Sunday, 15 September 2013

1991-1994 S-Chassis FSM Specs

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Original document HERE

Note: these are in Imperial Units 

AIR CONDITIONING:
-belt deflection mm(inches)
......max limit 12 (0.47)
......adjustment of belt in service 7.5-8.5 (0.295-0.335)
......new belt 6.5-7.5 ( 0.256-0.295)
......refrigerant 1.8 - 2.0 lb of R12

ALIGNMENT:
-Front wheel alignment (unladen)(ie fuel, radiator and engine oil full with
spare tire, jack, and tools.)
.....camber -1 degree 30' to 0 degree
.....caster 6 degree 00' to 7 degree 30'
.....toe in mm (in) 0.3 - 2.3 (0.012 - 0.091)
.....toe in degree 2' - 13' ( total toe in angle)
.....full turns inner wheel 39 degree - 43 degree
.....full turns outer wheel 33 degree

-Rear wheel alignment (unladen) as above
.....camber -1 degree 30' to -0 degree 36'
.....toe in mm (in) 0.5- 4.5 (0.020- 0.177)
.....toe in degree 3' - 25' (total toe in angle)

ALTERNATOR:
-belt deflection with engine cold mm(inches)
.....max limit 11 (0.43)
.....adjusting used belt 7-8 (0.28-0.31)
.....new belt 6-7 ( 0.24-0.28)

BELT ADJUSTMENT(DEFLECTION): see alternator, power steering, air conditioning

BRAKES:

CL22VB (non-abs)
-pad repair limit mm (in) 2.0 ( 0.079)
-minimum front rotor thickness limit 18.0 (0.709) mm (in)
-minimum rear rotor thickness limit 8.0 (0.315) mm (in)

CL25VA (abs)
-pad repair limit mm (in) 2.0 ( 0.079)
-minimum front rotor thickness limit 20.0 (0.709) mm (in)
-minimum rear rotor thickness limit 8.0 (0.315) mm (in)

-pedal free height M/T 177- 187 (6.97 - 7.36) mm (in)
-pedal free height A/T 186- 196 (7.32 - 7.72) mm (in)
-parking brake # of notches 6-8 (under force of 196N, 20kg, 44lb)

CLUTCH PEDAL:
- height mm (in) 186-196 ( 7.32- 7.72)
- pedal free play mm (in) 1.0-3.0 ( 0.039- 0.118)

COOLANT
(with reservoir tank) 7-1/8 quarts

COOLANT TEMPERATURE SENSOR:

Temperature(F).........................Resistance(kOhms)
68 F...................................................2.1-2.9
122 F.................................................0.68-1.0
176 F.................................................0.30-0.33

DIFFERENTIAL CARRIER:
-(R200) 2-3/4 pints
-(R200V) 3-1/8 pints
EGR TEMPERATURE SENSOR: 85.3 +- 8.53 k ohms @ 212 F
ENGINE OIL: 3-3/4 quarts(without filter); 4 quarts(with filter)


ENGINE COMPRESSION:
-standard 179 psi @ 300rpm
-minimum 151 psi @ 300 rpm
-difference limit between cylinders 14 psi @ 300rpm

ENGINE TUNE UP DATA:
-Engine model KA24DE
-Firing Order 1-3-4-2
-Idle speed (in "N" position, No-Load) 700 +/- 50 rpm
-Idle speed (In "N" position, Air Conditioning ON) 1000 +/- rpm
-Ignition timing 20 degrees = +/- 2 degrees B.T.D.C. at idle speed
FUEL PRESSURE at idling
-34 psi
-43 psi(vacuum hose to fuel pressure regulator disconnected)
FUEL PUMP: 0.5 omns

FUEL TANK: 15-7/8 gallons
IACV-AAC VALVE: 10 ohms
IGNITION COIL
-primary resistance(68F)..........................1.0 ohms
-secondary reistance(68F)......................10.0 k ohms
-primary voltage......................................battery voltage(11-14)
IGNITION WIRE: less than 30 k ohms(high tension cable resistance)
INJECTOR: approx 11 ohms

MASS AIR FLOW SENSOR(Engine warm and idling under no load)
-supply voltage.............battery voltage(11-14)
-output voltage............0.8-1.2

OIL PAN DRAIN PLUG tightening torque: ( 29-39 N-m; 3.0-4.0 kg-m; 22-29 ft-lb)

OIL PRESSURE:
-Idle Speed More than 11 PSI
-At 3000 rpm no load 60-70 PSI

POWER STEERING SYSTEM: 1.0 quart

automatic transmission fluid Dexron ll recommended

POWER STEERING PUMP BELT DEFLECTION (without SUPER HICAS):
-max limit 13mm (0.51 inches)
-deflection of used belt 7.5-8.5 ( 0.295- 0.335)
-deflection of new belt 6.5-7.5 (0.256- 0.295)
-Applied pressed force N (kg, lb) 98 (10, 22)

POWER STEERING PUMP BELT DEFLECTION(with SUPER HICAS):
-limit 9 (0.35)
-deflection after adjustment 6.5-7.5 ( 0.256- 0.295)
-deflection of new belt 5.5-6.5 (0.217- 0.256)
-Applied pressed force N (kg, lb) 98 (10, 22)

RADIATOR:
-relief pressure 11-14 psi
-leakage test pressure 23 psi
RESISTOR: approx 2.2 k ohms
SPARK PLUG:
- type-standard BKR5E-11
-cold BKR6E-11
-cold BKR7E-11
-gap mm (in) 1.0-1.1 (0.039-0.043)
-tightening torque(20-29 N-m; 2.0 - 3.0 kg-m ; 14-22 ft-lb)

THEROMSTAT
-valve opening temperature 170 degree fahrenheit
-maximum valve lift 0.31 inches @ 194 degree fahrenheit
THROTTLE POSITION SENSOR

Accelerator pedal conditions...............Resistance(k ohms)
completely released....................................approx 2
partially released........................................2-10
completely depressed................................approx 10


TRANSMISSION FLUID
-manual transmission (M/T) 5-1/8 pints
-automatic transmission (A/T) 8-3/4 quarts
VACUUM; 20 in-Hg @ idle.


Wheel Lug nut torque -Wheel Lug Nut 72-87

Tensioner locations for belt removal