Chassis & Body

Clutch
Manual Transmission
Automatic Transmission
Propeller Shaft
Differential
Suspension & Axle
Brake
Steering
Body
Service Points

Chassis & Body

Clutch
Hydraulic operated clutch is used for 1.5 G &
S M/T

Item

Specification
Type

Dry single-plate diaphragm

spring type

Drive system

Hydraulic

Pressure plate size (mm)

200 x 140

Indication (Color)

Pink

Outside diameter x Inside diameter

x Thickness (mm)

200 x 140 x 3.2

Identification (Color)

Pink

Clutch master
cylinder

Type

Conventional

Clutch release
cylinder

Type

Non-adjustable

Clutch

Clutch cover

Clutch disc

Chassis & Body

Clutch Orifice
To avoid impact input torque to the drive train when a sudden
start. This can minimize the size of the drive train units.

Chassis & Body

Clutch Orifice
Shape memory alloys springs are incorporated for the purpose
of preventing delayed clutch disengagement at cold temperature
(below 5 degrees C) due to high viscosity of clutch fluid.

Shape memory alloys spring

Valve lift 1.5mm
Orifice

Release cylinder

Master cylinder

Clutch pedal
Bias spring

Chassis & Body

Clutch Orifice
Normal condition

Bias spring stays on the right side.

Chassis & Body

Clutch Orifice
Normal condition, depressing clutch pedal

Bias spring moves to the left side.

Clutch disengages quickly.

Chassis & Body

Clutch Orifice
Normal condition, releasing clutch pedal

Bias spring returns to the right

side.
Clutch engages gradually.

Chassis & Body

Clutch Orifice
Cold temperature (below 5 degree)

Bias spring stays on the left side.

Chassis & Body

Clutch Orifice
Cold temperature, depressing clutch pedal

Bias spring stays on the left side.

Clutch disengages quickly.

Chassis & Body

Clutch Orifice
Cold temperature, releasing clutch pedal

Bias spring stays on the left side.

Clutch engages quickly.

10

Chassis & Body

M5S-CD Manual Transmission
5 Speed Manual Transmission for 1.5 G & S M/T
M5S-CD
Number of speeds
Reduction gear
ratio

Transmission oil

Shift pattern

5
1st

3.769

2nd

2.045

3rd

1.376

4th

1.000

5th

0.838

Reverse

4.128

Capacity

1.2L

Grade

API GL-4

Viscosity

75W-90
H pattern

Basically same as M5S-C9 (for Avanza)

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Chassis & Body

M5S-CD Manual Transmission
Hall IC Type speedometer sensor is used

Square wave form (4 pulses/rev)

Speedometer
sensor

Meter ECU

EFI ECU

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Chassis & Body

A4Q Automatic Transmission
4 Speed Automatic Transmission for 1.5 S A/T

Transmission type

A4Q

Number of speed

Reduction
ratio

1st

2.731

2nd

1.526

3rd

1.000

4th

0.696

Reverse

2.290

Automatic
Transmission Fluid
Oil capacity
Shift pattern

Dexron III
4.6L
1.5L (Drain and refill)

Gate pattern

P/#: 35010-B0020
* Same unit as AVANZA

13

Chassis & Body

Control System
Shift to low-speed gear inhibit control during high-speed driving
Reverse inhibit control
Gear change control at low temperatures

-10 or below

Shifting to 3rd gear prohibited

10 or below

Shifting to 4th gear prohibited

Shifting

Vehicle speed
(km/h)

4th

3rd

123 ~ 138

3rd

2nd

74 ~ 89

2nd

1st

36 ~ 51

Torque Reduction Control

Electrical Control of Line Pressure
Clutch-to-Clutch Transmission Control
Lock-up Timing Control
Uphill and downhill gear shift control
Diagnosis function

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Chassis & Body

Service Points
Fluid Level Check
(1). Park the car on a level surface and set the parking brake.
(2). With the engine idling and the brake pedal depressed, move the lever into
all positions from P to L, and return to P position.
(3). Take out the level gauge out and wipe it clean.
(4). Put it back all the way.
(5). Take it out again and check that the fluid level is within the HOT range.
Notice:
Drive the vehicle so that the engine and transaxle are at normal operating
temperature (70-90 degrees C).

15

Chassis & Body

Service Points
Check & Clear DTC (Using IT-II)
1. Check DTCs
(1). Connect IT-II to the DLC3.
(2). Turn the ignition switch to ON.
(3). Select ECT / DTC / Current (or Pending).
(4). Check DTCs and Freeze Frame Data.
2. Clear DTCs
(1). Connect IT-II to the DLC3.
(2). Turn the ignition switch to ON.
(3). Select ECT / DTC / Current (or Pending).
(4). Clear DTCs and Freeze Frame Data.

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Chassis & Body

Service Points
Check & Clear DTC (Not Using IT-II)
1. Check DTCs
(1). Short terminals 13 (ECUT) and 4 (E) of the DLC3.
(2). Turn the ignition switch to ON.
(3). Read the DTC indicated by the number of times D position lamp blinks.
2. Clear DTCs
(1). Disconnect the battery terminal or remove ECU-B fuse from the engine
room R/B for 60 seconds or more.

E (4)

(2). Short terminal 13 (ECUT) and 4 (E) of the DLC.

(3). Check that the normal code is output.
Notice:
If the system is operating normally, the
light will blink 2times per second.

ECUT
(13)17

Chassis & Body

Service Points
A/T Initialization (Using IT-II), is clearing A/T learned value
after replacing A/T assembly or valve body
(1). Shift into P position.
(2). Connect IT-II to the DLC3.
(3). Turn the ignition switch ON and IT-II ON.
(4). Select ECT- Utility
(5). Run Reset memory.
Notice:
Wait at least 1 minute after connecting the battery terminal before performing AT
initialization.
After performing AT initialization, be sure to perform the road test to store learned
value.

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Chassis & Body

E (4)

Service Points
A/T Initialization (Not Using IT-II)

(1). Short terminals 13 (ECUT) and 4 (E) of the DLC.

ECUT
(13)

(2). Depress the brake pedal within 3 seconds after turning the ignition
switch to ON and keep depressing until all procedures are completed.
(3). Shift the shift lever P R P within 1 second.
(4). Repeat this procedure above eight (8) times.
(5). Turn the ignition switch to OFF and turn the ignition switch to ON again.

Notice:
When deletion of AT learned value is completed, the D position indicator blinks
for 2.5 seconds to inform the driver about the completion.
After performing AT initialization, be sure to perform the road test to store
learned value.

D
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Chassis & Body

Service Points
A/T Initialization (Not Using IT-II)

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Chassis & Body

Propeller Shaft
3-joint type with Center Bearing

Center
Bearing

21

Chassis & Body

Differential
Filler Plug

Drain Plug

Gear Ratio
Ring Gear Size

Rush M/T

Rush A/T

Avanza S M/T

Avanza S A/T

5.571

5.857

4.875

5.125

183 mm

183 mm

180 mm

183 mm

Oil Capacity

1.6 Liter

Oil Grade

API GL-5

Oil Viscosity

SAE 80W-90, 85W-90, 90

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Chassis & Body

Suspension and Axle
Front: McPherson Strut with stabilizer

23

Chassis & Body

Suspension and Axle
Rear: 4-link coil spring w/ lateral rod rigid axle suspension
Lower control arm suspension construction is changed

Lower control arm

Construction is change
(cross section view)
Avanza

Rush

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Chassis & Body

Suspension and Axle
Front axle hub design, spindle and hub are integrated for low
cost and light weight purpose.

Rush
Lock Nut: Inner side

Avanza
Lock Nut: Outer side

25

Chassis & Body

Brake
ABS with EBD (1.5 S ONLY)

Recommended brake oil

DOT3

Front brake

Type

Solid disc

Rotor size

Outer dia. 273mm for 15inch wheel

Type

Leading-trailing drum

Drum size

Inner dia. : 254 mm

Rear brake

Brake control

ABS with EBD

Parking brake

Lever type

Brake Booster

9 inch, single

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Chassis & Body

Service Points
Front wheel speed sensor is not covered

27

Chassis & Body

Power Steering
Rack and Pinion power steering w/ energy absorbing
mechanism

No. of Turns Lock to Lock

3.9

Rack stroke

129 mm

Fluid type

ATF DEXRON II

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Chassis & Body

Body
Reinforcement of rocker panel

Reinforcement o the locker panel is exclusive for Rush only.

High tensile steel has been used in the highlighted areas.

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Chassis & Body

Spare Tire
Cover Key

Service Points
How to remove spare tire

1.

3.

Remove
spare tire
cover
ornament

Remove
spare tire
cover

2.

Unlock
with cover
key, then
remove
the nut

4.

Loosen 3
nuts and
remove
the tire

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Chassis & Body

Service Points
Jack point positions

Front

Rear

31