15 = 27.1 X 8.1 R 15 -1.1% - Small (Old Spare) - not common
P225/70R15 = 27.4 X 8.9 R 15 +0.0% - Normal (New Spare) - larger than tire cover
P215/75R15 = 27.7 X 8.5 R 15 +1.1% - Large
P241/79R15 = 30.0 X 9.5 R 15 +9.5% - BFG All Terrain
Date ODO Miles Notes
---- --- ----- -----
1991-10-01 0 < 83 k Original Tires
1995-07-15 83,358 > 26 k Goodyear Wrangler Radial
1997-06-06 109,835 52 k BFG All Terrain T/A KO - White out
2001-04-28 162,000 44 k BFG Mud Terrain T/A KM - White out
2008-12-15 205,824 34 k BFG Mud Terrain T/A KM2 - Black out
2017-04-06 240,152 28 k BFG All Terrain T/A KO2 - Black out
2019-12-28 247,174 0 k Phantom A/P 225/70R15 - Spare
2024-03-15 268,566 12 k+ BFG All Terrain T/A KO2 - Black out
Rotation:
2017-04-06 240,152 0 1 2 3 4 5
2019-12-26 247,174 7022 2 1 4 3 5
2024-03-05 268,566 0 1 2 3 4 5
2025-01-17 280,421 11855 2 1 4 3 5
Apr17 Dec19 Mar24 Jan25
----- ----- ----- -----
1 2 2 1 1 2 2 1
3 4 4 3 3 4 4 3
5 5 5 5
Body
----
Bumper, Front:
- tow hook bolt: 17 mm hex / M12-1.25 x 25+ "=" + LW + W (x2) [T:?? ft-lb]
- guard bar bolt: 17 mm hex / M10-1.25 x ?? "8.8" + LW + W (x4) [T:27 ft-lb]
- attaching bolt: 14 mm hex / M10-1.25 x ?? "=" + LW + W (x4) [T:27 ft-lb]
- bumper bolt: carriage / M8-1.25 x ?? (??) (x4) - chrome
- bracket nut: 12 mm hex / M8-1.25 x ?? + LW (x4)
- bumper bracket (x2)
- extension bolt: carriage / M6-1.00 x 16 (10) (x6) - black
- extension nut: 10 mm hex / M6-1.00 x 6 + LW (x6)
- extension (x2)
- turn signal lamp (x2) - screws, lens, housing, bulb
Bumper, Rear:
- attaching bolt: 14 mm hex / M10-1.25 x 25 "4" + LW + W (x8) - replaced w/"8.8"
- bumper bolt: carriage / M8-1.25 x ?? (??) (x12) - chrome
- bracket nut: 12 mm hex / M8-1.25 x ?? + LW (x12)
- bumper bracket (x4)
- bumper side bracket (x2)
- extension bracket (x2)
- bracket bolt: 10 mm hex / M6-1.00 x 16 "4" + LW + W (x4)
- extension bolt: carriage / M6-1.00 x 16 (10) (x2) - black
- extension nut: 10 mm hex / M6-1.00 x 6 + LW (x6)
- extension (x2)
Engine undercover (skid plate):
- bolt: 12 mm hex / M8-1.25 x 20 "=" + LW + W (x4) - replaced w/ 25 mm flanged
Fender, Front: (x2)
- mudguard
- mudguard bolt: 10 mm hex / M6-1.00 x ?? "4" + LW + W (x3)
- mudguard bracket bolt: 10 mm hex / M6-1.00 x ?? "?" + LW
- mudguard bracket
- fender liner + clips (x10?)
- wheel opening extension + pad
- wheel opening extension brackets (x7)
- bracket bolt: 10 mm hex / M6-1.00 x ?? " " + LW + W (x7)
- bracket bolt: 10 mm hex / M6-1.00 x ?? " " + LW + W (x7)
- fender bolt: 10 mm hex / M6-1.00 x ?? " " + LW + W (x10)
- marker lamp - screws, lens, housing, bulb
Fender, Rear: (x2)
- mudguard
- mudguard bolt: 10 mm hex / M6-1.00 x ?? "4" + LW + W (x3)
- fender liner + clips (x10?)
- wheel opening extension + pad
- wheel opening extension brackets (x6)
- bracket bolt: 10 mm hex / M6-1.00 x ?? " " + LW + W (x6)
- body bolt: 10 mm hex / M6-1.00 x ?? " " + LW + W (x6)
- marker lamp - screws, lens, housing, bulb
Grille:
- screw: (x2) - top
- clip: (x2) - top
- clip: (x3) - bottom
- emblem: DAIHATSU + 3 screws
Hood:
- hood rod: 7.1 mm diameter
- hood rod clip hole: 10 x 10 mm - pivot
- hood rod clip hole: 7 x 7 mm - clamp
- hood rod clip: ? - pivot
- hood rod clip: ? - clip
- jack rod: 12.1 mm diameter
- jack rod clip hole: 10 x 15 mm
- jack rod clip: ? - clip (x2)
- cushion, front: 20 mm diameter x 20 mm tall (x2) (hole: 14 mm diameter)
- cushion, sides: 40 mm long x 20 mm wide x 24 mm tall (x2) (hole: 20 mm x 8 mm)
- release latch bolt: 10 mm hex / M6-1.00 x 12? "=" + LW + W (x3)
- release latch cable: ? x ?? mm
- release latch spring: ?? x ?.? x ?.? mm - small
- release latch spring: ?? x ?.? x ?.? mm - large
- body latch bolt: 12 mm hex / M8-1.25 x 20 "4" + LW + W (x3 per side)
- hood latch bolt: 12 mm hex / M8-1.25 x 20 "4" + LW + W (x2 per side)
Horn:
- bolt: 12 mm hex / M8-1.25 x 16? "4" + LW + W
Instrument panel:
- lower finish panel - 2 screws
- hood lock control lever - 2 screws
- rheostat - knob, 2 screws, connector
- rear heater switch - connector (blank)
- finish panel retainer - 2 screws
- instrument panel reinforcement - 2 bolts
- left side - 2 bolts
- air duct - clip
- center brace - bolt
- instrument panel wire - connector
- steering column upper cover
- steering column lower cover - 3 screws
- upper finish panel - 2 screws
- upper finish panel bracket - 3 screws
- instrument cluster finish panel - 4 screws
- rear window defogger switch - connector
- hazard warning switch - connector
- rear wiper switch - connector
- combination meter - 4 screws, 2 connectors, speedometer cable, o-ring
- wire harness - clamp
- triple meter finish panel
- voltmeter, clinometer, clock - 3 connectors
- glove compartment door - 2 screws
- instrument panel reinforcement - 2 bolts
- right side - 2 bolts
- heater control switch - connector
- air conditioner switch - connector
- center brace - bolt
- mode selector (air mix) cable brown left driver DEF
- temp control (defroster) cable green center passenger COOL
- in/outside air (air inlet) cable gray right passenger RECIRC
- defroster nozzle - screw (x2)
- hole cover - bolt (x2)
- center - bolt
- defroster nozzle air duct - 4 screws
- center brace subassembly - 4 bolts (M8) [T:14 ft-lb]
- bracket - key reminder buzzer, heater relay, horn relay - bolt
- sub-fuse box - bolt
- steering column - 3 bolts (M8) [T:14 ft-lb]
- pillar-to-pillar member - 4 bolts (M10) [T:27 ft-lb]
- meter hood bracket - 3 screws (x2)
- driver air duct - screw
- passenger air duct - screw
- center air duct - screw
- ash receptacle box - retainer, 3 screws, optical cord
- cigar lighter - 3 connectors, set nut, knob, assembly, bezel, bulb
- speaker - connector, 2 screws (x2) - 101.6 mm (4.0") diameter
- center reinforcement - 2 screws
- lower center reinforcement - 2 screws
- glove compartment door lock striker - 2 screws
- glove compartment door lock retainer - 5 screws
- defroster nozzle opening cover - 9 screws
- safety pad - 8 screws, 10 clamps
- side safety pad - 4 clamps
- center instrument panel tray - 5 screws
- side & center registers (x4)
- instrument panel wire harness - snapring nuts
- heater control panel - 4 knobs, bulb
- heater control unit
- A/C switch - 1 screw, bulb
- blower unit - 2 bolts, 1 nut
- blower resistor - connector, 1 screw [L-M1: 1.40 L-M2: 2.13 H-M2: 0.33]
- blower motor - connector, 3 screws
- blower switch
- duct band - bolt
- cooling unit - 2 bolts, 1 nut; 3 screws, 3 clips
- wire harness - 4 connectors
- A/C amplifier - screw, connector
- A/C cut-off amplifier - bolt, connector
- thermistor - connector
- upper unit case
- lower unit case
- drain hose
- evaporator - expansion valve
- duct band - bolt
- heater unit - 2 bolts, 2 nuts
- heater cover - 2 screws
- heater core - 2 hose clamps
Jack & Tools:
- jack rod - under hood in engine bay
- bottle jack - under driver seat
- tool bag - side of driver seat
- tire lock key: McGARD No. 4,664,000
- jack handle / lug nut wrench: 21 mm
- L type handle tool - to remove center cap
- wheel cap replacer - to install center cap
- spanner wrench: 10 x 12 mm
- spanner wrench: 14 x 17 mm *
- spanner wrench: 19 x 22 mm *
- spark plug wrench: 16 mm (5/8") *
- pliers: slip-joint *
- screwdriver: phil / slot *
- roof panel wrench: phil R/A ratchet *
* = missing, replaced (TBD)
- wrenches:
- 8 mm - M5: distributor cap, throttle positioner
- 10 mm - M6: air chamber, body, bumper extensions, fenders, fluid coupling
cylinder head cover, oil pan, timing belt cover
- 12 mm - M8: alternator (adjust), engine undercover, hard top
intake manifold, throttle body, distributor, water pump
- 14 mm - M10: alternator (pivot), brake caliper, cylinder head, drive shafts
engine mount bolt, exhaust headers, starter, p/s pump
- 17 mm - M12: banjo bolt, brakes, front shock, guard bar, tow hook
engine mount, p/s pump nut, steering gearbox, transmission
- 19 mm - M16: crankshaft, BVSV, water temp sensor, intake air temp sensor
- 22 mm - M16: oxygen sensor, p/s pump banjo bolt, torsion spring
backup switch, transfer select switch, oil cooler
- 24 mm - M16: differential & transmission/transfer fill/drain plug
M10: air intake air/gas filter, oil pressure switch
- wrenches, flare nut:
- 10 mm - M10: brakes: master cylinder, rear wheel cylinders
- 17 mm - M16: power steering gearbox
- sockets:
- 14 mm - M12: flywheel (12-point)
- 16 mm - M14: spark plug (5/8")
- 19 mm - M16: crankshaft pulley
- 21 mm - M12: lug nut, steering knuckle stopper nut
- 22 mm - M18: oxygen sensor (7/8") (offset)
- 24 mm - M16: differential & transmission/transfer fill/drain plug
- 30 mm - M19: differential flange - front
M24: differential flange - rear
- 49 mm - M35: axle nut - outer
- 54 mm - M35: axle nut - inner
- hex keys:
- 5 mm - front axle hub cover
- 8 mm - front axle hub body
Paint color codes:
- 6A5 : Black Metallic
- 168 : Gray Metallic
Seat, Front: (x2)
- bolt: 14 mm hex / M10-1.25 x ?? "=" + LW + W (x4) [T:28 ft-lb]
- weight: ?.? kg
Seat, Rear: (x1)
- bolt: ?? mm hex / M__-1.__ x __ "?" + LW (x2) - seat hinges [T:18 ft-lb]
- bolt: ?? mm hex / M__-1.__ x __ "?" + LW (x2) - seat latch [T:?? ft-lb]
- bolt: ?? mm hex / M__-1.__ x __ "?" + LW (x2) - seat back [T:18 ft-lb]
- weight: ?.? kg
Window, Front Windshield:
- front wiper blade: 17" (x2)
- front wiper nut: 12 mm hex / M8-1.25 x 6 (x2)
- wiper motor
- wiper motor bolt: 10 mm hex / M6-1.00 x ?? "6" + W + grommet (x4)
- washer fluid reservoir
- washer fluid reservoir bolt: 10 mm hex / M6-1.00 x ?? " " (x4)
- washer fluid tube: 5.2 mm ID x ?? mm long black
- washer fluid tube Y splitter
- washer fluid inline filter (x2) - check for clogged lines
- washer fluid hood sprayers (x2)
- weatherstrip
- weight: ?.? kg
Window, Back Door:
- rear wiper blade: 14"
- rear wiper nut: 10 mm hex / M6-1.00 x 9.5 acorn + W
- rear wiper nut: 27 mm hex / M20-1.?? x 4.5
- window handle: 60 mm knob / M8-1.25 x 15 (x4)
- weatherstrip
- weight: ?.? kg
Window, Side Quarter: (x2)
- hard top bolt: 12 mm hex + phil / M8-1.25 x 23 tapered + W + flange (x10)
- hard top bolt: 14 phil / M8-1.25 x 25 tapered + W (x2) - into roll bar
- weight: ?.? kg
Windows, Tint law (AZ):
- https://www.tinting-laws.com/arizona
- windshield: above AS-1 line --> 35%
- front side: more than 33% Visible Light Transmission (VLT) --> 35%
- back side: any darkness --> 20%
- rear: any darkness --> 20%
- all: not more than 35% reflective
Body: Heater Foam
-----------------
1/4" (2x):
- 6 x 5
- 7 x 5 1/2
- 7 x 2
- 6 x 4
- 6 x 3
- 7 x 3
- 1 3/8 x 20
- 1 1/8 x 19
- 7 x 5
- 7 x 5
- 6 x 4
- vent ducts
Inside/Outside Air:
- White 6.0" x 4 7/8" 152 x 124 mm x2
Hot/Cold:
- Big 6 3/4" x 5 5/16" 172 x 135 mm x2
- Small 6 3/4" x 2.0" 172 x 50 mm x1
Select:
- Def 6 3/8" x 2 5/8" 162 x 67 mm x2
- Top 6 1/8" x 3 7/8" 155 x 98 mm x2
- Bot 6 3/4" x 2 3/8" 172 x 60 mm x2
Inside Air Filter: 6 1/4" x 5 1/2" x 1/8" (1/4" max)
- stiff/support
Brakes
------
Booster:
- vacuum hose + clamps (x2) - brake booster
- vacuum hose + clamps (x2) - intake manifold
- vacuum pipe: 9.0 mm OD
- vacuum pipe bracket (x3)
- vacuum pipe bracket bolt: 10 mm hex / M6-1.00 x ?? "4" + LW (x3)
Master cylinder:
- reservoir + cap + clamp: brake fluid
- sensor: brake fluid level
- mounting nut: 12 mm hex / M8-1.25 x 6 + LW (x2)
- flare nut: 10 mm hex / M10-1.00 fine x ? (x3)
P & B valve:
- bracket bolt: 10 mm hex / M6-1.00 x 40 (31) "=" + LW + W
1999-06-08 Brake Mast #5 307.17 R: front, rear
2002-02-01 Brake Mast #105 75.50 R: pads replaced, rotors turned
2006-02-28 Brake Mast #116 688.88 R: pads, rotors, shoes replaced, seal
2009-11-11 Brake Mast #116 973.54 R: pads, shoes replaced, seal, idler arm
2011-06-29 Brake Max #2 173.42 T: pads replaced, rear adjust
2012-04-18 Brake Max #2 152.63 T: pads, rotors replaced
2014-08-12 Brake Mast #101 143.73 T: pads replaced, rotors turned
2016-10-10 Brake Mast #101 225.82 T: pads, rotors replaced
2017-04-06 Brake Mast #101 91.03 R: inspect, rear adjust, fluid replaced
2019-12-15 inspection
Left (Driver): Right (Passenger):
Front:
- rotor: (11.5-12.5 mm) ??.? ( ?? % remaining) 12.0 ( 50 % remaining)
- pad, inner: (1.5-9.0 mm) ?.? ( ?? % remaining) 7.0 ( 73 % remaining)
- pad, outer: (1.5-9.0 mm) ?.? ( ?? % remaining) 6.0 ( 60 % remaining)
Rear:
- drum: (254-256 mm) ???.? ( ?? % remaining) ???.? ( ?? % remaining)
- shoe, lead: (1.0-5.0 mm) ?.? ( ?? % remaining) ?.? ( ?? % remaining)
- shoe, trail: (1.0-5.0 mm) ?.? ( ?? % remaining) ?.? ( ?? % remaining)
Charging
--------
Alternator:
- pulley: 4 groove, 56.50 OD x ??.?? ID x 20.00 W - original
- pulley: 4 groove, 50.20 OD x ??.?? ID x 20.00 W - current & ACDelco
- nut: 10 mm hex / M6-1.00 x 6 flanged (x2) - output terminal
- bolt: 12 mm hex / M8-1.25 x 25 "10.9" flanged + LW - adjust [T:10-18? ft-lb]
- bolt: 14 mm hex / M10-1.25 x 95 (42) "6" + LW + W - pivot [T:27-44? ft-lb]
- weight: 3.151 kg
- slotted bracket: steel
- slotted bracket bolt: 14 mm hex / M12-1.25 x 25 "6" flanged [T:?? ft-lb]
- slotted bracket bolt: 14 mm hex / M10-1.25 x 97 "11" + LW
- slotted bracket nut: 14 mm hex / M10-1.25 x 8
- lower bracket: iron
- lower bracket stud: M10-1.25 x ??
- lower bracket nut: 14 mm hex / M10-1.25 x 10.5 flanged - shared engine mount
- lower bracket bolt: 14 mm hex / M10-1.25 x ?? "6" + LW [T:31 ft-lb]
- lower bracket resistance to engine block: 0.20 - 0.17 = 0.03 ohms
Cooling
-------
Radiator:
- cap pressure: 13 psi (8.5 - 14.9 psi; 17 psi test)
- bolt: 12 mm hex / M8-1.25 x 25 "10.9" flanged - K&N air filter bracket
- bolt: 10 mm hex / M6-1.00 x 20 "6" + LW + W (x2) - fan shroud
- bolt: 12 mm hex / M8-1.25 x 35 " " + LW + W (x4) - mounting [T:10 ft-lb]
Radiator drain plug:
- bolt, plastic: 20 mm wing / M12-1.25 x 24 (9)
* washer, rubber: 11.4 x 20.0 x 1.3 mm (0.45" x 0.79" x 0.05")
Radiator under cover:
- screw: ?? mm hex + phil / M_-screw (x3)
Reserve tank:
- capacity: ?.? liters - FULL line
- capacity: ?.? liters - EMPTY line
Differential: Front
-------------------
Front breather tube: 4.8 mm OD, 5.6 mm bump
Front breather hose: 4.? mm ID (3/16" = 4.76 mm)
Front cover bolt: 12 mm hex / M8-1.25 x ?? "=" flanged (x10) [T:16 ft-lb]
Front cover gasket: fiber
Front fill & drain plugs:
- fill bolt: 24 mm (~15/16") hex / M16-1.50 x 10 [T:36 ft-lb]
- drain bolt: 24 mm (~15/16") hex / M16-1.50 x 10 [T:36 ft-lb]
* washer, aluminum: 16.5 x 26.1 x 1.0 mm (0.65" x 1.03" x 0.04")
* washer, aluminum: 16.5 x 26.1 x 1.0 mm (0.65" x 1.03" x 0.04")
Front driveshaft flange:
* nut, pinion: 30 mm hex / M19-1.?? x 20 + plate washer [T:130 ft-lb]
- dust deflector
* oil seal, pinion: 40 x 65 x 12 mm Timken 710269 / Daihatsu 90043-11243
Front carrier:
- tapered roller bearing (inner & outer), pinion #7
- shim
* drive pinion bearing spacer (crush sleeve)
- shim
- tapered roller bearing (inner & outer), pinion #11
- bearing, outer: 25 x 62 x 17 x 15 mm National 30305 - pinion
- bearing, inner: 30 x 72 x 19 x 16 mm National 30306 - pinion
- drive pinion
- ring gear: 170 mm ?
- case S/A
- bearing, carrier (x2)
- bearing, side: 20 x 38 x 43 x 49 mm Timken 16150 - carrier
- bearing, side: 14 x 72 x 62 x 67 mm Timken 16282 - carrier race
- bearing adjusting nut (x2)
* oil seal, carrier: ?? x ?? x ?? mm (x2) - remove axle drive shafts to replace
Front carrier support bracket: (front, right, left)
- bushing, upper: 16/24 x 54/60 x 25 + 8 mm
- bushing, lower: 16/24 x 54/60 x 25 mm
- spacer tube: 10 x 16 mm
- fender washer: 66 mm
- bolt: 14 mm hex / M10-1.25 x 89 (30) "9" + LW + W + flange [T:35 ft-lb]
- bolt: 17 mm hex / M12-1.25 x ?? "11" + LW + W (x3) [T:80 ft-lb]
Differential: Rear
------------------
Rear breather tube: 4.8 mm OD, 5.6 mm bump
Rear breather hose: 4.? mm ID (3/16" = 4.76 mm)
Rear carrier bolt: 14 mm hex / M10-1.25 x ?? "9" + LW (x10) [T:49 ft-lb]
Rear carrier sealant: TB 1104
Rear fill & drain plugs:
- fill bolt: 24 mm (~15/16") hex / M16-1.50 x 10 [T:36 ft-lb]
- drain bolt: 24 mm (~15/16") hex / M16-1.50 x 10 [T:36 ft-lb]
* washer, aluminum: 16.5 x 26.1 x 1.0 mm (0.65" x 1.03" x 0.04")
* washer, aluminum: 16.5 x 26.1 x 1.0 mm (0.65" x 1.03" x 0.04")
Rear driveshaft flange:
* nut, pinion: 30 mm hex / M24-1.?? x 20 + plate washer [T:150 ft-lb]
- dust deflector
* oil seal, pinion: 45 x 72 x 12 mm National 224570 / Daihatsu 90043-11248
Rear carrier:
- drive pinion bearing - front
- bearing, outer: 30 x 72 x 19 x 16 mm National 30306 - pinion
- shim
* drive pinion bearing spacer (crush sleeve)
- sleeve, rear: 45 x 53 x 17 mm National 99177 - outer
- drive pinion bearing - rear
- bearing, inner: 35 x 80 x 21 x 18 mm National 30307 - pinion
- shim
- pinion gear
- ring gear: 180 mm ?
- case S/A
- bearing, carrier (x2)
- bearing, side: 40 x 80 x 18 x 16 mm National 30208 - carrier
- bearing adjusting nut (x2)
Drive / Propeller Shafts
------------------------
* mark positions on differential flanges and drive shafts before removing bolts!
Front:
- bolt: 14 mm hex / M10-1.25 x 29 (14) "......" (x4)
- lock washer: M10
- nut: 14 mm hex / M10-1.25 x 8 (x4) [T:51 ft-lb]
- u-joint: ?? x ?? mm (x2)
Rear:
- bolt: 14 mm hex / M10-1.25 x 29 (14) "......" (x4)
- lock washer: M10
- nut: 14 mm hex / M10-1.25 x 8 (x4) [T:51 ft-lb]
- u-joint: 28 x 81 mm Koyo KC1719ECC / Daihatsu 04371-87303 (x2)
Electrical
----------
Engine bay:
- bolt: 10 mm hex / M6-1.00 x 22 "=" + LW + W - battery body ground terminal
- replaced w/ 10 mm hex + phil / M6-1.00 x 12
- bolt: 10 mm hex / M6-1.00 x 16 " " + LW + W (x2) - engine fuse box
Accessory cable wire colors:
BLK Ground
BRN +5V Switched
RED +12V Switched
ORG +12V Illumination
YEL +12V Battery
GRN Clock
BLU Data
VIO Digital
GRY Analog
WHT Control
Wiring color code:
B Black
Br Brown
R Red
O Orange
Y Yellow
G Green
Lg Light Green
L Blue
V Violet
P Pink
Gr Gray
W White
Wiring color examples:
W-B White w/ Black stripe Earth (Ground)
R Red AM2 (+12V)
B Black AM1 (+12V)
W White AM (+12V)
W White ACC (+12V switched)
L-W Blue w/ White stripe IG2 (+12V switched)
B-Y Black w/ Yellow stripe IG1 (+12V switched)
B-W Black w/ White stripe ST1 (+12V switched)
R-L Red w/ Blue stripe Gauge (+12V IG1)
G-L Green w/ Blue stripe Tail LH (+12V AM - Light sw)
W-G White w/ Green stripe Tail RH (+12V AM - Light sw)
R-B Red w/ Black stripe Rheostat (0-12V Tail RH - Light sw)
G-R Green w/ Red stripe Rheostat (0-12V Tail RH - Light sw)
G-B Green w/ Black stripe Dome Lock, radio, clock backup (+12V AM)
Gr Gray Cigar lighter, radio, clock (+12V ACC)
Electrical: Battery
-------------------
Hold-down bracket:
- bolt, body: 10 mm hex / M6-1.00 x 12? "?" + LW + W
- nut, j-bolt: 10 mm hex / M6-1.00 x 5 + W (x2)
- J-bolt, outer: M6-1.00 x 220 (46) mm ~ 8.5" long
- J-bolt, inner: M6-1.00 x 270 (49) mm ~ 10.5" long
Terminals:
- Negative nut: 10 mm hex / M6-1.00 x 7
+ Positive bolt: 10 mm hex / M6-1.00 x 25
Ground wires:
- bracket: steel (x2)
- bracket bolt: 10 mm hex / M6-1.00 x 12 "4" + LW + W (x4)
- ground bolt: 10 mm hex / M6-1.00 x 22 "=" + LW + W - top of wheel well
- replaced w/ ?? mm bolt
- battery to engine block - engine mount bolt
- battery to body - top of wheel well
- intake manifold to firewall - near fuel filter
Group Term L x W x H (mm) L x W x H (inches) Notes
----- ---- -------------- ------------------ -----
26 + - 208 173 197 mm 8.19 6.81 7.75 in Rocky OEM
25 + - 230 175 225 mm 9.06 6.88 8.88 in Rocky tall
34 + - 260 173 200 mm 10.25 6.81 7.88 in Rocky long
24 + - 260 173 225 mm 10.25 6.81 8.88 in Rocky long tall
-- + - 270 180 225 mm 10.63 7.08 8.88 in Rocky tray max
24F - + 273 173 229 mm 10.75 6.81 9.00 in Tacoma OEM V6
35 - + 230 175 225 mm 9.06 6.88 8.88 in Tacoma OEM L4
Date Mileage Vendor Part Price CCA MCA Min Ah Lb
---- ------- ------ ---- ----- --- --- --- -- --
1996-07-28 99,000 Batteries Plus DTA-6 $ 67 ??? ??? ?? ?? ??
1998-09-12 129,500 Batteries Plus DTA-7 $ 21 ??? ??? ?? ?? ??
2002-04-17 170,000 Checker Battery 26R $ 50 525 650 85 40 28
2003-07-12 178,000 AutoZone Duralast 24-DS $ 50 600 750 110 50 38
2005-01-30 186,308 AutoZone Duralast 24-DL $ 50 600 750 110 50 38
2007-06-12 197,410 AutoZone Duralast 24-DL $ 65 600 750 110 50 38
2009-09-14 213,572 AutoZone Duralast 24-DL $ 75 600 750 110 50 38
2014-08-18 234,211 AutoZone Duralast 24-DL $ 105 600 750 110 50 38
2018-07-18 241,977 O'Reilly Super Start Pre 26PRMJ $ 130 575 715 90 40 30
2022-07-08 252,828 AutoZone Duralast 24-DL $ 219 600 750 110 50 38
2024-03-15 268,563 AutoZone Duralast 24-DL $ 236 600 750 110 50 38
Group 34 SLA SLI Duracell Ultra SLI34 $ 143 690 850 ??? ?? 38
Group 34 SLA SLI Duracell Ultra Gold SLI34M $ 168 800 985 ??? ?? 39
Group 34 AGM SLI ACDelco Professional 34AGM $ 173 740 880 115 60 39
Group 34 AGM SLI DieHard Advanced Gold 38232 $ 190 775 920 120 55 45
Group 34 AGM DP Duracell Ultra Gold SLI34AGM $ 208 750 890 ??? 55 42
Group 34 AGM DP NorthStar Pure Lead NSB-AGM-34 $ 289 880 1050 134 65 51
Group 24 FLA SLI AutoZone Duralast 24-DL $ 155 600 750 110 50 38
Group 24 SLA SLI Duracell Ultra SLI24 $ 143 650 800 ??? ?? 41
Group 24 SLA SLI Duracell Ultra Gold SLI24M $ 168 725 890 ??? ?? 43
Group 24 AGM DP NorthStar Pure Lead NSB-AGM-24 $ 310 840 1000 160 76 57
Tacoma Mileage Vendor Part Price CCA MCA Min Ah Lb
------ ------- ------ ---- ----- --- --- --- -- --
2007-06-12 29,500 AutoZone Duralast Gold 24F-DLG $ 85 750 935 130 60 44
2010-11-20 44,514 AutoZone Duralast Gold 24F-DLG $ 90 750 935 130 60 44
2018-07-17 100,105 O'Reilly Super Start Ext 35EXTJ $ 160 640 800 100 45 38
2023-10-10 134,405 AutoZone Duralast Gold 35-DLG $ 232 640 800 130 45 38
Electrical: Check Terminal
--------------------------
________
| |
Fuel | 6 3 |_ Test
| - - _|
Lamp | 5 2 _| Ground
| - - _|
N/C | x 1 | O2
|________|
# Term ECU,WC Pin Con Wire SST Action Function Manual Pages
- ---- ------ --- --- ---- --- ------ -------- ------------
6 P68 P18,P17 37 F R-W Wht/Blk Sht-GND Fuel Pump relay EF-9,93,103,116
5 X109 X2,X1 16 W G-Y ? Sht-GND Diagnosis Lamp EF-33,HW-22,Sch
4 - - - - - - - N/C -
3 X57 Z46 11 T1+ Br-W Brown Sht-GND Test EM-16,EF-29,MA14
2 X58 Z48,138 39 T1- Br Black GND Ground EM-16,EF-29,EF-9
1 X20 X21 15 VF G Green Meter O2 Sensor FB EM-16,EF-83
Electrical: ECU
---------------
21 20 xx 18 xx 16 15 xx 13 12 11 xx 9 8 7 6 5 x 3 2 1
42 41 40 39 38 37 36 xx 34 33 32 xx 30 29 xx 27 26 xx xx xx 22
1 W-L Power +12V +B1 Main relay (Power supply)
2 W-G Power +12V Batt Battery (Backup power supply)
3 B-L In ? 12 / ? IG Ignition coil primary voltage
4 - - - - x
5 B Out 4.5-5.5 Vcc Pressure sensor power
6 R In 3.2-4.0 PIM Pressure sensor
7 Y In 0.4-0.6 THW Cooling water temperature sensor
8 Y-R In 0 / 12 SPD Vehicle speed sensor
9 B In 5 / 12 DSW1 Electrical load (Headlamp & defogger)
10 - - - - x
11 Br-W In 12 / 0 T Check connector (3)
12 Y-G In 5 / 12 IDL Throttle position switch (Idle)
13 B-R In 0 / 6 STA Starter
14 - - - - x
15 G Out 0 / 5 VF Oxygen sensor feedback (1)
16 G-Y Out 3 / 12 W Check engine lamp (5)
17 - - - - x
18 B-? Out 12 / 3 EVSV EGR VSV
19 - - - - x
20 W-L Out 1 / 12 #10 Fuel injector
21 Br Ground 0 E01 Z47 Actuator drive ground (Engine)
22 W-L Power +12V +B2 Main relay (Power supply)
23 - - - - x
24 - - - - x
25 - - - - x
26 R-B? In 0.4-0.5 Ox Oxygen sensor
27 Y-W In 1.5-3.0 THA Intake air temperature sensor
28 - - - - x
29 W-B Ground 0 E2 X35 Temperature sensors ground (Engine)
30 L-G In 12 / 2 DSW2 Electrical load (Blower fan)
31 - - - - x
32 Y-B In 12 / 5 PSW Throttle position switch (Power)
33 G-B In 1 / 12 B/K Stop lamp switch
34 B-W In 1 / 12 A/C Air conditioner magnet switch
35 - - - - x
36 N? Ground 0 E21 X99 Pressure Sensor ground
37 R-W Out 12 / 2 Fc Fuel pump relay (6)
38 ? Out 12 / 3 PVSV Pressure VSV
39 Br Ground 0 E1 Z48 System ground (2)
40 R-B Out 3 / 12 VISC Idle speed control VSV
41 W-L Out 1 / 12 #20 Fuel injector
42 W-B Ground 0 E02 Z76 Actuator drive ground (Engine)
Electrical: Fuses
-----------------
Battery - CDS FAN
- AM2 - HEAD
- HEAD RH
- HEAD LH
- HORN
- AM1
- EFI No. 1
- Alternator: S
- INJECTOR
- BACKUP
- F/L
- Alternator: B
- AM
- IG switch
- ACC
- CIG
- IG2
- EFI No. 2
- IG1
- ENGINE
- Alternator: IG
- WIPER
- DEFOG
- TURN
- GAUGE
- Charge warning lamp
- Alternator: L
- POWER
- ST1
- Starter relay
- Clutch switch
- DOME LOCK
- HEATER
- A/C
- STOP
- TAIL RH
- TAIL LH
- Starter
Fusible links: (engine bay, on battery)
Battery 30 A CDS FAN Air conditioning
Battery 30 A AM1 EFI,Injector,Backup - Relay & fuse box
Battery 40 A AM2 Headlamps, horn, hazard
Relay & fuse box: (engine bay, near battery)
* AM1 2 B 15 A EFI No. 1 ECU power
* AM1 2 B 10 A INJECTOR Fuel injectors
* AM1 2 B 10 A BACKUP Battery backup: ECU, clock, radio
Main fuse box: (under dash, left)
* HEAD 3 R 15 A HEAD RH R-B Headlamp, right
* HEAD 3 R 15 A HEAD LH R-B Headlamp, left
* AM 3 W 30 A HEATER L-R Heater (relay coil: IG1 - GAUGE)
- IG1 3 B-Y 10 A ENGINE W-R Engine
* HEAD 1 R 20 A HORN W-L Horn, hazard
- ACC 3 L-R 15 A CIG Gr Cigarette lighter
- IG1 3 B-Y 15 A WIPER L-B Windshield wiper
- IG1 3 B-Y 15 A DEFOG B-W Rear defogger
- IG1 3 B-Y 7.5A TURN GR Turn lamps, hazard warning switch
- IG1 3 B-Y 7.5A GAUGE R-L Instrument gauges
* AM SW 3 W-G 10 A TAIL RH W-G Tail lamp, side marker lamps, rheostat
* AM SW 3 W-G 10 A TAIL LH G-L Tail lamp, side marker lamps
Sub fuse box: (under dash, right)
- HTR 2 L-B 10 A A/C L-B Air conditioning
* AM 3 W 10 A STOP GY Stop lamp (brake) switch
- IG2 3 L-W 15 A EFI No. 2 L EFI
* AM 3 W 15 A DOME LOCK G-B Dome lamp, back door lock, radio backup
- IG1 3 B-Y 30 A POWER L Power window (breaker)
Electrical: Instrument Panel
----------------------------
Combination Meter:
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12
A1 BRN R-B C21 Illumination lamps (+) Power from Rheostat
A2 RED Br-B Z83 Gauge Earth (-) Ground for Reed switch
A3 ORG Y-R X3 Reed switch Output to EFI ECU (SPD)
A4 YEL Y-G H5 Oil Pressure warning lamp Input/G from Oil Pressure switch
A5 GRN Y O20 Charge warning lamp Input/G from Alternator (L)
A6 BLU R-W G6 Brake warning lamp Input/G from Park/Level switches
A7 VIO Y-R H22 Fuel gauge Input from Fuel sender
A8 PNK Br Z74 Fuel gauge (-) Input from Fuel sender
A9 WHT G F19 Turn LH lamp Input/P from Turn Signal switch
A10 BLK W-B Z8 Earth (-) Ground for Illu, Turn, Tach, SB
B1 BRN G-W F21 Turn RH lamp Input/P from Turn Signal switch
B2 RED V-? H18 Seat Belt warning lamp Input/O from Seat Belt switch
B3 ORG Y-W H20 Temp gauge Input from Temp sender
B4 YEL Br-B Z129 Temp gauge (-) Input from Temp sender
B5 GRN R-W A11 High beam lamp Input/G from Multi-Use switch
B6 BLU R-B A10 High beam lamp Input/P from HEADLAMP RH fuse
B7 VIO R-L H2 IG (+) Power from GAUGE fuse (IG1)
B8 WHT G-Y X1 CHECK ENGINE lamp Input/G from EFI ECU (W)
B9 BLK Lg-? H32 4WD ENABLED lamp Input/G from 4WD position switch
B10 --- Lg-? H49 DIFF LOCK lamp (N/A) Input/G from Transfer switch
B11 --- N/C N83 REAR ABS lamp (N/A) Input/G from Rear ABS ECU
B12 PNK B-L N11 Tachometer Input from Ignition Coil / ECU
Connector:
1A 2A 3A xx xx 6A 7A
1B 2B 3B 4B xx 6B 7B
1A W-B Ground -
2A R-L Alt Voltage +
3A G-B Batt Backup + (DOME LOCK 15A)
4A --- x
5A --- x
6A Lg-W Rear Spk RH +
7A L-W Rear Spk RH -
1B Gr Batt Acc + (CIG 15A)
2B Br Radio GND -
3B R-B Light Sw +
4B G-R Var Light +
5B --- x
6B P-W Rear Spk LH +
7B V-W Rear Spk LH -
Voltmeter:
1A 2A
1B 2B
1A R-B L.Sw Light +
2A W-B GND Ground -
1B R-L Alt Alt Volt +
2B W-B GND Ground -
^
- - R-B W-B
- - R-L W-B
Inclinometer:
- R-B L.Sw Light +
| W-B GND Ground -
Clock:
1A 2A
1B 2B
1A G-R Dim TAIL RH 10A
2A W-B GND Ground -
1B Gr Acc Accessory +
2B G-B Batt+ Backup +
^
- - G-R WHT/BLK
- - Gr GRN/BLK
Heater Control Climate Light:
- R/B L.Sw Light +
| W/B GND Ground -
Cigar Light:
- R/B L.Sw Light +
| W/B GND Ground -
Cigar Tip +:
- Gr Acc Accessory +
Cigar Ring -:
- W-B GND Ground -
Rheostat:
- E
| | C T (looking at Rheostat)
E 0 V Earth Ground
C 0-12 V Control Lamp
T 12 V Tension Battery
Lamp Control Relay:
F ST xx xx TSL RR
B B E HW TSR RL
F 12 Vo Front turn
ST 12 Vi Stop switch
TSL 12 Vi Turn Signal Left
RR 12 Vo Rear Right turn/brake
B 12 Vi Battery
B 12 Vi Battery
E 0 Vi Earth
HW 12 Vi Hazard/Warning
TSR 12 Vi Turn Signal Right
RL 12 Vo Rear Left turn/brake
Electrical: Lighting
--------------------
Number Type Base Bulb Size_mm Watts Ohms # Color Light
------ ---- ---- ---- ------- ----- ---- - ----- -----
Body Lighting:
H6054 Halogen P43t T-5 142x200 65/35 ?/? 2 Clear Headlamp, Sealed
H4/9003 Halogen P43t T-5 17x92 60/55 ?/? 2 Clear Headlamp, Bulb
1157 Bayonet BAY15d S-8 27x51 27/8.3 ?/? 2 Amber Front Turn,Clrnc
1157 Bayonet BAY15d S-8 27x51 27/8.3 ?/? 4 Red Rear Turn, Tail
1156 Bayonet BA15s S-8 27x51 27 ? 2 Clear Back-up
168 Wedge W5W/T10 T3-1/4 10x27 5 3.7 2 Amber Front Marker
168 Wedge W5W/T10 T3-1/4 10x27 5 3.7 2 Red Rear Marker
168 Wedge W5W/T10 T3-1/4 10x27 5 3.7 2 Clear License Plate
3022 Festoon SV7 T2-1/4 8x29 5 ? 1 White Room 10W 8x29
3175 Festoon SV8.5 T3 10x31 10 ? 1 White Room 10W 8x29
6418 Festoon SV8.5 T3-1/4 11x35 5 ? 1 White Luggage 8W 10x36
3425 Festoon SV8.5 T4 12x36 10 ? 1 White Luggage 8W 10x36
Combination Meter:
194 Wedge W3W/T10 T3-1/4 10x27 3.78 ~ 4.8 4 Red Illumination,Alt
158 Wedge W3W/T10 T3-1/4 10x27 3.36 ~ 5.1 4 Green Illumination
158 Wedge W3W/T10 T3-1/4 10x27 3.36 5.1 3 B,A,G Indicators
74 Wedge W21x49d T1-3/4 5.5x20 1.40 13.5 5 Red Warnings
74 Wedge W21x49d T1-3/4 5.5x20 1.40 13.5 2 Green Turn Signals
Triple Meters:
74 Wedge W21x49d T1-3/4 5.5x20 1.40 ~ 13.5 1 Green Voltmeter
74 Wedge W21x49d T1-3/4 5.5x20 1.40 ~ 13.5 1 Green Inclinometer
- 7-Seg - - - - 13.5 1 Green Digital Clock
Instrument Panel:
74 Wedge W21x49d T1-3/4 5.5x20 1.40 ~ 13.5 1 Clear Heater Control
2721 Wedge W2x4.6d T1-1/2 5x19 1.20 ~ 15.0 1 Clear Cigar Lighter
2721? Wedge W2x4.6d T1-1/2 5x19 1.20 ? 1 Blue A/C Switch
2721? Wedge W2x4.6d T1-1/2 5x19 1.20 ? 1 ? Rear Heat Switch
2721? Wedge W2x4.6d T1-1/2 5x19 1.20 ~ ? 2 ? Defogger Switch
2721? Wedge W2x4.6d T1-1/2 5x19 1.20 ~ ? 2 ? Hazard Switch
Wattage:
70 2x35 H6054 Halogen T-5 Sealed Headlamps, Low
130 2x65 H6054 Halogen T-5 Sealed Headlamps, High
110 2x55 H4 Halogen T-5 Bulb Headlamps, Low
120 2x60 H4 Halogen T-5 Bulb Headlamps, High
50 6x8.3 1157 Bayonet S-8 Clearance & Tail
54 2x27 1157 Bayonet S-8 Turn, Front
108 4x27 1157 Bayonet S-8 Turn/Stop, Rear
54 2x27 1156 Bayonet S-8 Back-up
20 4x5 168 Wedge T10 Markers, Front & Rear
10 2x5 168 Wedge T10 License Plate
10 1x10 3175 Festoon SV7 Room
10 1x10 3425 Festoon SV8 Luggage
14 ~ 4x3.4 158 Wedge T10 Illumination
10 3x3.4 158 Wedge T10 Indicators
7 5x1.4 74 Wedge T5 Warnings
3 2x1.4 74 Wedge T5 Turn Signals
3 ~ 2x1.4 74 Wedge T5 Triple Meters
10 ~ 8x1.2 2721 Wedge T5 Instrument Panel
--- ----- ---- ----- --- --------------------
363 Total, w/o Headlamps
433 +70 Total, w/ Sealed Headlamps, Low
563 +70+130 Total, w/ Sealed Headlamps, Low + High
Electrical: Relays
------------------
AC-47 A/C Condenser Fan Relay 30 A engine bay near driver side headlight
EF-56 EFI Main Relay 15 A relay block in engine bay near battery
EF-57 Fuel Injector Relay 10 A relay block in engine bay near battery
EF-58 Fuel Pump Relay 15 A relay block in engine bay near battery
BE-45 Headlamp Relay 40 A relay block in engine bay near battery
BE-71 Headlamp Cleaner Relay AM behind instrument panel, passenger side
BE-55 Intermittent Wiper Relay 15 A behind instrument panel, driver side
BE-96 Door Lock Control Relay AM behind instrument panel, driver side N/A
BE-42 Lamp Control Relay 7.5 A behind instrument panel, driver side
ST-20 Starter Relay AM near clutch pedal & fuse box, left
BE-87 Rear Heater Relay 30 A near clutch pedal & fuse box, right N/A
BE-34 Horn Relay 20 A near clutch pedal & sub fuse box, left
BE-80 Front Heater Relay 30 A near clutch pedal & sub fuse box, right
Electrical: Switches
--------------------
AC-46 A/C Switch heater control panel
BE-80 Blower Switch heater control panel
BE-97 Back Door Opener Switch center console
BE-91 Remote Control Mirror Switch center console
BE-33 Horn Switch steering wheel
BE-40 Light & Dimmer Passing Switch steering column, left
BE-41 Turn Signal Switch steering column, left
BE-53 Front Wiper Switch steering column, right
BE-54 Front Washer Switch steering column, right
BE-31 Ignition Key Switch steering column
BE-42 Hazard Warning Switch instrument panel, right
BE-67 Rear Defogger Switch instrument panel, left
BE-86 Rear Heater Switch instrument panel
BE-61 Rear Wiper Switch instrument panel
BE-42 Stop Lamp Switch brake pedal
BE-20 Brake Fluid Level Switch brake master cylinder
BE-21 Parking Brake Switch center console
BE-97 Back Door Opener Switch center console
BE-91 Remote Control Mirror Switch center console
BE-22 Seat Belt Switch seat belt, driver
BE-48 Interior Room Lamp Switch interior roof
BE-48 Side Door Switch side doors
BE-49 Luggage Room Lamp Switch luggage area
BE-49 Back Door Switch back door
BE-6 Oil Pressure Switch engine oil pump
BE-6 Back-up Lamp Switch transmission
BE-6 Transfer Position Switch transfer
EF-65 Throttle Position Switch throttle body
Engine
------
Clutch:
- bearing, pilot: 12 x 28 x 8 mm Timken 101SS - crankcase rear bearing
- bearing, release: 28 x 57 x 29 mm Timken 614145 - inside bell housing
- clutch cable: ?? x 3.0 mm (87.625"), ?? mm travel - Pioneer CA418
* clutch cable snap E-ring: 12 mm x 1.0 mm
- clutch cover bolt: 12 mm hex / M8-1.25 x 16 "6" + LW (x6) [T:14 ft-lb]
- clutch cover: ?? x ?? mm - Luk 23003
- weight: 3.406 kg
- clutch disc: 7.875" x ?.? mm (new), input shaft: 21 mm diameter, 20-spline
- clutch disc: 139.8 x 200.2 mm - flat side flywheel; raised side pressure plate
- clutch disc thickness (old): flywheel: 3.30 mm, pressure plate: 3.10 mm
- clutch disc thickness (new): flywheel: 3.50 mm, pressure plate: 3.50 mm
- clutch disc height (old): 1.57 - 1.67 mm from each rivet (0.3 mm min limit)
- clutch disc height (new): 1.80 - 1.85 mm from each rivet (0.3 mm min limit)
- weight: 1.018 kg
Cooling fan:
- attached to water pump pulley flange
Cylinder block:
- Crankshaft:
- pulley: 5 groove, 111.00 OD x 30.20 ID x 21.50 W - front side
- pulley: 4 groove, 142.40 OD x 30.20 ID x 18.60 W - engine side
- pulley bolt: 10 mm hex / M8-1.25 x 22 " " small, tall head (x4) [T:18 ft-lb]
- bolt: 19 mm hex / M12-1.25 x 52 (30) "10" flanged [T:69 ft-lb]
- pulley gear: 20 tooth, 59.37 OD x 22.00 ID x 26.00 W [59.37 mm]
- flange: 25.2 x 67.0 x 1.0 mm Daihatsu 13482-87102
* oil seal, front: 34 x 48 x 5 mm Daihatsu 90043-11345 = NOK BH5406F
* oil seal, front: 34 x 48 x 6 mm NOK BH3757E
* oil seal, front: 34 x 48 x 7 mm Timken 223420 fluoro-elastomer, CW spiral lip
- bearing, rear: 12 x 28 x 8 mm Timken 101SS - clutch pilot bearing
- EM-116: cylinder block bore code: 2 1 2 1 - on cylinder block
- EM-116: piston code number: 2 1 2 1 - on piston tops
- EM-116: crankshaft journal diameter code: 7 7 7 6 6 - on cylinder block
- EM-116: crankshaft main journal diameter code: 3 3 3 3 2 - on crankshaft rear
- EM-117: connecting rod big end bore code: 5 5 5 5 - on connecting rods
- EM-117: crankpin journal diameter code: 2 2 2 2 - on crankshaft front
- crankshaft thrust clearance: 0.?? mm [0.30 mm]
- connecting rod thrust clearance: 1: 0.?? 2: 0.25 3: 0.25 4: 0.?? [0.45 mm]
- nut, connecting rod cap Daihatsu 90041-70221 (x8) [T:29 ft-lb]
- bearing, connecting rod Daihatsu 13041-87101-01~5 (#1-5) - alternate
- bearing, connecting rod Daihatsu 13041-87102-030 (#3 BRN) - have 1, need 4
- bearing, connecting rod Daihatsu 13041-87103-030 (#3 BRN) - alternate
- bearing, crankshaft main Daihatsu 11701-87101-030 (#3 BRN) - did not order 1
- bearing, crankshaft main Daihatsu 11701-87101-040 (#4 BLK) - did not order 4
- bearing, crankshaft main Daihatsu 11701-87102-01~7 (#1-7) - alternate
- thrust washer Daihatsu 11011-87101
- piston rings, std size Daihatsu 13011-87107 (1 set)
- weight: ?.? kg
Cylinder head:
- cylinder head cover - aluminum "DAIHATSU 16 VALVE"
- oil cap: 35 / 37 mm thread, 42.4 x 52.4 x 1.8 mm gasket, 55 mm cap OD
* oil cap gasket: rubber
- bolt: 10 mm hex / M6-1.00 x 16 "4" + W - plastic spark plug wire holder
* spark plug tube grommet: 25 mm tube x 34 mm hole (x4) Daihatsu 90044-80402 ?
- spark plug: 16 mm hex deep / M14-1.25 x 19 + crush washer (x4) [T:14 ft-lb]
- clip: accelerator cable
- cover bolt: 10 mm hex / M6-1.00 x 25 "=" + W (x8) - cross [T:3 ft-lb]
* cover gasket: rubber
- Camshaft:
- bolt: 12 mm hex / M8-1.25 x 16 "=" flanged (x3) [T:14 ft-lb]
- pulley gear: 40 tooth, 119.96 OD x 13.00 ID x 30.00 W [119.90 mm]
* oil seal, front: 38 x 50 x 8 mm Daihatsu 90043-11229 / Daihatsu 90043-11343
* oil seal, front: 35 x 50 x 8 mm Reycon 35 50 8 - shaft size too small
* oil seal, front: 38 x 50 x 8 mm Koyo MHSA 38 50 8 XRT
* oil seal, front: 38 x 50 x 8 mm NOK AH2218L
* oil seal, front: 38 x 50 x 6 mm Timken 223801 - nitrile
* oil seal, front: 38 x 50 x 8 mm Timken 223802 - polyacrylate, CW spiral lip
- water temp sensor (rear, green): 19 mm hex / M17-1.4? x 12 [T:22 ft-lb]
- water temp sender gauge (rear, spade): 12 mm hex / M10-0.9? x ?? [T:12 ft-lb]
* seal tape: teflon
- rear cap bolt: 12 mm hex / M8-1.25 x 40 (??) "=" + LW (x2) - above distributor
- head bolt: 14 mm hex / M10-1.25 x ?? (??) + LW (x10) - cross [T:46 ft-lb]
- valve rocker shaft sub assembly No. 1 (intake) and No. 2 (exhaust)
- rocker bolt: 12 mm hex / M8-1.25 x ?? (??) " " flanged (x10) [T:11 ft-lb]
- head bolt: 14 mm hex / M10-1.25 x 155 (35) " " flanged + W (x2) [T:24 ft-lb]
- head bolt: 14 mm hex / M10-1.25 x 110 (35) " " flanged + W (x8) [T:24 ft-lb]
- rocker arms (x16)
- valve springs (x16)
- valve guides (x16)
* oil seal, valve: ?? x ?? x ? mm Daihatsu 90048-12011 / 90913-02051 ? (x16)
- intake valves (x8) Daihatsu 13711-B1030
- exhaust valves (x8) Daihatsu 13715-B1030
- valve clearances: 0.00? (cold) 0.00? (hot) (x16)
* head gasket: metal
- weight: ?.? kg
Distributor:
- bolt: 8 mm hex + slot+phil / M5-0.8? x 22 " " + LW + W (x2) - distributor cap
- bolt: 12 mm hex / M8-1.25 x 28 "=" + LW + W (x2) [T:14 ft-lb]
- groove: 29.9 x 36.0 x 4.80 mm
* o-ring: 29.7 x 36.8 x 3.53 mm AS -217 * 0.7% str, 16% comp, 67% fill
* o-ring: 29.7 x 36.7 x 3.50 mm JIS P30 * 0.7% str, 15% comp, 66% fill
* gasket: rubber - distributor cap
- cap: JD934, 2 screws
- rotor: JP953, press on
Engine mount (x2 sides):
- mount nut: 17 mm hex / M12-1.25 x 10 + LW [T:33 ft-lb]
- mount bolt: 14 mm hex / M10-1.25 x 30 "6" + LW + W (x2) [T:27 ft-lb]
- bracket: steel
- bracket nut: 14 mm hex / M10-1.25 x 10.5 flanged -shared w/ alt lower bracket
- bracket bolt: 14 mm hex / M10-1.25 x 25 "6" + LW (x2)
- bracket bolt: 14 mm hex / M10-1.25 x 30 "6" + LW - shared w/ rear bracket
- bracket bolt: 14 mm hex / M10-1.25 x 25 "6" + LW - rear bracket
- rear bracket: attaches to bottom of transmission
Flywheel:
- flywheel bolt: 14 mm 12-pt hex / M12-1.25 x 22 (17) flanged (x6) [T:65 ft-lb]
- flywheel hub: 36 mm diameter, 253 mm OD, 265 mm ring gear OD
- flywheel surface: 110 mm ID, 203 mm OD
- thickness before turning: 0.50 - 0.60 mm
- thickness after turning: 0.40 - 0.50 mm --> removed ~ 0.10 mm
* thread sealant: TB 1324
- weight: ?.? kg
Hook brackets:
- bolt: 14 mm hex / M10-1.25 x 20 "6" + LW - front
- nut: 12 mm hex / M8-1.25 x 8 flanged - rear [T:44 ft-lb]
- shared w/ intake manifold bracket and engine ground wire
Idle pulley:
- pulley: flat, 79.80 OD x 37.00 ID x 20.00 W
- bolt: 14 mm hex / M10-1.25 x 30 (14) " " flanged
- flange, spacer, flange
- snap ring: 39.40 (relaxed) x 1.5 mm
- bearing, idle: 12 x 37 x 12 mm SNR 6301J30 / 6301 RSR/1 (in Black Rocky)
- bearing, idle: 12 x 37 x 12 mm NSK 6301DU2 Japan (in Blue Rocky)
- bearing, idle: 12 x 37 x 12 mm National / Timken 301SS
- bearing, idle: 12 x 37 x 12 mm Koyo 6301-2RSC3
Ignition coil:
- bolt: 12 mm hex / M8-1.25 x 18 "=" + LW + W
- resistance, primary: 1.35 - 1.65 ohms
- resistance, secondary: 22 - 30 k ohms
Oil cooler:
- set bolt: 22 mm hex deep socket / 3/4"-16 x 83 (24,18) hollow [T:22 ft-lb]
* gasket: 56.0 x 65.0 x 4.2+ mm
* gasket: 56.0 x 65.0 x 4.50 mm 4.5x56
* gasket: 55.0 x 65.0 x 5.00 mm GM055
Oil cooler pipe:
- bolt: 10 mm hex / M6-1.00 x 12 "6" + LW + W
- banjo bolt: 17 mm hex / M12-1.25 x 27 (14) [T:22 ft-lb]
* washer, copper: 12.1 x 16.1 x 1.0 mm (0.48" x 0.63" x 0.04") (x2)
Oil filter:
- same as Toyota Celica 1988-2005
* gasket: 55 x 63 x ?.? mm (attached to filter)
- filter: ACDelco PF1233 20 micron 2.65" dia x 2.90" $ 3.05
- filter: Bosch 3311 20 micron 2.68" dia x 3.52" $ 4.52
- filter: Denso 1502000 ?? micron 2.6?" dia x 2.95" $ 3.19
* filter: Fram TG4967 3 micron 2.69" dia x 2.93" $ 6.10
* filter: Mobile 1 M1-103A ? micron 2.6?" dia x 2.9?" $ 8.96 current filter
* filter: WIX 51394XP ? micron 2.69" dia x 2.98" $ 6.47
Oil level gauge guide:
- dipstick: 495 x 5.0 x 1.0 mm (19.5")
- bolt: 14 mm hex / M10-1.25 x 14 "4" + LW [T:18 ft-lb]
- groove: 10.1 x 13.3 x 1.60 mm x 2.2 mm
* o-ring: 9.8 x 13.6 x 1.90 mm JIS P10 * 3.1% str, 19% comp, 81% fill
- use an extra one above groove, for redundancy and to keep debris out of hole
Oil pan:
- bolt, drain: 14 mm hex / M12-1.25 x 11 [T:18 ft-lb]
* washer, metal/rubber: 12 x 25 x 2.? mm (0.47" x 0.98" x 0.0?")
- washer: gasket: 17 mm, flange: 22 mm
- bolt, mounting: 10 mm hex / M6-1.00 x 12 "6" + LW (x10) [T:7 ft-lb]
- nut, mounting: 10 mm hex / M6-1.00 x 6 flanged (x4) [T:7 ft-lb]
- stud, mounting: M6-1.00 x 27 (x4)
* gasket: rubber, molded (pan front) Daihatsu 12151-87103-001
* gasket: rubber, molded (pan rear) Daihatsu 12152-87102-001
* sealant: TB 1207C
Oil pump:
- sensor bracket bolt: 10 mm hex / M6-1.00 x 16 "4" + LW + W
- sensor bracket
- oil pressure switch: 24 mm hex / M10-0.9? x 10 (1/8"x28 BSPT ?) [T:12 ft-lb]
* seal tape: teflon
- groove: 31.6 x 39.6 x 2.60 mm
* o-ring: 31.7 x 38.7 x 3.50 mm JIS P32 * 0.0% str, 35% comp, 93% fill - flat
- bolt: 10 mm hex / M6-1.00 x 40 (32) "=" + LW (x4) [T:6 ft-lb]
- bolt: 10 mm hex / M6-1.00 x 20 "6" + LW (x3) [T:6 ft-lb]
* sealant: TB 1207C
Oil strainer:
- bolt: 12 mm hex / M8-1.25 x 12 "6" + LW (x2) [T:14 ft-lb]
- nut: 12 mm hex / M8-1.25 x 8 + LW (x2) [T:14 ft-lb]
* gasket: fiber
Rear end plate:
- bolt: 12 mm hex / M8-1.25 x 14 "4" + LW - upper plate [T:14 ft-lb]
- bolt: 12 mm hex / M8-1.25 x 35 "6" + LW - lower plate [T:14 ft-lb]
- nut: 12 mm hex / M8-1.25 x 6 welded - lower plate [T:14 ft-lb]
Rear oil seal retainer:
- bolt: 10 mm hex / M6-1.00 x 20 "6" (x4) [T:6 ft-lb]
* oil seal, rear: 80 x 100 x 8.5 mm Daihatsu 90043-11344 = NOK AH37300
* oil seal, rear: 80 x 100 x 10 mm Timken 228009 - silicone, CCW spiral lip
* sealant: TB 1207C
Spark plug wires: (x4 + ignition coil)
- resistance, maximum: 15 k ohms
Timing belt:
- bolt, cover: 10 mm hex / M6-1.00 x 45 (32) "6" + LW + W (x1) - top [T:2 ft-lb]
- replaced w/ 40 mm flanged
- bolt, cover: 10 mm hex / M6-1.00 x 22 "6" + LW + W (x2) - upper
- replaced w/ 20 mm flanged
- bolt, cover: 10 mm hex / M6-1.00 x 22 "6" + LW + W (x1) - upper+lower, R
- bolt, cover: 10 mm hex / M6-1.00 x 25 "6" + LW + W (x1) - upper+lower, L
- bolt, cover: 10 mm hex / M6-1.00 x 22 "6" + LW + W (x3) - lower
- cover, upper: plastic
- cover, lower: plastic
* gasket, cover, upper: 5 mm x 650 mm long
* gasket, cover, lower: 5 mm x 490 mm long
- access plug, cover, lower: 28 mm
- tensioner bolt: 14 mm hex / M10-1.25 x 60 (32) "6" + LW + W [T:27 ft-lb]
- tensioner bearing: 50.0 mm diameter x 27.0 mm wide GMB E6005RVN
- tensioner spring: 46.70 mm long x 11.2 mm OD, 1.45 mm thick + rubber sleeve
Water inlet:
- bolt: 10 mm hex / M6-1.00 x 22 "=" + LW (x3) [T:6 ft-lb]
- thermostat: 52.0 mm diameter, NTC 78 C - install jiggle pin at upper side
* thermostat gasket: rubber AISIN THP-105 / Fel-Pro 35278 ('83-'95 Toyota 22RE)
* gasket: none
Water outlet:
- bolt: 12 mm hex / M8-1.25 x 22 "|" + LW
- nut: 12 mm hex / M8-1.25 x 8 flanged
- bracket: O2 oxygen sensor
- BVSV: 19 mm hex / M17-1.4? x 13 "AISIN 90048-29027" [T:22 ft-lb]
- A/C water temp sensor: 17 mm hex / M17-1.4? x 14 "10S 20 110." [T:22 ft-lb]
* seal tape: teflon
* gasket: fiber
Water pump:
- fluid coupling
- nut: 10 mm hex / M6-1.00 x 6 flanged (x4) [T:10 ft-lb]
- pulley: 4 groove, 109.30 OD x 32.00 ID x 20.50 W
- bolt: 12 mm hex / M8-1.25 x 30 "6" + LW (x3) [T:14 ft-lb]
- nut: 12 mm hex / M8-1.25 x 8.4 + LW (x2) [T:14 ft-lb]
- stud: M6-1.00 x 25 (8,14) (x4)
* thread sealant: TB 1377B (studs into water pump pulley flange)
- dust seal: gap between water pump & cyl head, under timing cover (CO-5)
- 15.7 L x 10.8 W x 17.5 T mm; gap: 11.0 L x 3.8 W x 5.0 T
- dust seal: gap between water pump & oil pump, under timing cover (EM-82)
- 27.1 L x 10.8 W x 10.0 T mm; gap: 18.8 L x 3.2 W x 5.8 T
* gasket: fiber
Engine Exhaust
--------------
Coolant pipe:
- bolt: 10 mm hex / M6-1.00 x 12 "?" + LW (x2) - replaced w/ flanged
Exhaust manifold:
- replaced w/ header
- heat shield
- heat shield bolt: ?? mm hex / M_-1.__ x __ "?" + LW + W (x?)
Pipe:
- replaced w/ header
* gasket, upper: metal
* gasket, lower: metal
Header:
- bolt: 14 mm hex / M10-1.25 x 30 "6" + LW (x6) [T:27 ft-lb]
- nut: 14 mm hex / M10-1.25 x 8 + LW (x2) [T:27 ft-lb]
- oxygen sensor: 22 mm hex / M18-1.50 x 10 thread
- oxygen sensor gasket: metal crush washer: 17.9 x 22.7 x 1.8 mm
Flex pipe:
- 3" diameter, 6" long
- exhaust bolt: ?? mm hex / M_-1.__ x __ "?" + LW (x3) [T:36 ft-lb]
* exhaust gasket: steel
Catalytic converter:
- "38602"
- 10 x 6 x 4", 14" long incl end pipes
- 330 x 95 mm (13" x 3.75") - O-Reilly - MagnaFlow 91004 - $79
- u-bolt: 5/16"-?? x ?" (x2)
- nut: 1/2" hex / 5/16"-?? x 1/4" flanged (x4)
* gasket, front: metal
* gasket, rear: metal
Pipe:
- 2" diameter x 13" long
Muffler:
- 15 x 9 x 5", 20" long incl end pipes
Tailpipe:
- 47.2 x 50.8 x 1.8 mm (1.86" x 2.00" x 0.07")
Engine Intake
-------------
Air filter housing:
- bolt: ?? mm hex / M_-1.__ x __ "?" + LW - side
- bolt: ?? mm hex / M_-1.__ x __ "?" + LW + bushing (x2) - bottom
- air ducting - removed
- replaced w/ K&N R-1380 air filter
Air chamber:
- bolt, top: 10 mm hex / M6-1.00 x 20 "?" + LW + W (x3)
- replaced w/ 10 mm flanged
- bolt, bottom: 10 mm hex / M6-1.00 x 16 "?" + LW + W (x2) - exhaust [T:3 ft-lb]
- bolt, bottom: 12 mm hex / M8-1.25 x 16 "4" + LW + W (x1) - intake
- bracket, exhaust side
- bracket, intake side
Intake manifold:
- bolt: 12 mm hex / M8-1.25 x 25 "6" + LW (x7) [T:14 ft-lb]
- nut: 12 mm hex / M8-1.25 x 8 flanged (x4) [T:14 ft-lb]
- bolt: 10 mm hex / M6-1.00 x 12 flanged - front harness bracket (bolt)
- bolt: 10 mm hex / M6-1.00 x 10 flanged - rear harness bracket (stud & nut)
- weight: 4.400 kg
Throttle body:
- connector: black
- wire clip: throttle position sensor
- bolt: 12 mm hex / M8-1.25 x 55 (32) "6" + LW (x2) [T:14 ft-lb]
- bolt: 12 mm hex / M8-1.25 x 60 (32) "=" + LW + W - bracket [T:14 ft-lb]
- nut: 12 mm hex / M8-1.25 x 8 flanged [T:14 ft-lb]
- stud: M8-1.25 x 63 (11 each end)
* thread sealant: TB 1207C
* gasket: fiber
- weight: 1.638 kg
Accelerator cable:
- bracket - to throttle body
- bracket bolt: 10 mm hex / M6-1.00 x ?? " " flanged (x2)
- cable: ?? x 1.6 mm
- cable nut: 12 mm hex / M8-1.25 x 5 (x2)
- dust cap: 7.8 mm ID
- valve nut: 12 mm hex / M8-1.25 x 5 + LW
- throttle positioner
- throttle positioner nut: 8 mm hex / M5-0.8? x 4 (x2)
Bracket (throttle body):
- nut: 12 mm hex / M8-1.25 x 8 flanged [T:14 ft-lb]
Bracket (rear):
- nut: 12 mm hex / M8-1.25 x 8 flanged (x2) [T:18 ft-lb]
- ground wire: 8 mm
Bracket (lower):
- nut: 14 mm hex / M10-1.25 x 10.5 flanged [T:27 ft-lb]
- bolt: 14 mm hex / M10-1.25 x 20 "6" + LW [T:27 ft-lb]
Cooling pipe:
- hose: 14.0 mm / 15.6 mm ridge + clamps (x2)
EGR tube:
* hole plug: 10.1 mm (x2)
* hole plug: 12.1 mm (x2)
* hole plug: 14.0 mm (x1) - end
Fuel injector:
- injector: ?
* o-ring: ?.? x ?.? x ?.?? mm ? (x4)
Fuel rail:
- banjo bolt: 17 mm hex / M12-1.25 x 27 (14)
* washer, copper: 12.6 x 17.2 x 1.0 mm (0.50" x 0.68" x 0.04") (x2) - joined
- nut: 12 mm hex / M8-1.25 x 8 flanged (x2) [T:14 ft-lb]
- spacer, plastic: 8.6 x 18.2 x 5.0 mm (x2)
Fuel regulator:
- pressure: 33 - 40 psi
* hose clip: 13 mm (x2)
- bolt: 10 mm hex / M6-1.00 x 14 "6" + LW + W (x2) [T:6 ft-lb]
- groove: 8.0 x 11.1 x 2.50 mm
* o-ring: 7.8 x 11.6 x 1.90 mm JIS P8 * 2.6% str, 23% comp, 73% fill
* lubricant: silicone oil
Fuel return pipe:
- pipe: 8.2 mm / 9.3 mm ridge + clamps (x2)
- bolt: 10 mm hex / M6-1.00 x 14 "6" + LW + W (x2)
Vacuum pipe assembly:
- nut: 12 mm hex / M8-1.25 x 8.0 flanged (x2) - hose bracket/clip, ISC VSV nuts
Air temperature sensor:
- connector: red
- thread: 19 mm hex / M16-1.50 x 10 [T:26 ft-lb]
* washer, copper: 16.4 x 23.9 x 2.1 mm (0.65" x 0.94" x 0.08")
Air / gas filter:
- color: white
- thread: 24 mm hex / M10-0.9? x 16 (11) hollow [T:12 ft-lb]
* seal tape: teflon
Hose bracket/clip:
- nut: 12 mm hex / M8-1.25 x 8 flanged
ISC VSV:
- connector: blue
- nut: 12 mm hex / M8-1.25 x 8 flanged
* thread sealant: TB 1104
Pressure sensor / Pressure VSV: (firewall)
- connector: red
- bolt: 10 mm hex / M6-1.00 x 14 "4" + LW + W
A/C VSV: (firewall)
- connector: blue
- bolt: 10 mm hex + phil / M6-1.00 x 16 + LW + W
A/C idle speed adjust:
- thread: M10-0.9? x 10 hollow
* seal tape: teflon
- hose + clips (x2) - to air chamber
- hose bracket
- hose bracket bolt: 10 mm hex + phil / M6-1.00 x 12 + LW + W
EGR VSV:
- connector: blue
- bolt: 12 mm hex / M8-1.25 x 12 "4" + LW
* thread sealant: TB 1104
EGR modulator:
- bolt: 12 mm hex / M8-1.25 x 12 "4" + LW
- bracket
EGR valve:
- nut: 10 mm hex / M6-1.00 x 6 flanged (x2)
* gasket: fiber (high temperature)
Engine Stand
------------
bolts:
- depth: 27 mm both top, 20 mm bottom
- hole: 25 mm
- stand all: 50 mm
- current bolt: 60 mm
50 + 27 + 3 + 3 = 83 -> 80 mm
50 + 27 + 3 + 3 = 83 -> 80 mm
50 + 20 + 3 + 3 + 3 + 3 = 82 -> 80 mm
50 + 25 + 3 + 3 + 10 = 91 -> 90 mm
Fuel
----
BVSV:
- below 45 C (113 F): Closed
- above 66 C (151 F): Open
* threads: liquid sealer
Charcoal canister:
- bolt: 10 mm hex / M6-1.00 x 16 "4" + LW - tighten
- nut: 10 mm hex / M6-1.00 x 5 - tighten
- bolt: 10 mm hex / M6-1.00 x 14 "4" + LW + W - firewall
- hose: 2.2 x 4.0 x 0.9 mm x 445 mm long - hard plastic between 24 and char can
Fuel liquid separator:
- hose: 6.0 ID x ?? mm - lower front to fuel tank
- hose: 6.0 ID x ?? mm - lower rear to fuel tank
- hose: 6.5 ID x 55 mm - from separator to safety valve
- hose: 7.0 ID x ?? mm - from safety valve to pipe
Fuel line safety valve:
- behind rear quarter panel trim
- check for cracks & leaks
Fuel cap:
- behind fuel door
- check cap, gasket, valve
Fuel filter:
- Fram G-6898 --> WIX 33500
- banjo bolt: 17 mm hex / M12-1.25 x 27 (14) (x2) [T:29 ft-lb]
* washer, copper: 12.4 x 15.9 x 0.85 mm (0.49" x 0.63" x 0.03") (x4)
- bracket
- bracket bolt: 10 mm hex / M6-1.00 x 12 " " + LW - tighten fuel filter
- bracket bolt: 10 mm hex / M6-1.00 x 12 "4" + LW + W - pressure sensor harness
- bracket bolt: 10 mm hex / M6-1.00 x 16 "=" + LW + W - ground wire to manifold
- bracket bolt: 10 mm hex / M6-1.00 x 25 "6" + LW + W + bushing + flange (x2)
Fuel pump:
- bolt: 12 mm hex / M8-1.25 x ?? "?" + LW (x3) - bracket [T:10 ft-lb]
- bolt: 12 mm hex / M8-1.25 x ?? "?" + LW (x3) - pump [T:10 ft-lb]
Gaskets
-------
material:
- rubber-fiber sheet, 26" x 10" x 1/32": Fel-Pro 3157
Cylinder Head Gasket Metal EM-36, EM-69, EM-82, EM-138
Cylinder Head Cover Gasket Rubber EM-12, EM-36, EM-72, EM-139
Differential Front Gasket Fiber DF-7, DF-26
Differential Rear Sealant TB1104 DF-32, DF-49
Distributor Cap Gasket Rubber IG-5
EGR Valve Gasket Fiber EC-11
Exhaust Manifold Gasket Metal EM-65
Exhaust Pipe Gasket Metal EM-70
Fuel Injectors Grommet Rubber EM-67
Hubs Front Gasket Fiber FS-29, FS-46, FS-54
Intake Manifold Gasket Fiber EM-68
Oil Filler Cap Grommet Rubber EM-36
Oil Pan Sealant TB1207C EM-82, EM-132
Oil Pan Front Gasket Rubber EM-82, EM-132
Oil Pan Rear Gasket Rubber EM-82, EM-132
Oil Pump Sealant TB1207C EM-82, EM-131
Oil Strainer Gasket Fiber EM-82, EM-132
Spark Plug Tubes Grommet Rubber EM-13, EM-36, EM-73
Thermostat Grommet Rubber EM-105
Throttle Body Gasket Fiber EM-67, EF-122
Timing Belt Covers Gasket Rubber EM-21, EM-33, EM-82
TM Front Bearing Gasket Fiber MT-21, MT-47, MT-71, MT-98
TM Case Cover Sealant TB1216 MT-52, MT-70
TF Adapter Sealant TB1216 MT-50
TF Front Case Sealant TB1216 MT-51
TF Rear Case Gasket Fiber TR-2, TR-30
TF Output Bearing Gasket Fiber TR-32
TF Shift Lever Gasket Rubber TR-4, TR-33, MT-16, MT-109
Water Inlet None None EM-85, EM-136
Water Outlet Gasket Fiber EM-64
Water Pump Gasket Fiber EM-82, EM-136
TM Front Bearing
--- Gasket ---
TM Case --- Sealant --- TM Case Cover
--- Sealant ---
TF Adapter
--- Sealant ---
TF Front Case
--- Gasket ---
TF Rear Case
--- Gasket ---
TF Output Bearing --- Gasket --- TF Shift Lever
Hoses: A/C
----------
metal pipe --> compressor U: 14.5 mm 9/16" x 17" hose
metal pipe <-- compressor U: 12.0 mm <1/2" x 16" hose
Hoses: Brake
------------
engine intake --> metal pipe U: 9 mm >5/16" x 9" hose
brake booster <-- metal pipe U: 9 mm >5/16" x 7" hose
Hoses: Cooling
--------------
radiator outlet --> lower pipe, bot L: 32 mm 1.25" x 7" Con 60425 Day 70704
engine inlet <-- lower pipe, top L: 32 mm 1.25" x 9" Con 60427 Gat 21528
engine outlet --> upper pipe, rear L: 32 mm 1.25" x 5" Con 60425 Day 70704
radiator inlet <-- upper pipe, front Z: 33 mm 1.28" x 11" Con 61267 Gat 21025
engine side --> heater core, bot S: 17 mm >5/8" x 22" Con 63806 Day 80400
engine inlet <-- heater core, top S: 17 mm >5/8" x 28" Con 63819 Day 80403
engine rear --> bypass pipe, rear I: 14 mm >1/2" x 4" hose
intake manifold <-- bypass pipe, front I: 14 mm >1/2" x 6" hose
intake manifold --> throttle body, bot U: 8 mm 5/16" x 12" hose
engine inlet <-- throttle body, top C: 8 mm 5/16" x 24" hose
intake manifold --> radiator air, top L: 8 mm 5/16" x 11" Con 63100 Day 86801
oil cooler pipe --> oil cooler, top L: 8 mm 5/16" x 3" Con 64310 Day 86800
radiator bottom <-- oil cooler, bot J: 12 mm <1/2" x 24" hose
radiator cap --> reserve tank, in I: 8 mm 5/16" x 13" hose
overflow ground <-- reserve tank, out I: 6 mm <1/4" x 16" tube, clear
5/8" ID hose : 5 ft - Continental 65004 / Gates 28417
1/2" ID hose : 3 ft - Continental 65000 / Gates 28410
5/16" ID hose : 5 ft - Continental 64995 / Gates 28408
1/4" ID tube : 2 ft - ACDelco 30120 / Gates 28407
Hoses: Fuel
-----------
metal pipe --> fuel filter, bot U: 8 mm 5/16" x 18" hose HP
fuel rail <-- fuel filter, top U: 8 mm 5/16" x 10" hose HP
fuel regulator --> return pipe I: 8 mm 5/16" x 3" hose
metal pipe <-- return pipe S: 8 mm 5/16" x 18" hose
5/16" ID hose HP : 3 ft - Gates 27340
5/16" ID hose LP : 2 ft - Gates 27003
Hoses: Power Steering
---------------------
reservoir outlet --> vane pump inlet S: 16 mm >5/8" x 20" hose
metal pipe <-- vane pump outlet U: 10 mm >3/8" x 18" hose HP
metal pipe --> gear box inlet I: 10 mm >3/8" x 6" hose HP
metal pipe <-- gear box outlet I: 10 mm >3/8" x 9" hose
metal pipe --> reservoir inlet I: 10 mm >3/8" x 14" hose
5/8" ID hose LP : 2 ft - Gates 362200
3/8" ID hose LP : 2 ft - Gates 350010
10 mm ID hose HP : 18" - Grainger 55AC17
10 mm ID hose HP : 12" - Grainger 55AC16
10 mm ID hose HP : 6" - Grainger 55AC--
Hoses: Trans & Diff Breather
----------------------------
breather tube: 4.8 mm OD, 5.6 mm bump
breather hose: ?.? mm ID (3/16" = 4.76 mm)
## Mark Pipe ID OD Len Now From To Notes
-- ---- ---- -- -- --- --- ---- -- -----
FD0 ? 4.8? 4.5? 8.0? ??? ??? FD EB-PF ?
RD0 ? 4.8? 4.5? 8.0? ??? ??? RD CS ?
TM0 ? 4.8? 4.5? 8.0? ??? ??? TM EB-U ?
TM1 ? 4.8? 4.5? 8.0? ??? ??? EB-U EB-DF ?
TF0 ? 4.8? 4.5? 8.0? ??? ??? TF TM ?
Front Diff --> Engine bay, passenger fender
Rear Diff --> Cross support pipe above diff
Transmission --> Engine bay, union --> Engine bay, driver fender
Transfer --> Transmission union
Hoses: Vacuum
-------------
62 _______ 31 10 60 61
12 _______ \ | | | /
22 \ | | | | |
41 \ | | \______________________________________ 30
21 \______________________________________________________ 40
81 \___________________________________________________________ 20
\________________________________ __________________________ 50
23 ____ \ /
| | |
| | |
/ | |
11 / |
80 |
51
- connections below: 10-11-12 , 22-23 , 60-61-62
## Mark Pipe ID OD Len Now From To Notes
-- ---- ---- -- -- --- --- ---- -- -----
10 #*. 4.0 3.5 7.3 128 130 AirCh-R VP R
11 #26. 4.0 3.5 7.3 140 140 VP EVSV-B R
12 #*. 4.0 3.5 7.3 160 160 VP PVSV-P R
20 #13. 4.0 3.5 7.3 59 60 TB VP R
21 #*. 4.0 3.5 7.3 600 600 VP BVSV-P R
22 #1. 4.0 3.5 7.3 600 600 BVSV-D VP R
23 #*. 4.0 3.5 7.3 90 90 VP PP-D R
24 #*. 4.0 3.5 7.3 59 60 PP-P Can-R R
25 - 6.4 6.0 12.0 (555) 550 Can-F Tank O
26 - 8.0 8.0 12.0 (435) 450 Can-B Atmo O
30 - 6.4 6.0 9.0 78 80 TB VP O
31 - 6.4 6.0 9.0 142 145 VP IVSV-F O
40 #13. 4.0 3.5 7.3 59 60 TB VP R
41 #*. 4.0 3.5 7.3 420 420 VP Dist-B R
50 #13. 4.0 3.5 7.3 59 60 TB VP R
51 #1. 4.0 3.5 7.3 110 110 VP EVSV-T R
52 #26. 4.0 3.5 7.3 142 140 EVSV-M EMod-P R
53 #5. 4.0 3.5 7.3 120 120 EMod-D EVal-T R
54 - 6.4 6.0 9.0-12 (92) 105 EMod-B EVal-B R
60 #1. 4.0 3.5 7.3 110 110 ST-Filt VP R
61 #*. 4.0 3.5 7.3 280 280 VP FPR R
62 #*. 4.0 3.5 7.3 214 215 VP PVSV-D R
63 #*. 4.0 3.5 7.3 42 45 PVSV-M Filt-T R
64 #1. 4.0 3.5 7.3 110 110 Filt-B PSen R
70 - 6.4 6.0 9.0 140 140 ST IVSV-R O
80 #13. 4.0 3.5 7.3 59 60 ST VP R
81 #2. 4.0 3.5 7.3 390 390 VP Dist-T R
A0 - 8.5 8.0 11.5 (480) 500 AirCh-P ASC-F O
A1 #*. 4.0 3.5 7.3 420 420 AVSV-P ASC-T R
A2 #0. 4.0 3.5 7.3 390 390 AVSV-D ASC-B R
C0 - 8.0 8.0 11.5-14 (590) 500 TB Cool O
E0 - 6.4 6.0 9.0-12 (305) 310 TB Head-F N
E1 - 14.0 13.0 20-22 (335) 340 TB Head-R N
P0 - 7.0 6.0 9-11.5 (580) 580 AirCh-D PSP-F N
P1 - 6.4 6.0 9-11.5 (310) 270 ST PSP-R N
Total: 4.0 3.5 7.3 4716 mm (15.5 ft)
Total: 6.4 6.0 9.0-12 1625 mm (5.3 ft)
Total: 8.5 8.0 11.5 1000 mm (3.3 ft)
Total: 14.0 13.0 20-22 340 mm (1.1 ft)
Names:
------
A/C = Air Conditioner
ASC = A/C Speed Control
AVSV = A/C VSV
AirCh = Air Chamber, Filtered
Atmo = Atmosphere
BVSV = Bimetal VSV
Can = Canister, Charcoal
Cool = Coolant, Inlet
Dist = Distributor
EGR = Exhaust Gas Recirculation
EMod = EGR Modulator
EVal = EGR Valve
EVSV = EGR VSV
Filt = Filter
FPR = Fuel Pressure Regulator
Head = Head, Engine
ISC = Idle Speed Control
IVSV = ISC VSV
PP = Plastic Pipe
PSen = Pressure Sensor
PSP = Power Steering Pump
PVSV = Pressure VSV
ST = Surge Tank
Tank = Tank, Gas
TB = Throttle Body
VP = Vacuum Pipe
VSV = Vacuum Switching Valve
Key:
----
F = Front
R = Rear
D = Driver
P = Passenger
T = Top
I = Inner
B = Bottom
U = Upper
M = Middle
L = Lower
O = Original
R = Replaced
N = New
Hoses: Washer
-------------
Headlamps:
- reservoir --> Y fitting --> Driver / Passenger sprayers
Front Window:
- reservoir --> Y fitting --> Driver / Passenger sprayers
Rear Window:
- reservoir --> Rear sprayer
Hoses: Weep Holes
-----------------
Location Hole Tube_OD Hose Length Notes
-------- ---- ------- ---- ------ -----
water pump 4.0 mm 3.18 mm 1/8" 15 mm original iron
water pump 4.0 mm 3.18 mm 1/8" 15 mm replacement aluminum
water pump 5.0 mm 4.76 mm 3/16" 15 mm replacement iron
distributor 6.0 mm 4.76 mm 3/16" 20 mm remove metal cover
engine front 6.0x3.5 4.76 mm 3/16" 20 mm rectangle
engine rear L 8.0x11 6.35?mm 1/4?" 20 mm rectangular
engine rear R 8.0x7 6.35?mm 1/4?" 20 mm rectangular
transmission 5.0 mm 4.76 mm 3/16" 35 mm asymmetrical
Maintenance: Belts
------------------
Alternator + Water Pump belt:
- small: 30.5" / 31.25"
- ACDelco 4K305, Bando 4PK775 , Cont/GY 4040305, Dayco 5040305, Gates K040305
Air Conditioning + Power Steering belt:
- large: 49.0" / 49.75"
- ACDelco 5K490, Bando 5PK1245, Cont/GY 4050490, Dayco 5050490, Gates K050490
Timing belt:
- Goodyear GTK0182 kit w/ timing tensioner bearing
Maintenance: Fluids
-------------------
Engine oil: 3.5 l 3.7 qt SAE 10W30 or 10W40 API SG or SF
Transmission: 1.7 l 1.8 qt SAE 75W85 or 75W90 API GL-3 or GL-4, not GL-5
Transfer: 1.4 l 1.5 qt SAE 75W85 or 75W90 API GL-3 or GL-4, not GL-5
Front differential: 0.9 l 1.0 qt SAE 90 or 80W90 Hypoid API GL-5, not GL-4
Fear differential: 2.0 l 2.1 qt SAE 90 or 80W90 Hypoid API GL-5, not GL-4
Brake fluid: ?.? l ?.? qt DOT3 or SAE J1703
Power steering: ?.? l ?.? qt ATF (DEXRON-II), not "Power Steering Fluid"
Coolant: 6.5 l 6.9 qt Ethylene-glycol Antifreeze, Green, 50/50 mix
Misc: Links
-----------
https://en.wikipedia.org/wiki/Daihatsu_Rocky_(F300)
https://en.wikipedia.org/wiki/Daihatsu_Rocky_(A200)
https://en.wikipedia.org/wiki/Daihatsu_Rugger
https://en.wikipedia.org/wiki/Toyota_Blizzard#Blizzard_(LD20)
Misc: Parts
-----------
RockAuto:
- https://www.rockauto.com/en/catalog/daihatsu,1991,rocky,1.6l+l4,1068195
- new aftermarket parts
- all replacement parts: bearings, seals, brakes, steering, suspension, fuel
- lowest prices, but shipping costs can add up. a few days to a week delivery
AutoZone / Napa / O'Reilly:
- https://www.autozone.com/parts/daihatsu/rocky
- https://www.napaonline.com/en/auto-parts/daihatsu/rocky
- https://www.oreillyauto.com
- new aftermarket parts
- basic replacement parts: belts, brakes, clutch, fluids, filters, spark plugs
- local, often same day pickup, sometimes days. some parts much more expensive
Amayama:
- https://www.amayama.com/en/catalogs/toyota/blizzard
- https://www.amayama.com/en/catalogs/toyota/cami
- new original parts from Daihatsu & Toyota - Japan & international
MegaZip:
- https://www.megazip.net/zapchasti-dlya-avtomobilej/toyota/blizzard-38217
- https://www.megazip.net/zapchasti-dlya-avtomobilej/toyota/cami-38221
- new original parts from Toyota - Japan & international
EPC Data:
- https://toyota.epc-data.com/blizzard/ld20/113121
- https://toyota.epc-data.com/cami/j100e
- new original parts from Toyota - Japan & international
Amazon:
- https://www.amazon.com
- new parts: accessories, bearings, seals
eBay:
- https://www.ebay.com/b/Parts-for-Daihatsu-Rocky/6030/bn_24392422
- new parts - Indonesia & international
- used parts - USA & international
- accessories
Milner Off Road (UK):
- https://www.milneroffroad.com/vehicle/daihatsu/sportrak-feroza
- new aftermarket parts: rear leaf springs
4WheelParts:
- https://www.4wheelparts.com/parts-and-accessories/daihatsu-rocky/_/N-1sigc
- offroad parts & accessories
Pull-A-Part:
- https://www.pullapart.com/locations/tucson/
- used parts junkyard in Tucson, AZ - rare to find one
Daihatsu Rocky Parts Northwest:
- https://daihatsurockyparts.wixsite.com/drpn
- located in Washington state, USA
- used parts
Facebook:
- https://www.facebook.com/groups/185676521473095/
- WARFS4x4 - Worldwide Association of Rocky, Feroza, & Sportrak
- private, 1195 members, ~20 posts/month
- information, advice, parts, sell, buy
Google:
- https://www.google.com/search?q=daihatsu+rocky
- Daihatsu Rocky / Feroza / Sportrak
O-rings
-------
P8 fuel regulator
P10 oil level gauge
P20 speedometer cable
P30 distributor
P32 oil pump
111 speedometer cable (combination meter)
217 distributor (alternate)
P3 steering pump idleup
S12 steering pump inlet
014 steering pump piston
022 steering pump inside
033 steering pump inner
034 steering pump outer
034 steering pump rear
125 steering pump reservoir
033 steering shaft
Starting
--------
Starter motor:
- bolt: 14 mm hex / M10-1.25 x 50 (32) "6" + LW - upper [T:44 ft-lb]
- bolt: 14 mm hex / M10-1.25 x 80 (40) "=" + LW - lower [T:44 ft-lb]
- nut: 12 mm hex / M8-1.25 x 8 flanged ?
- weight: 4.020 kg
Starter relay:
- coil resistance: 40 - 100 ohms
Clutch switch:
- nut: 12 mm hex / M8-1.25 x 8 flanged ? [T:18 ft-lb]
Steering
--------
Steering wheel:
- size: ?? mm OD x ??.? mm CS
- bolt: ?? mm hex / M__-1.__ x __ "?" [T:29 ft-lb]
Steering column:
- rubber boots: upper, lower
- bolt: 12 mm hex / M8-1.25 x ?? "10" + LW [T:22 ft-lb]
- shaft: 18.? mm diameter, ?? spline
- mark universal joint & steering gear housing shaft before removing
Steering gear housing:
- mark lock ring & cap to housing before removing
- lock ring: screwed to cap
- cap: use drill bits in holes to turn
* oil seal, shaft: 19 x 32 x 7 mm NOK AP8096E / SKF 7007 / Toyota 90311-24001 ?
- old one stretched (18.0 mm very tight)
- shaft: 50.86 mm OD
- o-ring: 50.5 x 53.6 x 1.80 mm old - 0.7% str, 16% comp, 91% fill - flat
* o-ring: 50.5 x 54.1 x 1.78 mm AS -033 * 0.7% str, 15% comp, 89% fill - good
- o-ring: 49.5 x 53.5 x 2.00 mm JIS S50 x 2.7% str, 29% comp,113% fill - big
- bearing: 11 balls
- rear bolt: 14 mm hex / M10-1.25 x ?? "|||" + LW (x4)
- top bolt: 14 mm hex / M10-1.25 x ?? "|||" + LW (x4)
- top nut: 17 mm hex / M12-1.25 x 12 - doesn't remove. for non-power steering
- mount bolt: 17 mm hex / M12-1.25 x ?? "7" + LW (x3) [T:65 ft-lb]
- mount nut: 17 mm hex / M12-1.25 x ?? [T:65 ft-lb]
Steering linkage:
* steering link joint dust seal
- tie rod end, LH
- tie rod adjusting tube
- tie rod adjusting tube lock nut (x2) [T:105 ft-lb]
- tie rod, LH
- pitman arm
- relay rod
- idler arm
- tie rod, RH
- tie rod adjusting tube lock nut (x2) [T:105 ft-lb]
- tie rod adjusting tube
- tie rod end, RH
* steering link joint dust seal
Power Steering Vane Pump front stay:
- bolt: 14 mm hex / M10-1.25 x 75 (17) "9" flanged - pivot [T:44 ft-lb]
- bolt: 14 mm hex / M10-1.25 x 30 "6" flanged - groove [T:29 ft-lb]
- bolt: 12 mm hex / M8-1.25 x 120 (120) "10" tapered - adjustment [T:14 ft-lb]
- nut: 12 mm hex / M8-1.25 - adj lock nut
- bolt: 10 mm hex / M6-1.00 x 16 " " + LW (x2) - tube clamp [T:4 ft-lb]
- bolt: 12 mm hex / M8-1.25 x 20 "4" + LW + W (x2) - tube support [T:10 ft-lb]
- bolt cover, plastic
- bolt: 14 mm hex / M10-1.25 x 20 "7." + LW (x2) - vane pump [T:31 ft-lb]
Power Steering Vane Pump bracket:
- bolt: 14 mm hex / M10-1.25 x 25 "6" + LW - front [T:29 ft-lb]
- bolt: 12 mm hex / M8-1.25 x 40 (32) "4" + LW - intake manifold [T:10 ft-lb]
Power Steering Vane Pump:
- weight: ?.? kg
- pulley: 5 groove, 101.90 OD x 14.00 ID x 23.25 W
- nut: 17 mm hex / M12-1.25 x 10 flanged [T:32 ft-lb]
- key: 5.0 x 6.4 x 15.2 mm curved
* oil seal, shaft: 18 x 32 x 8 mm TTO C2181 4 TBR 18 32 8
* oil seal, shaft: 18 x 32 x 7 mm NOK BP2175E
* oil seal, shaft: 18 x 32 x 7 mm Timken 710156 - nitrile (34 mm ?)
* oil seal, shaft: 18 x 32 x 7 mm Timken 18X32X7-R2LS32-S - nitrile
* oil seal, shaft: 18 x 32 x 7 mm EAI Viton TC18*32*7
* oil seal, shaft: 18 x 32 x 8 mm Honda 91251-045-005
- banjo bolt: 22 mm hex / M16-1.50 x 26 (12) [T:36 ft-lb]
* washer, copper: 16.4 x 23.0 x 1.0 mm (0.65" x 0.91" x 0.04") (x2)
- bolt: 10 mm hex / M6-1.00 x 10 "=" + LW - top hose bracket, rear
- bolt: 12 mm hex / M8-1.25 x 12 "=" + LW - top hose bracket, front
- inlet: 12.0 x 14.5 G 2.20 mm
- o-ring: 10.8 x 14.4 x 1.78 mm AS -013 x 11% str, 42% comp, 90% fill - str
* o-ring: 11.5 x 14.5 x 1.50 mm JIS S12 * 4.3% str, 20% comp, 64% fill - good
* snap ring: 18 x 1.0 mm
- piston: 13.7 x 17.0 G 2.60 mm
* o-ring: 12.4 x 16.0 x 1.78 mm AS -014 * 10% str, 7% comp, 58% fill - str
* o-ring: 12.9 x 16.7 x 1.90 mm ~AS -014+* 6.2% str, 13% comp, 66% fill - kit
- o-ring: 13.5 x 16.5 x 1.50 mm JIS S14 x 1.5% str,-10% comp, 45% fill - small
- spring: 13.6 x 16.0 x 1.20 mm x 38.5 mm
- idleup valve: 17 mm hex / M14-1.50 x 16 + teflon seal tape [T:27 ft-lb]
- front port (with bump) hose to air chamber
- rear port (without bump) hose to surge tank - in case fluid leaks past valve
- when removed from pump, blow 20 PSI air into rear port to eject piston
- idleup piston: [outer] c-ring black white [middle] black white [inner]
- idleup: 2.8 x 6.1 W 2.20 mm (x2)
- o-ring: 2.6 x 6.2 x 1.78 mm AS -005 x 7.7% str, 8% comp, 69% fill - small
* o-ring: 2.8 x 6.6 x 1.90 mm JIS P3 * 0.0% str, 15% comp, 78% fill - loose
* c-ring: 57.0 x 63.0 x 3.00 mm
- body: 58.1 mm ID
- rear: 55.0 x 58.0 G 1.90 mm
* o-ring: 53.7 x 57.3 x 1.78 mm AS -034 * 2.4% str, 16% comp, 87% fill - good
- o-ring: 54.5 x 58.5 x 2.00 mm JIS S55 x 0.9% str, 29% comp,110% fill - big
- washer: 29.8 x 36.0 x 1.00 mm
- outer: 55.0 x 58.0 G 1.90 mm
* o-ring: 53.7 x 57.3 x 1.78 mm AS -034 * 2.4% str, 16% comp, 87% fill - good
- o-ring: 54.5 x 58.5 x 2.00 mm JIS S55 x 0.9% str, 29% comp,110% fill - big
- oval: 55.0 mm OD
- plate: 15.0 x 8.2 x 1.80 mm (x10) - rounded side of plates must face outward
- rotor: 39.0 mm OD, 14-spline
- shaft: 18.0 mm OD, 14-spline
* c-ring: 10.5 x 12.5 x 1.00 mm
- inner: 53.5 x 56.5 G 1.90 mm
* o-ring: 50.5 x 54.1 x 1.78 mm AS -033 * 5.9% str, 16% comp, 87% fill - good
- o-ring: 52.5 x 56.5 x 2.00 mm JIS S53 x 1.9% str, 33% comp,110% fill - big
- inside: 26.5 x 29.5 G 1.90 mm
* o-ring: 25.1 x 28.7 x 1.78 mm AS -022 * 5.6% str, 16% comp, 87% fill - good
- o-ring: 25.5 x 29.5 x 2.00 mm JIS S26 x 3.9% str, 33% comp,110% fill - big
- pin: 28.0 x 4.0 mm - loose
- pin: 37.8 x 4.1 mm - fixed
Power Steering Vane Pump seal kits:
- Toyota 04446-06040 Toyota 4Runner '95-'09 V6
- Kotek SK-8244 = 350660 Toyota 4Runner '89-'91 V6 - used 5/2013
- Kotek SK-8386 Toyota 4Runner '92-'95 V6
- Kotek SK-8389 = 349030 Toyota 4Runner '89-'95 L4
- Edelmann 8641 = 350660 Toyota 4Runner '89-'91 V6
- Edelmann 8760 = 349030 Toyota 4Runner '84-'95 L4
- Gates 350660: Toyota 4Runner '89-'91 V6
* oil seal, shaft: 18 x 32 x 8 mm TTO C2181
* o-ring: 11.5 x 14.5 x 1.50 mm JIS S12 - inlet
* o-ring: 12.9 x 16.7 x 1.90 mm ~AS -014+ - piston
- o-ring: 19.5 x 22.5 x 1.50 mm JIS S20
- o-ring: 53.7 x 57.3 x 1.78 mm AS -034
* o-ring: 53.7 x 57.3 x 1.78 mm AS -034 - rear
* o-ring: 53.7 x 57.3 x 1.78 mm AS -034 - outer
- snap ring: 18.5 x 1.0 mm
Power Steering o-rings:
* o-rings: AS568 -014 -022 -033 -033 -034 -034 -125
* o-rings: JIS P3 P3 S12
Power Steering oil reservoir:
- groove: 33.5 x 38.0 x 3.20 mm
* o-ring: 33.0 x 38.2 x 2.60 mm AS -125 * 1.5% str, 16% comp, 74% fill - good
- o-ring: 33.0 x 39.0 x 3.00 mm 3.00x33 x 1.5% str, 33% comp, 98% fill - big
- bolt: 10 mm hex / M6-1.00 x 14 " " + LW + W - tightening
- bolt: 12 mm hex / M8-1.25 x 16 " " + LW (x2) - reservoir
- bolt: 12 mm hex / M8-1.25 x 16 " " + LW (x2) - bracket
Power Steering pressure feed tubes:
- flare nut: ?? mm hex / JIC Size ? - custom added for high pressure pipes
- flare nut: 17 mm hex / M16-1.50 x 14 / 10.0 mm OD pipe (x2) [T:33 ft-lb]
- bolt: 12 mm hex / M8-1.25 x 16 "4" (x1) - gearbox
- bolt: 12 mm hex / M8-1.25 x 20 "=" (x3) - frame
- clamp: for 10 mm hard pipe
- bracket screw: 10 mm hex + phil / M6-screw x 12 (x4)
- bracket: steel (x4)
- bushing, plastic (x8)
Transfer
--------
Transfer breather tube: 4.8 mm OD, 5.6 mm bump
Transfer breather hose: 4.? mm ID (3/16" = 4.76 mm) - to transmission breather
Fill / Drain bolts:
- same as Front & Rear Differential
- same as Transmission
- fill bolt: 24 mm (~15/16") hex / M16-1.50 x 10 [T:29 ft-lb]
- drain bolt: 24 mm (~15/16") hex / M16-1.50 x 10 [T:29 ft-lb]
* washer, aluminum: 16.5 x 26.1 x 1.0 mm (0.65" x 1.03" x 0.04")
* washer, copper: 16.4 x 21.8 x 1.3 mm (0.65" x 0.86" x 0.05")
* washer, fiber: 16.5 x 26.7 x 1.9 mm (0.65" x 1.05" x 0.07")
* oil seal, front: 32 x 48 x 8 mm Daihatsu 90043-11160 = NOK AH1894F
* oil seal, front: 32 x 48 x 8 mm Timken 32X48X8-R2LS32-S - nitrile
* oil seal, rear: 36 x 50 x 7 mm Daihatsu 90043-11240 = Koyo MHSA 36 50 7
* oil seal, rear: 36 x 50 x 7 mm Timken 36X50X7-R2LS32-S - nitrile
Transmission
------------
Transmission breather tube: 4.8 mm OD, 5.6 mm bump
Transmission breather hose: 4.? mm ID (3/16" = 4.76 mm)
Fill / Drain bolts:
- fill bolt: 24 mm (~15/16") hex / M16-1.50 x 10 [T:29 ft-lb]
- drain bolt: 24 mm (~15/16") hex / M16-1.50 x 10 [T:29 ft-lb]
- same as Front & Rear Differential
- same as Transfer
- weight: ?.? kg (w/ transfer)
Speedometer cable:
- bolt: 10 mm hex / M6-1.00 x 12 "6" + LW + plate [T:6 ft-lb]
* washer, rubber: 8.0 x 20 x 1.65 mm (0.31" x 0.75" x 0.06")
* oil seal, shaft: 8 x 14 x 6 mm NOK AG0123F 17.8 -> 8X14X4SC / 8X14X4TC
- groove: 20.0 x 24.0 x 3.20 mm
* o-ring: 19.8 x 24.6 x 2.40 mm JIS P20 * 1.0% str, 20% comp, 71% fill
Instrument cluster, rear:
* o-ring: 10.8 x 16.0 x 2.62 mm AS -111 * 0.0% str, ?% comp, ?% fill
Transmission shift lever:
- transmission knob (1 2 3 4 5 R): 48 mm knob / M12-1.25 x 20
- bolt: 10 mm hex / M6-1.00 x 18 "4" + W (x6)
* snap-ring: ~43 mm inner
* lithium base multi purpose grease
Transfer shift lever:
- transfer knob (2H 4H 4L): 40 mm knob / M10-1.25 x 20
- bolt: 14 mm hex / M8-1.25 x 26 (14) "7" + W (x4) [T:14 ft-lb]
- shank: 10 mm dia x 12 mm long
* snap-ring: ~43 mm inner ?
* lithium base multi purpose grease
* thread sealant: TB 1324
* gasket: rubber
Transmission / Engine:
- bolt: 17 mm hex / M12-1.25 x 60 (32) "=" + LW (x6) - large [T:44 ft-lb]
- bolt: 12 mm hex / M8-1.25 x 35 "6" + LW (x1) - small, bottom [T:14 ft-lb]
- bolt: 10 mm hex / M6-1.00 x 14 "4" + LW + W - wire harness bracket
Transmission mount:
- bolt: 12 mm hex / M8-1.25 x 25 "=" + LW + W (x2) ~[T:14 ft-lb]
- nut: 17 mm hex / M10-1.25 x 8 + LW (x2) [T:51 ft-lb]
- washer: 10.5 x 30.0 x 3.3 (x2)
Transmission crossmember No. 2:
- bolt: 14 mm hex / M10-1.25 x 25 "7" + LW + W (x8) [T:35 ft-lb]
Transmission undercover: (missing)
- bolt: 12 mm hex / M8-1.25 x ?? "?" + LW + W (x8) [T:36 ft-lb]
Transmission exhaust mount:
- bolt: 12 mm hex / M8-1.25 x 20 "6" + LW (x2) - transmission [T:14 ft-lb]
- bolt: 14 mm hex / M10-1.25 x ?? "?" + LW (x1) - exhaust pipe [T:30 ft-lb]
Backup lamp switch:
- switch: 22 mm hex / M??-1.?? x ?? [T:29 ft-lb]
- washer, aluminum: ??.? x 26.0 x ?.?
Transmission position detect switch:
- switch: 22 mm hex / M??-1.?? x ?? [T:29 ft-lb]
- washer, aluminum: ??.? x 26.0 x ?.?
Transmission front bearing retainer:
- bolt: 12 mm hex / M8-1.25 x ?? "6" + LW (x7) [T:14 ft-lb]
- gasket: fiber
Transmission case:
Transmission case cover:
- bolt: 12 mm hex / M8-1.25 x ?? "=" + LW (x6) [T:14 ft-lb]
- bolt: 10 mm hex / M6-1.00 x ?? "6" + LW (x3) [T:6 ft-lb]
* sealant: TB 1216
Transfer adapter:
- bolt: 12 mm hex / M8-1.25 x ?? "?" + LW (x6) - internal ? [T:27 ft-lb]
* sealant: TB 1216
* thread sealant: TB 1324
Transfer front case:
- bolt: 14 mm hex / M10-1.25 x 40? "6" + LW (x7) [T:27 ft-lb]
- bolt: 14 mm hex / M10-1.25 x 45? "6" + LW (x1) - bracket/clamp [T:27 ft-lb]
- thread sealant: TB 1324
* gasket: TB 1216
Transfer rear case:
- bolt: 14 mm hex / M10-1.25 x 65? "6" + LW (x8) [T:27 ft-lb]
- bolt: 14 mm hex / M10-1.25 x 80? "6" flanged (x3) - bracket [T:27 ft-lb]
- bracket: iron - transmission shifter
- bolt: 12 mm hex / M8-1.25 x ?? "=" + LW (x4) - shifter [T:14 ft-lb]
* gasket: fiber
Transfer output bearing retainer:
- bolt: 12 mm hex / M8-1.25 x ?? "6" + LW (x8) - alternately [T:14 ft-lb]
* gasket: fiber
* oil seal, cover: 16 x 24 x 6 mm Timken 16X24X6-R2LS32-S - nitrile
* oil seal, front: ?? x ?? x ? mm ?
* oil seal, inner: ?? x ?? x ? mm ?
3 - needle roller bearing: ?? x ?? x ?? mm ?
6 - radial ball bearing: ?? x ?? x ?? mm ?
9 - drive gear bearing: ?? x ?? x ?? mm ?
10 - needle roller bearing: ?? x ?? x ?? mm ?
19 - radial ball bearing: ?? x ?? x ?? mm ?
25 - radial ball bearing: ?? x ?? x ?? mm ?
30 - radial ball bearing: ?? x ?? x ?? mm ?
48 - radial ball bearing: ?? x ?? x ?? mm ?
50 - radial ball bearing: ?? x ?? x ?? mm ?
65 - radial ball bearing: ?? x ?? x ?? mm ?
Installation procedure:
- jack up passenger side of vehicle as high as possible using low point on frame
- place transmission on upside-down carpet & slide under vehicle - keep on cart?
- jack down vehicle slowly, watching transmission clearance
- lift up transmission front (bell housing) a few inches on to wood block
- lift up transmission rear (transfer side) a few inches on to wood block
- repeat with more blocks until transmission is high enough to get jack under
- place jack in front of transmission mount
- turn jack to line up with vehicle length, if possible
- jack up transmission to height of clutch
- push jack & transmission forward into clutch
- rotate transmission back & forth to line up shaft splines & alignment pins
- rotate input shaft if necessary
- push transmission fully into engine
- install transmission / engine bolts
- install transmission mount on bottom of transmission
- install cross member, transmission mount nuts
Tests: Engine Compression
-------------------------
Manual:
- EM-18~20
Tools:
- compression tester
- spark plug socket
- various sockets and wrenches
Preparation:
- warm up engine
- turn engine off
- transmission in neutral or park
- parking brake on
Removal:
- remove fuel injector relay or fuse
- remove fuel pump relay or fuse
- remove intake air chamber
- disconnect distributor wire connector from ignition coil
- disconnect all spark plug wires from spark plugs
- remove all spark plugs. label or keep in order
Test:
- insert compression gauge in first spark plug hole
- press accelerator pedal down. throttle fully open
- crank engine 6-8 times. do the same for all cylinders
- record maximum psi reading for cylinder
- reset gauge
- repeat for other cylinders
Results:
- compression: min:100 psi (Rocky:150 psi) typ:140-160 psi (Rocky:200 psi)
- variation: < 10% (Rocky:21 psi)
Diagnose:
- low compression in 1 cylinder: bad exhaust valve
- low compression in 2 adjacent cylinders: bad head gasket
- low compression in all cylinders: piston rings or cylinders are worn
- pour 1/2 teaspoon 10W-30 engine oil into spark plug holes and retest
- if pressure increases: piston rings or cylinders are worn
- if pressure stays the same: valve leakage
Installation:
- install all spark plugs. keep original order. torque to 11-16 ft-lb
- connect all spark plug wires to spark plugs
- connect distributor wire connector to ignition coil
- install intake air chamber
- install fuel pump relay or fuse
- install fuel injector relay or fuse
Tests: Engine Sensors
---------------------
- Fuel sender gauge: float resistance (BE-15)
- F: 6? 1/2: 32.5? E: 97? ohms --> ok?
- Fuel safety valve: air resistance (EC-6,7)
- side A: blow light, air resistance? blow strong, no air resistance? --> ok?
- side B: suck light, air resistance? suck strong, no air resistance? --> ok?
x Charcoal canister: test air flow, purge with compressed air (EC-7)
- tank: 1-3 psi fast decay slow flow. purge: 10 psi slow decay no flow --> ok
- purge: 43 psi (3 tanks emptied, ~3 minutes total). purge pipe closed --> ok
x EGR valve: test function (EC-11)
- blow into pipe with hole plugged: no air. vac 6 inHg: air --> ok
x EGR modulator: test function (EC-12)
- plug port P. blow into port Q: air. pres 2.8 psi: blow: no air --> ok
x BVSV (vacuum hoses): air continuity in hot water (EC-8)
- temp open: 45 to 66 C. temp < 45 C: no air. temp > 66 C: air --> ok
- A/C water temperature switch (black): continuity in hot water (AC-48)
- on --> off: 110 C?. off --> on: 103 C? --> ok?
x Water temperature sensor (green): resistance in hot water (EF-60,62)
- -20 0 20 40 60 80 90 C: 16200 5880 2450 1140 584 322 200. no cont --> ok
x Water temperature sender gauge (spade): resistance in hot water (BE-16)
- 0 20 40 50 60 80 100 115 C: ??? ??? ??? 232 ??? ???? ????? 26800 --> ok
x Thermostat: valve open lift in hot water (CO-8,9)
- closed at 20 C. valve opening 76-80 C. valve lift 8.5 mm at 91 C --> ok
x Radiator cap: relief valve pressure test (CO-10)
- opens at 8.5 to 14.9 psi. no seal damage --> ok
- Radiator: pressure test cooling system (CO-11)
- pressure test 17 psi air: holds > 16 psi after 60 sec? no bubbles? --> ok?
x Throttle body: check pipes, idle adjust screw (EF-119,124)
- screw: 4.5 turns CCW from bottom (9.3 mm deep)
- head: 12.6 mm deep at bottom (full CW), 5.2 mm deep at 10 turns CCW
x Throttle position sensor: resistances closed, open (EF-65,66)
- 12-29 TV closed: 0.0 ohms TV fully open: inf ohms --> ok
- 32-29 TV closed: inf ohms TV fully open: ~30 to 200 ohms varies --> ok
- Throttle positioner: engine rpm, check dashpot (EC-9, EF-121)
- dashpot contact: 1600 rpm? full contact. comes out --> ok?
x Intake air temperature sensor: resistance in hot water (EF-63,64)
- -20 0 20 40 60 80 90 C: 16200 5880 2450 1140 584 322 200. no cont --> ok
x Intake gas filter: test air flow (EM-66)
- air flows both directions --> ok
x ISC VSV: coil resistance, test function (EF-70,71)
- coil: 4 M - 36 ohms --> ok? 0V: no air 12V: air --> ok
x EGR VSV: coil resistance, test function (EF-76,77)
- coil: 78 - 45 ohms --> ok? 0V: no, no, no, air 12V: air, no, no, no --> ok
x A/C VSV: coil resistance, test function (AC-52,53)
- coil: 43 ohms --> ok 0V: air filter 12V: air --> ok
x Pressure VSV: coil resistance, test function (EF-79,80,81)
- coil: 43 ohms --> ok 0V: no air, air 12V: air, no air --> ok
- Pressure sensor: voltage output (EF-67,68)
- altitude: 2400 ft. voltage 6-39: 3.? V --> ok?
x Oil pressure switch: test continuity (BE-23,24)
- 32 k ohms, cleaned, 0.5 ohms --> ok
- Oxygen sensor: voltage changes (EF-82,83)
- depress accelerator: 0.45 V or more? changes >= 8 times in 10 secs? --> ok?
x Spark plug wires: wire resistances (IG-5)
- 1: 1.029k 2: 0.900k 3: 2.087k 4: 1.645k IG: 0.640k --> ok (old)
- 1: 1.872k 2: 1.549k 3: 1.205k 4: 0.902k IG: 1.637k --> ok (new)
- Spark plugs: check/set gap (IG-6,7)
- 1: 1.0? 2: 1.0? 3: 1.0? 4: 1.0? mm --> ok?
x Ignition coil: coil resistances (IG-8)
- primary: 1.76 - 0.16 = 1.60 ohms. secondary: 26.340k. insul = inf --> ok
x Distributor: vacuum advancer (IG-10, IG-17)
- 8 inHg vacuum operates. governor returns rapidly. air gap: 0.3 mm --> ok
- vacuum main: rod drawn in. vacuum sub: rod drawn in --> ok
- rotor: contact ok
- distributor cap: all contacts ok