Chilton's Toyota Pick-Ups/Land Cruiser/4Runner 1989-96 Repair Manual 0801986826, 9780801986826
“Originally published: Radnor, Pa. : Chilton Book Co "Covers all U.S. and Canadian models of Toyota pick-up, Tacom
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ptcK-upsmcRumum 1989-% REPAIR MANUAL
Covers all U.S. and Canadian models of Pick-Up, Tacoma, T100, Land Cruiser and 4Runner 2 and 4 wheel drive
WIRING AND
VACUUM DIAGRAMS
Boston Public Library
Copley Square
TO YOTA
Senior Vice President Publisher & Editor-In-Chief Executive Editors
Managing Editor Special Products Manager Senior Editors
Project
Managers
Production Manager Product Systems Manager Director of Manufacturing Editor
PICK-UPS/LAND CRUISER/4RUNNER 1989-96
REPAIR MANUAL
Ronald A. Hoxter Kerry A. Freeman, S.A.E. Dean F. Morgantini, S.A.E. W. Calvin Settle, Jr., S.A.E. Nick D’Andrea Ken Grabowski, A.S.E., S.A.E. Jacques Gordon, Michael L. Grady, Ben Greisler, S.A.E., Debra McCall, Kevin M. G. Maher, Richard J. Rivele, S.A.E., Richard T. Smith, Jim Taylor, Ron Webb Martin J. Gunther, Will Kessler, A.S.E., Richard Schwartz Andrea Steiger ,
Robert Maxey Mike D’lmperio Dawn M. Hoch
F/llfeOOK
wniiii %sww company
ONE OF THE DIVERSIFIED PUBLISHING COMPANIES, A PART OF CAPITAL CITIES/ABC, INC.
Manufactured
©
in
USA
1996 Chilton Book Company
Way, Radnor, PA 19089 ISBN 0-8019-8682-6
Chilton
Congress Catalog Card No. 96-84181 1234567890 5432109876
Library of
Contents GENERAL INFORMATION AND MAINTENANCE
1-2
HOW TO USE
1-24
ROUTINE MAINTENANCE
1-3
TOOLS AND EQUIPMENT
1-78
FLUIDS AND LUBRICANTS
1-8
SAFETY
1-9
FASTENERS
1-104 JACKING 1-112 SPECIFICATIONS CHARTS
2-5
ELECTRONIC DISTRIBUTOR IGNITION
BOOK
SYSTEM
ENGINE ELECTRICAL
2-12
DISTRIBUTORLESS IGNITION
ENGINE AND ENGINE
SYSTEM
3-2
ENGINE MECHANICAL
3-5
SPECIFICATIONS CHARTS
2-15
FIRING
ORDERS
2-16
CHARGING SYSTEM
2-23
STARTING SYSTEM
2-27
SPECIFICATIONS CHARTS
3-171 EXHAUST SYSTEM
OVERHAUL
1
DRIVEABILITY AND EMISSION CONTROLS
FUEL SYSTEM
1
CHASSIS ELECTRICAL
THIS
4-2
AIR POLLUTION
4-3
AUTOMOTIVE EMISSIONS
4-6
EMISSION CONTROLS
4-26
ELECTRONIC ENGINE
CONTROLS
4-46
TROUBLE CODES
4-66
VACUUM DIAGRAMS
5-2
BASIC FUEL SYSTEM DIAGNOSIS
5-21
MULTI-PORT FUEL
5-2
CARBURETED FUEL SYSTEM
5-41
SEQUENTIAL FUEL
5-20
SPECIFICATIONS CHARTS
5-60
FUEL TANK
6-2
UNDERSTANDING ELECTRICAL SYSTEMS
6-35
RADIO
6-37
WINDSHIELD WIPERS
BAG SYSTEM
6-50
LIGHTING
6-76
WIRING DIAGRAMS
6-11
AIR
6-13
HEATER & A/C
INJECTION INJECTION
Contents TRANSFER CASE
AUTOMATIC TRANSMISSION
7-45 7-46 7-58 7-72
8-2
WHEELS
8-39
8-3
2WD FRONT
8-42
2WD REAR SUSPENSION 4WD REAR SUSPENSION
SUSPENSION
8-48
STEERING
4WD FRONT
8-80
SPECIFICATIONS CHARTS
REAR DISC BRAKES
7-2
MANUAL TRANSMISSION
7-15
CLUTCH
7-23
8-22
SUSPENSION
DRIVELINE
FRONT DRIVE AXLE
9-2
BRAKE OPERATING SYSTEMS
9-27 9-30
PARKING BRAKE
9-11
FRONT DISC BRAKES
9-33
;
9-48
i
9-19
10-2
REAR DRUM BRAKES
DRIVE TRAIN
REAR DRIVE AXLE
7
SUSPENSION AND STEERING
i
i
BRAKES
9
BODY AND TRIM
10
EXTERIOR
10-23 INTERIOR
10-74 GLOSSARY
GLOSSARY
10-79 MASTER INDEX
MASTER INDEX
SAFETY NOTICE Proper service and repair procedures are of
vital to
the safe, reliable operation of
The procedures contain many NOTES, CAUTIONS and
WARNINGS
which should be followed along with standard procedures
damage
eliminate the possibility of personal injury or improper service which could
It
motor vehicles, as well as the personal safety
all
This manual outlines procedures for servicing and repairing vehicles using safe, effective methods.
those performing repairs.
the vehicle or
compromise
its
to
safety.
important to note that the repair procedures and techniques, tools and parts for servicing motor vehicles, as well as the
is
and experience
of the individual
conditions under which vehicles
performing the work vary widely.
may be
It
not possible to anticipate
is
serviced, or to provide cautions as to
all
of the possible
all
skill
conceivable ways or
of the
hazards that
may
result.
Standard
and accepted safety precautions and equipment should be used when handling toxic or flammable fluids, and safety goggles or other protection should be used during cutting, grinding, chiseling, prying, or any other process that can cause material removal or projectiles.
Some
procedures require the use of tools specially designed
you must be completely
Although information
for
a specific purpose.
satisfied that neither your personal safety, nor the
in this
manual
is
based on industry sources and
is
Before substituting another tool or procedure,
performance of the vehicle
complete as possible
will
be endangered.
at the time of publication, the
some car manufacturers made later changes which could not be included here. While striving Book Company cannot assume responsibility for any errors, changes or omissions that may occur
possibility exists that
for total
accuracy, Chilton
in
the
compilation of this data.
PART NUMBERS Part that
numbers
listed in this
They are references
reference are not recommendation by Chilton for any product by brand name.
can be used with interchange manuals and aftermarket supplier catalogs
to locate
each brand supplier’s discrete
part
number.
SPECIAL TOOLS Special tools are
recommended by
the vehicle manufacturer to perform their specific job.
where absolutely necessary, they are referred
to in the text
by the part number of the
purchased, under the appropriate part number, from your local dealer or regional locally
from a tool supplier or parts
outlet.
tool
Use has been kept to a minimum, These tools can be
distributor, or
an equivalent
Before substituting any tool for the one recommended, read the
tool
can be purchased
SAFETY NOTICE
at the
top of this page.
ACKNOWLEDGMENTS The
No
Chilton
Book Company expresses appreciation
part of this publication
may be
to
Toyota Motor Corp.
reproduced, transmitted or stored
including photocopy, recording, or by information storage or retrieval
in
for their
generous assistance.
any form or by any means, electronic or mechanical,
system without
but
manufacturer.
prior written
permission from the publisher.
FASTENERS, MEASUREMENTS AND
MEASUREMENTS 1-16 TORQUE 1-11 FLUIDS AND LUBRICANTS AUTOMATIC TRANSMISSION BODY LUBRICATION AND MAINTENANCE 1-95 CHASSIS GREASING 1-94 COOLING SYSTEM 1-90 DRIVE AXLES 1-87 ENGINE 1-80 FLUID DISPOSAL 1-78 FUEL AND ENGINE OIL
1-84
RECOMMENDATIONS 1-78 MANUAL TRANSMISSION 1-82 MASTER CYLINDER (BRAKE AND CLUTCH)
1-93
TRANSFER CASE 1-85 WHEEL BEARINGS 1-95 HOW TO BUY A USED VEHICLE TIPS 1-109
THIS
DO’S
1-8
DON’TS 1-8 SPECIFICATIONS CHARTS AUTOMATIC TRANSMISSION 1-18 CAPACITIES 1-122 ENGINE IDENTIFICATION 1-18 GASOLINE ENGINE TUNE-UP 1-124 MAINTENANCE INTERVAL
CHARTS 1-112 MANUAL TRANSMISSION 1-18 STANDARD (ENGLISH) TO METRIC CONVERSION CHARTS 1-126 VEHICLE IDENTIFICATION
1-92
POWER STEERING PUMP STEERING GEAR 1-94
HOW TO USE
TIRES AND WHEELS 1-74
VALVE LASH ADJUSTMENT 1-55 WINDSHIELD WIPERS 1-70 SERIAL NUMBER IDENTIFICATION ENGINE 1-18 TRANSMISSIONS 1-18 VEHICLE 1-18 SERVICING YOUR VEHICLE SAFELY
CONVERSIONS BOLTS, NUTS AND OTHER THREADED RETAINERS 1-9 STANDARD AND METRIC
BOOK
COOLING GENERAL
1-100
RECOMMENDATIONS
AVOIDING THE MOST COMMON MISTAKES 1-2 AVOIDING TROUBLE 1-2 MAINTENANCE OR REPAIR? 1-2 WHERE TO BEGIN 1-2 JACKING 1-104
JUMP STARTING A DEAD BATTERY JUMP STARTING PRECAUTIONS 1-103 JUMP STARTING PROCEDURE 1-103 MODEL IDENTIFICATION 1-16 ROUTINE MAINTENANCE
1-18
TOOLS AND EQUIPMENT SPECIAL TOOLS 1-6 TOWING THE VEHICLE 1-101 TRAILER TOWING
Hiisut
1-100
HANDLING A TRAILER 1-101 HITCH (TONGUE) WEIGHT 1-100 TRAILER WEIGHT 1-100
AND MAINTENANCE FASTENERS, MEASUREMENTS
AND CONVERSIONS
HOW TO BUY A USED VEHICLE HOW TO USE THIS BOOK
1-109
JACKING JUMP STARTING A DEAD
1-104
BATTERY
1-103
AIR CONDITIONING 1-67 AIR FILTER 1-24
BATTERY BELTS
MODEL
1-33
SERIAL
1-44
SAFELY
1-50
SPECIFICATIONS CHARTS
EVAPORATIVE CANISTER (CHARCOAL CANISTER) FUEL CAP GASKET 1-30 FUEL FILTER 1-29 GENERAL INFORMATION HEAT INSULATOR 1-36
1-32
1-24
HOSES 1-41 IDLE SPEED AND MIXTURE ADJUSTMENTS 1-67 IGNITION TIMING 1-51
PCV VALVE 1-30 SPARK PLUG WIRES SPARK PLUGS 1-44 TIMING BELTS 1-40
1-24
IDENTIFICATION 1-18
SERVICING YOUR VEHICLE
DISTRIBUTOR CAP AND
ROTOR
NUMBER
1-2
IDENTIFICATION 1-16
ROUTINE MAINTENANCE
1-37
CV-BOOTS
1-9
FLUIDS AND LUBRICANTS T-78
1-49
TOOLS AND EQUIPMENT TOWING THE VEHICLE TRAILER TOWING
1-8
1-18 1-3
1-101
1-100
GENERAL INFORMATION AND MAINTENANCE
1-2
HOW TO USE Chilton’s Total
BOOK
THIS
Car Care manual
Toyota Truck
for the
is
Maintenance or Repair?
intended to help you learn more about the inner workings of
money on
your vehicle while saving you
upkeep and
its
It’s
operation.
The beginning of the book will likely be referred to the most, since that is where you will find information for maintenance and tune-up. The other sections deal with the more complex systems
through brakes are covered to the extent that the average do-
becomes mechanically
it-yourselfer
book
involved. This
will
not
make
special tools
uneconomical.
this task
change your own brake pads and shoes, replace spark plugs, and perform many more jobs that can save you money, give you personal
tools at
all
for repair
caused by lack
often
is
of
the automatic
refilling
maintenance recommended by the
fluid is
do
intervals. Failure to
this
expensive
ruin the transmission/transaxle, requiring very
While no maintenance program can prevent items from
repairs.
breaking or wearing out, a general rule can be stated:
MAINTENANCE whenever the
meant
is
CHEAPER THAN REPAIR.
IS
basic mechanic’s rules should be mentioned here. side of the vehicle or engine
left
to specify the driver’s side.
means
of the vehicle
are required.
which show
of parts
something has broken or
is
maintenance. Example: draining and
and help you avoid expensive problems.
no
A need
not working.
Two
A secondary purpose of this book is a reference for owners who want to understand their vehicle and/or their mechanics better. In this case,
and replacement
signs of normal wear. Maintenance compensates for wear or
can
give you detailed instructions to help you
satisfaction
Maintenance includes routine
manufacturer at specific mileage
in
however,
will,
It
repair.
inspections, adjustments,
transmission
explain such things as rebuilding a differential for the simple
reason that the expertise required and the investment
mention the difference between
to
deterioration. Repair implies that
your vehicle. Operating systems from engine
of
necessary
maintenance and
First,
referred to,
is
Conversely, the
it
right side
the passenger’s side. Second, most
screws and bolts are removed by turning counterclockwise,
and tightened by turning clockwise.
Where
Begin
to
Safety
aware Before removing any bolts, read through the entire procedure. This supplies
having
be required. There
will
walk
to
more
nothing
frustrating than
and
the
on Sunday afternoon. So read ahead
bolt
Avoiding the Most Pay
procedures, and
When
procedures.
you how
to
repair
remove the
rebuilt
replacement.
costs.
Backyard repair
in
and then how
way, you
In this
1.
cases, repair or overhaul
not considered practical,
is
part
of
some
we
to install the
tell
new
or
save the labor
at least
some components
When
mistakes
practical.
Incorrect order of assembly, disassembly or adjustment.
taking something apart or putting
the
in
however,
wrong order usually
CAN
it
Avoiding Trouble
to
Many procedures in this book require you to “label and ...” a group of lines, hoses or wires. Don’t be lulled into thinking you can remember where everything goes you won’t. you hook up vacuum or fuel lines
disconnect
If
electrical wiring incorrectly,
you
may
at
all.
you hook up
If
don’t
need
piece on
as the your
line.
its fitting
letter
A
own code,
in
know the
to
A
official
or engineering
name
for
will
own label such as you remember
allow you to assign your
name. As long
names. Do remember
gasoline or other
fluids;
if
that tape
a component
is
marker can be very handy
Remove any tape
or
paper labels
for
after
to
will
dissolve
be washed or
A permanent
marking metal parts.
assembly.
it.
When
affects another,
one
at
in
in
the order
draw a
to
point
in
order
proper position.
its
When
the proper order; often,
and you cannot expect even
each adjustment
is
made
only
when
cannot be changed by any other. it is more cause damage, undertorquing may loose causing serious damage.
Overtorquing (or undertorquing). While for overtorquing to
allow a fastener to vibrate Especially
when
dealing with aluminum parts, pay attention to
torque specifications and
a torque figure
is
utilize
a torque wrench
not available,
remember
using the right tool to perform the job, you
have
to strain yourself to get
pitch of
most threads
the wrench
will
what you are is
in
you’re taking apart
you might want
when assembled
satisfactory results unless it
time;
you can’t
if
supply exploded views whenever possible.
one adjustment
If
the lines can be reconnected by matching
looks
it
for
intricate,
making adjustments, perform them
2.
piece of masking tape on the hose and a
cleaned, use another method of identification. felt-tipped
will
very
is
sure you get everything back
common
or a short
similar letters or
make
We
instantly learn a very
expensive lesson.
You
how
picture of
if
you extra
which the instructions say you should, even
something that
incorrectly, the vehicle will run poorly,
together, performing
it
just costs
break something. Read the entire procedure
immediately see a reason
—
There are 3
mechanical work:
in
before beginning disassembly. Perform everything
just not
is
steps
in
each hose or
Mistakes
attention to the instructions provided.
common
sections contain adjustments, maintenance, removal and
All
Common
procedures thoroughly understood before
ali
attempting any work.
installation
in this
SERVICING YOUR VEHICLE SAFELY and SAFETY NOTICE on the acknowledgment page.
section regarding
and plan ahead. Each operation should be approached logically
Constantly be
rule.
working on an automobile
in
bus stop on Monday morning because
to the
you were short one
is
dangers involved
and take the proper precautions. See the information
give you the overall view of what tools and
will
always the most important
is
of the
is
in
will
tight
A good example
in
of
in if
assembly.
you are
probably not
enough. The
slight that the tension
be multiplied many times
tightening.
can be seen
so
a fastener
that
you put on
actual force on
how
critical
torque
the case of spark plug installation, especially
GENERAL INFORMATION AND MAINTENANCE where you are putting the plug head. Too
torque can
little
an aluminum cylinder
into
to
fail
difficult.
and engine
parts.
Too much torque can damage the
There are many commercial products available
come loose, even they common brand is Loctite®).
very
just right (a
about getting something together loose
one
enough
to avoid
tight
for
ensuring
are not torqued
if
you’re worried
If
enough
start
mechanical damage during assembly,
turning
will
when a
screwed
part
such as a
bolt
a nut or casting at the wrong angle and
into
is
more
likely to
occur
access
if
mind
that
if you don’t force wrench on the part
many
parts,
that gentle
make
to
sure
it’s
it
or resist a
change
been
until it’s
you suddenly encounter
If
has not seated
part
fully,
don’t force
it.
Pull
clean and threading properly.
Always take your time and be
materials, fluids, etc. involved.
Crossthreading. This occurs
in
automatically bring the part you’re threading to the
and the
back out
in.
you
If
over again at
start
have tapered threads, so
tightened a couple of turns by hand.
it
is
Keep
effort.
angle. Don’t put a
in
compatible with the
your fingers.
etc. with
can be inserted and turned several
it
especially spark plugs,
package and make sure the product
forced. Crossthreading
until
much
times without
resistance,
3.
spark plug,
bolt,
encounter resistance, unscrew the part and
choosing a threadlocking compound, read the label on the is
the
proper angle, but only
to hold, but
these products might offer substantial insurance. Before
of
Then,
a different angle
threads or distort the plug, changing the spark gap.
that fasteners won’t
helps to clean and lubricate fasteners, then to start
It
threading with the part to be installed positioned straight
crush the gasket, causing
leakage of combustion gases and consequent overheating of the plug
1-3
patient;
experience, working on your vehicle
may
once you have some well become an
enjoyable hobby. is
TOOLS AND EQUIPMENT See Figures
I
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12,
and equipment
Naturally, without the proper tools
impossible to properly service your vehicle.
perform
of the operations in this
all
would be unwise
for the
amateur
more of them at some time. The best approach is to proceed
12-point
tools.
It
far better to
is
more for better quality. Forged wrenches, 6 or sockets and fine tooth ratchets are by far preferable expensive counterparts. As any good mechanic
you, there are few worse experiences than trying to
tell
work on a vehicle with bad far
good
little
to their less
be
may need one
slowly, gathering a
be misled by the low cost of bargain
spend a
It
and buy an
those tools that are used most frequently. Don’t
quality set of
can
is
book. Of course,
to rush out
expensive set of tools on the theory that he/she or
it
would also be
impossible to catalog every tool that you would need
virtually
to
It
13 and 14
outweighed by
tools.
frustration
Your monetary savings
will
tecs 1200
and mangled knuckles. Fig. 1 All but the most basic procedures assortment of ratchets and sockets
Begin accumulating those tools that are used most
maintenance and
frequently: those associated with routine
will
require an
tune-up. In addition to the normal assortment of screwdrivers
and •
pliers,
you should have the following
In
tools:
wrenches
in
sizes from Vs- 3/4
in.
or
3mm-19mm
(depending on
whether your vehicle uses standard or metric fasteners) and a 13 /ie
or
in.
%
in.
addition to the
above items there are several others
These include gravel
Oil
— such
antifreeze
spark plug socket (depending on plug type).
Dry®
as cat
and
needed. This
'If possible, buy various length socket drive extensions. Universal-joint and wobble extensions can be extremely useful, but be careful when using them, as they can change the amount of torque applied to the socket.
fluids, is
(or
an equivalent
a basic
list
for routine
maintenance, but only
your personal needs and desire can accurately determine your list
of tools.
After performing a
amazed
few projects on the vehicle,
at the other tools
you’ll be and non-tools on your workbench.
Some
• Oil
wrench.
Spout or funnel
for
pouring
to information
any grease
fluids.
fittings
—
for details,
on Fluids and Lubricants found
is
please refer
later in this
Hydrometer
for
checking the battery (unless equipped with
A
•
Rags
store parts), ball of
tagging lines or hoses, markers and pens, a note pad, golf
tees of
(for
plugging
vacuum
mechanics’s wire
container for draining for wiping
oil
and other
mirror (to
see
into
(to
lines),
metal coat hangers or a
fluids.
up the inevitable mess.
be drawn up cated, they
roll
hold things out of the way), dental pick
and a small
recesses and under manifolds).
A more advanced
a sealed, maintenance-free battery). •
(to
or similar long, pointed probe, a strong magnet,
section).
•
useful household items are: a large turkey baster or
twine, electrical tape for wiring, small rolls of colored tape for
• Grease gun for chassis lubrication (unless your vehicle not equipped with
of lubricants,
although these can be purchased as
siphon, empty coffee cans and ice trays
filter
absorbent
oil
and the usual supply
litter)
• Jackstands for support.
•
that
are not absolutely necessary, but handy to have around.
Wrenches/sockets and combination open end/box end
set of tools, suitable for tune-up work, can
slightly more sophistineed not be outrageously expensive. There are
easily.
While the tools are
GENERAL INFORMATION AND MAINTENANCE
1-4
ff*
tecs 1204
Fig. 2
In
addition to ratchets, a
and hex keys
will
good set
of
wrenches
be necessary
Fig. 5
Various drivers, chisels and prybars are great
tools to have in your toolbox
tecs 1202
Fig. 3
A
hydraulic floor jack and a set of jackstands
are essential for
lifting
and supporting the vehicle
Fig. 6
Many
wrench
repairs will require the use of a torque
to assure the
components are properly fastened
tecs 1203
Fig. 4 An assortment of pliers, grippers and cutters will be handy, especially for old rusted parts and stripped bolt heads
Fig.
7 Although not always necessary, using specialized
brake tools
will
save time
GENERAL INFORMATION AND MAINTENANCE
tecs 12 10
Fig. 8
A few inexpensive
lubrication tools will
make
maintenance easier
Fig. 11
Dwell/tachometer unit (typical)
Fig. 12
Inductive type timing light
tccsl211
Fig. 9
Various pullers, clamps and separator tools are
needed
for
many
larger,
more complicated
repairs
1-5
GENERAL INFORMATION AND MAINTENANCE
1-6
should have a xenon tube for brightness.
an electronic
system, a timing
ignition
pickup that clamps around the No.
On any
light
vehicle with
with an inductive
spark plug cable
1
is
preferred. In
addition to these basic tools, there are several other tools
and gauges you may •
find useful. These include: Compression gauge. The screw-in type is slower
to use,
but eliminates the possibility of a faulty reading due to escaping pressure.
Manifold
•
12V
•
A combination volt/ohmmeter
•
Induction
test light.
or not there
wire tccsl213
Fig.
Total Car Care
as good
for the
model. Just be sure that the tach scale gines.
(If
and
that
is
plug ignition systems).
list
with
of
goes
to
works on
a least 1200-1500 rpm on 4,
The key
to these
purchases
is
to
make
an eye towards adaptability and wide range. A basic
tune-up tools could include:
Feeler gauges for valve or point adjustment. (Even
tool.
determining whether for
use
a
if
a wiring harness.
probably find a torque wrench nec-
will
to use.
The
The beam type models
type torque wrenches tend
click
be more expensive. Also keep
calibrated.
in
mind
that
all
types of
You
will
have
to
decide
re-
which better
for yourself
fits
your purpose.
Special Tools
if
your
does not use points or require valve adjustments, a gauge is helpful for many repair/overhaul procedures).
tachometer/dwell meter
>
See Figure 15 Normally, the use of special factory tools
with
vehicle
will
on vehicles without electronic
made
in
but the most basic work.
do-it-yourself mechanic.
•
should be
for
ensure accurate tune-up work
ignition.
carefully.
A
is
avoided for
re-
pair procedures, since these are not readily available for the
Spark plug wrench and gapping
light
you
used
required since diesels don't use spark
•
A
all
is
a wire. These are handy
6 and 8-cylinder en-
• Tach/dwell meter.
feeler
in
torque wrenches should be periodically checked and/or
you have one or more vehicles with a diesel engine,
a special tachometer
them
it
average mechanic as a professional it
final note,
away) are easier
manual handy
several inexpensive tach/dwell meters on the market that are bit
current
broken somewhere
essary for
to
every
Ammeter. This
is
are perfectly adequate, although the newer click types (break-
the proper information, so always have a Chilton
is
is
As a
14 The most important tool you need to do the job
vacuum gauge.
•
light
The choice
of a timing
which works on the
current supplied by the vehicle’s battery
is
the best choice;
DC it
more commonly
When
occasionally, a special tool function
it
is
possible to perform the job
available tools,
and should be used. Before
you should be convinced
formance
it
will
was designed
be pointed to
out, but
perform a specific
substituting another tool,
that neither your safety nor the per-
of the vehicle will
be compromised.
Special tools can usually be purchased from an automotive parts store or from your dealer. In
may be
some cases
special tools
available directly from the tool manufacturer.
GENERAL INFORMATION AND MAINTENANCE
1-7
GENERAL INFORMATION AND MAINTENANCE
1-8
SERVICING YOUR VEHICLE SAFELY t See Figures 16, 17, 18 and 19
Do’s It
is virtually
impossible to anticipate
all
of the
hazards
in-
volved with automotive maintenance and service, but care and
•
common sense
•
The
rules of safety for
around gasoline,” to
prevent most accidents.
will
to
avoiding injuries
is
mechanics range from “don’t smoke
“use the proper to
tool for the job.”
develop safe work habits and
The
trick
to take
Do keep a fire extinguisher and first aid kit handy. Do wear safety glasses or goggles when cutting, drilling,
grinding or prying, even
glasses
you have 20-20
if
vision.
If
you wear
the sake of vision, wear safety goggles over your
for
regular glasses.
every possible precaution.
•
Do
eyes or
eyes whenever you work around the bat-
shield your
tery. Batteries
contain sulfuric acid.
skin, flush the
case
In
of contact with the
area with water or a mixture of water
and baking soda, then seek immediate medical •
Do use
service.
attention.
safety stands (jackstands) for any undervehicle
Jacks are
jackstands are for mak-
for raising vehicles;
ing sure the vehicle stays raised until
down. Whenever the vehicle
you want
it
to
come
wheels
raised, block the
is
re-
maining on the ground and set the parking brake. •
Do use adequate
icals or
ventilation
tos dust resulting from
ous •
in sufficient
Do disconnect
some brake
lining
any chem-
wear can be hazard-
the negative battery cable
The secondary
EXTREMELY HIGH VOLTAGE. exceed 50,000
Do
with
quantities.
the electrical system.
•
when working
hazardous materials. Like carbon monoxide, the asbes-
In
ignition
when working on
system contains
some cases
it
can even
volts.
whenever working
follow manufacturer's directions
potentially
hazardous materials. Most chemicals and
poisonous
if
taken
fluids
with
are
internally.
Do properly maintain your tools. Loose hammerheads, mushroomed punches and chisels, frayed or poorly grounded •
worn screwdrivers, spread
electrical cords, excessively
wrenches (open end), cracked sockets, faulty droplight
tecs 1020
• Fig. 16
Screwdrivers should be kept
in
good condition off
to prevent injury or
damage which could
result
if
the
slipping ratchets, or
sockets can cause accidents.
Likewise, keep your tools clean; a greasy wrench can slip
a bolt head, ruining the bolt and often harming your knuck-
les in the process.
blade slips from the screw
•
Do use the proper size and type of Do select a wrench or socket that
hand.
tool for the job at fits
the nut or bolt.
The wrench or socket should sit straight, not cocked. • Do, when possible, pull on a wrench handle rather than push on •
it,
Do be
and adjust your stance
to prevent a
sure that adjustable wrenches are
the nut or bolt
and pulled so
that the force
is
fall.
tightly
closed on
on the side
of
the fixed jaw. • •
Do Do
strike
squarely with a hammer; avoid glancing blows.
set the parking brake
and block the
drive
wheels
if
the
work requires a running engine.
Don’ts •
up a deadly supply little
of
every day. You
ing yourself.
in
— EVER!
takes a long time to
a
a garage or anywhere else without Carbon monoxide is poisonous; it leave the human body and you can build
Don’t run the engine
proper ventilation
it
in
may
your system by simply breathing
Always use power vents, windows, fans and/or
open the garage door.
in
not realize you are slowly poison-
GENERAL INFORMATION AND MAINTENANCE
1-9
Don’t work around moving parts while wearing loose cloth-
•
much
Short sleeves are
ing.
safer than long, loose sleeves.
Hard-toed shoes with neoprene soles protect your toes and give a better grip on slippery surfaces. Jewelry such as
watches, fancy belt buckles, beads or body adornment of any kind
not safe working around a vehicle. Long hair should be
is
back under a hat or cap.
tied
A
Don’t use pockets for toolboxes.
•
fall
bump can
or
drive
a screwdriver deep into your body. Even a rag hanging from
your back pocket can wrap around a spinning shaft or fan. •
smoke when working around
Don’t
gasoline, cleaning sol-
vent or other flammable material. •
smoke when working around
Don’t
battery
•
is
being charged,
gives
it
Don’t use gasoline to
When
the battery.
the
explosive hydrogen gas.
off
wash your hands;
there are excel-
soaps available. Gasoline contains dangerous additives
lent
which can enter the body through a cut or through your pores. Fig.
18 Using the correct size wrench
will
help prevent
Gasoline also removes
bone dry hands
the possibility of rounding-off a nut
•
all
the natural oils from the skin so that
suck up
will
Don’t service the
and grease.
oil
conditioning system unless you are
air
equipped with the necessary tools and
compressed gas sure
it
will
refrigerant
absorb heat from whatever
non-toxic, of
contacts. This
it
will chill
is
normally
R-12 becomes a deadly poisonous gas
in
the pres-
it
an open flame. One good
burning refrigerant can be
whiff of the
vapors from
fatal.
Don’t use screwdrivers for anything other than driving
•
screws!
A
screwdriver used as an prying tool can snap
you least expect ruin
liquid or
touches. Although refrigerant
or freeze anything
ence
When
training.
released to atmospheric pres-
is
causing
it,
injuries.
when
At the very least, you’ll
a good screwdriver. Don't use a
•
bumper
or
emergency jack
(that
little
ratchet,
scissors, or pantograph jack supplied with the vehicle) for anything other than changing a for
a maintenance
tool.
road; they are
NOT
designed as
you are serious about maintaining your
If
vehicle yourself, invest
IV2 ton capacity, and
These jacks are only intended
flat!
emergency use out on the in
a hydraulic floor jack of at least a
at least
two sturdy jackstands.
FASTENERS, MEASUREMENTS AND CONVERSIONS rust or corrosion
Bolts, Nuts
and Other Threaded
Retainers >
See Figures
20, 21, 22
and 23
Although there are a great variety of fasteners found
modern car
or truck, the
threaded fastener (nuts, threaded retainers
damaged
in
most commonly used bolts,
may be
screws, studs,
retainer
etc).
the
in is
the
Most
reused, provided that they are not
use or during the
repair.
Some
retainers (such as
stretch bolts or torque prevailing nuts) are designed to
deform
when tightened or in use and should not be reinstalled. Whenever possible, we will note any special retainers which should be replaced during a procedure. But you should always
when is removed and damage. Check all threads
inspect the condition of a retainer
replace any that
show signs
of
which can increase the torque necessary to which that fastener was
achieve the desired clamp load
for
originally selected. Additionally,
be sure
that the driver surface
of the fastener
has not been compromised by rounding or
other damage.
In
some cases a
driver surface
may become
only partially rounded, allowing the driver to catch direction. In
many
of
installed and tightened, but the and loosen the fastener again.
down
in
these occurrences, a fastener
the line should that
driver
only one
may be
would not be able
to grip
(This could lead to frustration
component ever need
to
be disas-
sembled again). If
you must replace a fastener, whether due
damage, you must placement. rial
In all
ALWAYS
be sure
to
cases, a retainer of the
to
design or
use the proper
same
re-
design, mate-
and strength should be used. Markings on the heads
of
it
for
most
bolts will help
determine the proper strength
of the fast-
1-10
Fig.
GENERAL INFORMATION AND MAINTENANCE
20 Here are a few of the most
common
screw/bolt driver styles
NUTS
PLAIN
JAM
CASTLE (CASTELLATED)
SELF-LOCKING
SPEED
SCREWS /
ROUND
fillister
hexagon
split
plain
sheet METAL
LOCKW ASHERS
internal
external
TOOTH
TOOTH
STUD 111m
mm tecs 1036
Fig. 21
There are many different types of threaded retainers found on vehicles
GENERAL INFORMATION AND MAINTENANCE
1-11
A Length -
B
-
Diameter (major diameter)
C - Threads per inch D Thread length
or
mm
-
E
Fig.
--
E
-
Size of the wrench required
F
-
Root diameter (minor diameter)
22 Threaded retainer sizes are determined using these measurements ener.
The same material thread and
assure proper
installation
pitch
must be selected
and safe operation
to
of the vehicle
afterwards.
Thread gauges are available
to help
measure a
bolt or
Most automotive and hardware stores keep
stud's thread.
gauges available to help you select the proper size. you can use another nut or bolt for a thread gauge. you are replacing
match by you
not too badly
is
finding another bolt
damaged, you can
which
will
thread
in
then use that nut to help select the replacement ever, the bolt
you are replacing
or drilled out) that
might
its
by looking
start
damaged
bolt’s
so badly
select a place.
bolt.
damaged
placement
how-
If
(broken
for
same assem-
another bolt (from the
on your vehicle) which
mounting.
If
will
so, the other bolt
thread into
can be used
a nut; the nut can then be used to select the
to select
If
bolt,
threads cannot be used as a gauge, you
bly or a similar location
the
is
its
the bolt
If
damaged
a nut which threads properly onto the
find
a pinch,
In
re-
bolt.
cases, be absolutely sure you have selected the
In all
proper replacement. Don’t be shy, you can always ask the store clerk for help.
['WARNING Be aware that when you find a bolt with damaged threads, you may also find the nut or drilled hole it was threaded into has also been damaged. If this is the case, you may have to drill and tap the hole, replace the nut or otherwise repair the threads. to
fit
NEVER
damaged
into the
try to force a
replacement bolt
threads.
Torque Torque
is
defined as the
ing or rotating. rotation.
Fig.
23 Special fasteners such as these
Torx® head
used by manufacturers to discourage people from working on vehicles without the proper tools bolts are
It
A common example
threaded retainer such as a torque
is
measurement
one
of resistance to turn-
tends to twist a body about an axis of
of the
of this
would be tightening a
nut, bolt or
most common ways
screw. Measuring to help
assure that a
threaded retainer has been properly fastened.
When
tightening a threaded fastener, torque
is
applied
in
three distinct areas, the head, the bearing surface and the
GENERAL INFORMATION AND MAINTENANCE
1-12
load. About 50 percent of the measured torque is used overcoming bearing friction. This is the friction between the
Once
clamp
setting.
in
signalling feature that
the torque
is
reached, the wrench has a reflex
causes a momentary breakaway
of the
bearing surface of the bolt head, screw head or nut face and
torque wrench body, sending an impulse to the operator’s
the base material or washer (the surface on which the fastener
hand.
is
rotating).
used
in
Approximately 40 percent of the applied torque
overcoming thread
is
This leaves only about 10
friction.
percent of the applied torque to develop a useful clamp load (the force tion
which holds a
can account
for
joint together).
means
This
as much as 90 percent
Pivot I
that fric-
Head Type
See Figures 28 and 29
Some
of the applied
torque wrenches (usually of the click type)
equipped with a pivot head which can allow
torque on a fastener.
areas of limited access. BUT,
pull
on the handle,
comes
the handle
readings In
most applications, a torque wrench can be used
proper installation of a fastener. Torque wrenches
come
various designs and most automotive supply stores variety to suit your needs.
any time we supply a
A
because there
is
will
assure
loading point.
in
make
specific torque value for a fastener.
A
you are following the gen-
if
accompanying
charts.
Keep
no worldwide standardization
in
mind
that
of fasteners, the
charts are a general guideline and should be used with caution.
Again, the general rule of
for the job,
“if
you should not have
you are using the
right tool
to strain to tighten a fastener”
The design
See Figure 27
It
usually such as to
Wob-
can greatly affect the readings; avoid
is
one
of the
most popular
>
their
at all times.
Rigid
Case
(Direct Reading)
See Figure 30
consists of a pointer attached to the head that runs
the length of the flexible the handle.
beam
As the wrench
is
(shaft) to
pulled, the
A
a scale located near
beam bends and
the
a
case or
rigid
is
Another popular design of torque wrench the click type wrench you pre-adjust
affecting accuracy.
have a great degree
I See Figure 28 is it
the click type. to
values.
can be held
because they tend
preferred
Type
show torque
that they
wrench without Click (Breakaway)
direct reading torque
dial indicator to
wrenches
pointer indicates the torque using the scale.
To use
is
^It should be mentioned that the use of any U-joint, wobble or extension will have an effect on the torque readings, no matter what type of wrench you are using. For the most accurate readings, install the socket directly on the wrench driver. If necessary, straight extensions (which hold a socket directly under the wrench driver) will have the least effect on the torque reading. Avoid any extension that alters the length of the wrench from the handle to the
use
Beam Type
types.
could alter the wrench
this
handle
of the
inconvenient to deliberately misuse the wrench.
it
ble extensions
The beam type torque wrench
If
a very good chance the torque
head/driving point (such as a crow’s foot). U-joint or
applies here.
>
and as you
carry a
torque wrench should be used
torque wrench can also be used eral guidelines in the
to
is
be inaccurate because
will
lightly,
contact with the yoke extension during
the process of pulling, there
I See Figures 24, 25 and 26
in
should be floated on the pivot point.
it
in
may be
be used
must be used properly. To
it
hold a pivot head wrench, grasp the handle
TORQUE WRENCHES
to
it
to
at
wrench
is
equipped with
One advantage
of
these
any position on the
These wrenches are
be compact, easy
to
often
read and
of accuracy.
TORQUE ANGLE METERS
a torque >
See Figure 31 Because the
frictional characteristics of will
on torque
vary as well.
is
will
not significant
vary,
enough
to
In
most
method
cylinder heads).
of installation
In
But, in certain appli-
may determine
precise clamp loads are necessary (such
gle
strictly
applications, this variance
cause worry.
cations, a manufacturer’s engineers
many aluminum
each fastener or
clamp loads which are based
threaded hole
is
that
more
the case with
these cases, a torque an-
would be specified.
When
installing
fasteners which are torque angle tightened, a predetermined seating torque and standard torque wrench are usually used first
to
remove any compliance from the
joint.
The fastener
is
then tightened the specified additional portion of a turn mea-
sured
in
tor) is
used
degrees. for
A
torque angle gauge (mechanical protrac-
these applications.
GENERAL INFORMATION AND MAINTENANCE
1-13
1-14
GENERAL INFORMATION AND MAINTENANCE Specified torque
Class
Diameter
Pitch
mm
mm
Hexagon head
N-m
4T
1
0T
1T
N-m
kgf-cm
6
60
bolt ft-lbf
1
55
48
1.25
12.5
130
9
14
145
10
10
1.25
26
260
19
29
290
21
12
1.25
47
480
35
53
540
39
14
1.5
74
760
55
84
850
61
16
1.5
115
1,150
83
-
-
-
5
in.-lbf
*
52
6
1
6.5
65
56
7.5
75
65
8
1.25
15.5
160
12
17.5
175
13
10
1.25
32
330
24
36
360
26
12
1.25
59
600
43
65
670
48
14
1.5
91
930
67
100
1,050
76
16
1.5
140
1,400
101
-
-
-
8
80
69
9
90
78
in.-lbf
6
1
8
1.25
19
195
14
21
210
15
400
29
44
440
32
in.-lbf
10
1.25
39
12
1.25
71
730
53
80
810
59
14
1.5
1
10
1,100
80
125
1,250
90
16
1.5
170
1,750
127
-
-
-
6
1
10.5
110
8
12
120
8
1.25
25
260
19
28
290
21
10
1.25
52
530
38
58
590
43
12
1.25
95
970
70
105
1,050
76
14
1.5
145
1,500
108
165
1,700
123
16
1.5
230
2,300
166
-
-
-
7T
1
fft-lbf
8
6T
9T
Hexagon flange
bolt
6
5T
8T
kgf-cm
8
1.25
29
300
22
33
330
24
1.25
61
620
45
68
690
50
12
1.25
110
1,100
80
120
1,250
90
8
1.25
34
340
25
37
380
27
10
1.25
70
710
51
78
790
57
12
1.25
125
1,300
94
140
1,450
105
8
1.25
38
390
28
42
430
31
64
10
1.25
78
800
58
88
890
12
1.25
140
1,450
105
155
1,600
116
8
1.25
42
430
31
1.25
87
890
64 116
480 990
35
10
47 97 175
12
1.25
155
1,600
in.-lbf
in.-lbf
9
10
1,800
in.-lbf
72 130 tecs 1241
Fig.
26 Standard bolt torque for metric fasteners
— WARNING:
use only as a guide
GENERAL INFORMATION AND MAINTENANCE
1-15
1-16
GENERAL INFORMATION AND MAINTENANCE
in their installation. Some of the most common measurements include length (in. or cm/mm), torque (ft. lbs., inch lbs. or Nm) and pressure (psi, in. Hg, kPa or mm Hg). In most cases, we strive to provide the proper measurement as
or to assist you
determined by the manufacturer's engineers.
Though,
measured of the
some
in
cases, that value
what
with
is
available
in
may
not be conveniently
measuring devices which are available today
will
two scales so the Standard or Metric measurements ily
be taken.
any
If
available to you specifications,
end
of the various
do not contain the same scale as
factor.
factor chart
and multiplying
it
is
in
listed in
the
at the
used by taking the given
first line,
if
you have a
inches such as “free-play should be 2
your ruler reads only
eas-
by the necessary conversion
For instance, looking at the
measurement
may
determine the proper value.
of this section to
specification
have
measuring tools which are
use the conversion factors chart found
The conversion
many
your toolbox. Luckily,
millimeters, multiply 2
in
in.
in.”
but
by the con-
version factor of 25.4 to get the metric equivalent of 50.8mm. Likewise,
surement,
Standard and Metric Measurements this
manual, specifications are given
to help
was given only in a Metric meaNewton Meters (Nm), then look at the measurement is 100 Nm, multiply
the specification
for
example
the center column it
Throughout
if
first.
in If
by the conversion factor
of
0.738 to get 73.8
ft.
lbs.
you
determine the condition of various components on your vehicle,
MODEL IDENTIFICATION I
Tacoma 4WD,
See Figure 32
V-6.
Toyota’s have a model identification plate which
under the hood on the
firewall.
The models are
located
identified
code. These codes explain exactly what your truck
For example; model number
is
VZN170L-CRMDKAB
is
by a
purchase a part
a 1996
walk for
into
a dealer or your local parts store to
your truck, and are not sure exactly the
type of vehicle you drive, the model
and has. fication
is
5 speed manual transmission, Xtracab Deluxe
When you
numbers are the
key.
number and
vehicle identi-
GENERAL INFORMATION AND MAINTENANCE
MODEL CODE AND MODEL
LINE-UP
MODEL CODE
VZN1 85 ©
G K
L
GEARSHIFT TYPE
©
ENGINE
DRIVE TYPE
RZN180
K A
?
BASIC MODEL CODE
CODE
MG M
:
P
:
5-Speed Manual 4-Speed Automatic
3RZ-FE
2WD
VZN180
5VZ-FE
RZN185
3RZ-FE
4WD
VZNI85
GRADE
©
5VZ-FE
S
:
—
G SR5 :
Z
:
Limited
WHEEL POSITION ^ P STEERING L Left-Hand Drive
:
ENGINE SPECIFICATION K DOHC and MF1 or SFI
CAB TYPE
Q
:
G Wagon :
BODY TYPE
'TV
v5>
K
:
vs;
4-Door
MODEL
DESTINATION A U.S.A., Canada :
LINE-UP TRANSMISSION
DRIVE TYPE
ENGINE
GRADE
5-Speed Manual
W59 3RZ-FE
-
5VZ-FE
SR5
3RZ-FE
-
2WD
4WD
R150F
RZN180L-
RZN180L-
GKPSKA
Model
VZN180LRZN185L-
RZN185L-
GKMSKA
GKPSKA
SR5
for U. S. A.
A340F
GKPGKA
VZN185L-
VZN185L-
GKMGKA
GKPGKA VZN185L-
Limited
:
A340E
GKMSKA
5VZ-FE
[=
4-Speed Automatic
and Canada (others
GKPZKA for U. S. A. only). 86821044
Fig.
32 The model code
is
helpful for obtaining the correct part
1-17
GENERAL INFORMATION AND MAINTENANCE
1-18
SERIAL NUMBER IDENTIFICATION Vehicle > See Figures 33, 34, 35, 36 and 37 All
models have the vehicle
on a plate attached
The
plate
is
visible
identification
number stamped
to the left side of the instrument panel.
by looking through the windshield from the
outside. All
trucks
and 4Runner’s also have the VIN stamped into the right front frame rail. The num-
metal of the outer face of the
ber also appears on the Certification Label attached to the
door In
left
pillar.
addition to the instrument panel number,
all
display the VIN on the Certification Label on the
Land Cruisers left
front
door
The 1991-96 Land Cruisers also have the number stamped into the outer face of the right front frame rail. The serial number consists of a series of 17 digits including the six digit serial or production number. The first three digits are the World Manufacturer Identification number. The next five digits are the Vehicle Description Section. The remaining nine digits are the production numbers including various codes on body style, trim level (base, luxury, etc.) and safety equipment post.
or other information.
Engine >
See Figures
38, 39, 40, 41
Each engine
is
and 42
referred to by both
its
family designation,
The serial number can be important when ordering parts. Certain changes may have been made during production of the engine; different the engine was assembled before or parts will be required after the change date. Generally, parts stores and dealers list this data in their catalogs, so have the engine number handy such as 22R-E, and
its
production or serial number.
if
Fig.
35 The VIN locations found on 1989-90 Land
Cruisers
when you go. Refer number location. It’s
to the illustrations to
determine the engine
a good idea to record the engine number while the
vehicle
is
new. Jotting
it
inside the cover of the owner’s
ual or similar easy-to-find location
many years
of
grime
off
will
the engine
man-
prevent having to scrape
when
the
number
is finally
needed.
Transmissions Automatic and manual transmissions are used
in all of
the
Land Cruiser. The Land Cruiser only uses an automatic. The identity of the transmission is on the driver’s trucks excluding the
door tag. You can also obtain the type the model number.
of transmission
from
GENERAL INFORMATION AND MAINTENANCE
Example:
J T
4
R N 8
1
D
_P_
_0^
0
0
0
0 0
1-19
1
Serial Number
[Six characters]
Plant of Manufacture [One character
Vehicle Model Year [One character P:
:
:
]
1993 Model
Check Digit
[One character
]
Vehicle Description Section (VDS) [Five characters ]
Manufacturer.
:
]
Make and Type [Three characters] 86821023
Fig.
37 The serial number on
all
1989-96 models consists of a series of 17 digits
1-20
GENERAL INFORMATION AND MAINTENANCE
VEHICLE IDENTIFICATION CHAftT Engine Code
Code
Liters
Cu. cc.
Cyl.
Model Year Fuel Sys.
Eng. Mfg.
5 th digit
R R U U V V
2.4
(22R-E)
2.4
(2RZ-FE)
2.4
(3RZ-FE)
2.7
(3VZ-E)
3.0
(3VZ-FE)
3.0
2366 2366 2438 2693 2959 2959
4
2
BBL
4
EFI
4
EFi
4
EFI
6
EFI
6
EFI
F (3F-E)
4.0
241
6
EFI
U (5VZ-FE)
3.4
6
EFI
F
4.5
3378 4477
6
EFI
2366 2693 3378 4477
4
EFI
4
EFI
6
EFI
6
EFI
FZ-FE)
Year
10 th digit
(22R)
(1
Code
TMC TMC TMC TMC TMC TMC TMC TMC TMC
K
1989
L
1990
M
1991
N
1992
P R
1994
S T
1993 1995 1996
6 th digit L (2RZ-FE)
2.4
N (3RZ-FE)
2.7
M
(5VZ-FE)
3.4
FZ-FE)
4.5
J
(1
TMC TMC TMC TMC
8BL Carbureted -
EFI
-
TMC
Electronic Fuel Iniected -
Toyota Motor Corporation 86821035
GENERAL INFORMATION AND MAINTENANCE
1-21
1-22
GENERAL INFORMATION AND MAINTENANCE
ENGINE IDENTIFICATION Engine
Year 1989
1990
1991
1992
1993
1994
1995
Model
Displacement
Engine Series
Fuel
No. of
Liters (cc)
(ID/VIN)
System
Cylinders
Type
BBL
4
SOHC SOHC SOHC SOHC SOHC SOHC OHV
4Runner
2.4 (2366)
22R
4Runner
2.4 (2366)
22R-E
EFI
4Runner
3.0 (2959)
3VZ-E
EFI
Pick-up
2.4 (2366)
22R
Pick-up
2.4 (2366)
22R-E
EFI
4
Pick-up
3.0 (2959)
3VZ-FE
EFI
6
Land Cruiser
4.0 (3956)
3F-E
EFI
6
4Runner
2.4 (2366)
22R-E
EFI
4
4Runner
3.0 (2959)
3VZ-E
EFI
6
Pick-up
2.4 (2366)
22R
Pick-up
2.4 (2366)
22R-E
EFI
4
Pick-up
3.0 (2959)
3VZ-FE
EFI
6
Land Cruiser
4.0 (3956)
3F-E
EFI
6
4Runner
2.4 (2366)
22R-E
EFI
4
2
BBL
2
BBL
2
4 6 4
4
4Runner
3.0 (2959)
3VZ-E
EFI
6
Pick-up
2.4 (2366)
22R-E
EFI
4
Pick-up
3.0 (2959)
3VZ-E
EFI
6
Land Cruiser
4.0 (3956)
3F-E
EFI
6
4Runner
2.4 (2366)
22R-E
EFI
4
4Runner
3.0 (2959)
3VZ-FE
EFI
6
Pick-up
2.4 (2366)
22R-E
EFI
4
Pick-up
3.0 (2959)
3VZ-FE
EFI
6
Land Cruiser
4.0 (3956)
3F-E
EFI
6
4Runner
2.4 (2366)
22R-E
EFI
4
4Runner
3.0 (2959)
3VZ-E
EFI
6
Pick-up
2.4 (2366)
22R-E
EFI
4
Pick-up
3.0 (2959)
3VZ-E
EFI
6
T100
3.0 (2959)
3VZ-E
EFI
6
Land Cruiser
4.5 (4477)
1FZ-FE
EFI
6
4Runner
2.4 (2366)
22R-E
EFI
4
4Runner
3.0 (2959)
3VZ-E
EFI
6
Pick-up
2.4 (2366)
22R-E
EFI
4
Pick-up
3.0 (2959)
3VZ-E
EFI
6
T100
2.7 (2693)
3RZ-FE
EFI
4
T100
3.0 (2959)
3VZ-E
EFI
6
Land Cruiser
4.5 (4477)
1FZ-FE
EFI
6
4Runner
2.4 (2366)
22R-E
EFI
4
4Runner
3.0 (2959)
3VZ-E
EFI
6
Pick-up
2.4 (2366)
22R-E
EFI
4
Pick-up
3.0 (2959)
3VZ-E
EFI
6
Tacoma
2.4 (2438)
2RZ-FE
EFI
4
Tacoma
2.7 (2693)
3RZ-FE
EFI
4
Tacoma
3.4 (3378)
5VZ-FE
EFI
6
T100
2.7 (2693)
3RZ-FE
EFI
4
T 1 00
3.4 (3378)
5VZ-FE
EFI
6
Land Cruiser
4.5 (4477)
1FZ-FE
EFI
6
Engine
SOHC SOHC SOHC SOHC SOHC OHV SOHC SOHC SOHC SOHC OHV SOHC SOHC SOHC SOHC OHV
SOHC SOHC SOHC SOHC SOHC DOHC SOHC SOHC SOHC SOHC DOHC SOHC DOHC SOHC SOHC SOHC
SOHC DOHC DOHC DOHC DOHC DOHC DOHC 86821042
GENERAL INFORMATION AND MAINTENANCE
1-23
ENGINE IDENTIFICATION Engine
Model
Year
Engine
Cylinders
Type
DOHC DOHC DOHC DOHC DOHC DOHC DOHC DOHC
2.7 (2693)
3RZ-FE
EFI
4
3.4 (3378)
5VZ-FE
EFI
6
Tacoma
2.4 (2438)
2RZ-FE
EFI
4
Tacoma
2.7 (2693)
3RZ-FE
EFI
4
Tacoma
3.4 (3378)
5VZ-FE
EFI
6
2.7 (2693)
3RZ-FE
EFI
4
T100
3.4 (3378)
5VZ-FE
EFI
6
Land Cruiser
4.5 (4477)
1FZ-FE
EFI
6
Electronic fuel injection
SOHC
-
Single overhead camshaft
DOHC
•
Double overhead camshaft
OHV
No. of
System
Barrel carburetor
-
-
Fuel
(IDA/IN)
4Runner
T100
EFI
Engine Series
Liters (cc)
4Runner
1996
BBL
Displacement
-
Overhead valve 86821043
MANUAL TRANSMISSION CHART Transmission Type
Years
Models
G40
1989-90
Truck
G57
1989-92
G58
1989-96
W46 W55 W56
1989-90
W59
1996
R150
1989-96
R150F
1989-96
Truck Truck, 4Runner,
Tacoma
Truck
1989-95
Truck
1989-96
Truck, 4Runner,
TlOO
Tacomoa, TlOO Truck, 4Runner, Truck, 4Runner,
Tacoma
Tacoma, TlOO 86821045
AUTOMATIC TRANSMISSION CHART Transmission Type
Years
Models
A43D
1989-96
Truck,
A340E
1989-96
Truck, 4Runner, TlOO,
A340F
1989-96
Truck,
4Runner
A340H
1989-95
Truck,
4Runner
A440F
1989-92
Land Cruiser
A442F
1993-95
Land Cruiser
A343F
1996
Land Cruiser
Tacoma Tacoma
86821046
GENERAL INFORMATION AND MAINTENANCE
1-24
ROUTINE MAINTENANCE •
General Information
Seats
— be
aware
of
seat while you’re driving
is
any adjuster problems, a moving dangerous
— are they working properly — check smooth operation pedal — check smooth operation and free-play
• Seat belts
> See Figures 43, 44, 45, 46, 47, 48 and 49
all
• Accelerator pedal
Proper maintenance cle
life.
and
the key to long
is
As a conscientious owner and
trouble-free vehi-
• Clutch
aside a
driver, set
Saturday morning, say once a month, to check or replace items which could cause major problems
personal log to
much
down which
jot
and
Keep
filters,
it-yourselfer,
all
to
literature
was performed. will
In
you no longer have
schedule
is
provided later
have the factory
in this
replacement
A maintenance
of the
— use
either
by your-
•
LOW if
sure the level
between
is
marks
you have a maintenance
battery,
check the
Engine
— have the
fluid levels
near the
levels
the reservoirs
line of
oil
level
— with
the engine
OFF, check
fluid level
•
Power
and
COLD
steering fluid
Exhaust system
— the
level
should be between
— visually check
for cracks,
HOT
holes and in
the
A
tune-up
is
not what
used
it
to
is
also part
be years ago where
you need to replace the spark plugs every 7500 miles (12,000 km).
These days you can replace
the plugs on
some
vehicles
every 48,000 miles (77,000 km) or even 100,000 miles
in
— check the tread
(160,900 km).
depth and
place
r
Air Filter
— rotate every 6200 miles (1000 km) Fluid leaks — check the underneath leaks any kind Doors and the engine hood — check the latches ensuring
• Tire rotation •
—
Battery
fluid level
level
Along with these maintenance items, a tune-up
a gauge to check the pressure
the lug nuts are
all
FULL and
of this.
scheduled maintenance items that
• Tire surfaces and lug nuts
ensure
fluid
exhaust
be checked frequently:
Tire pressure
Engine coolant
•
OUTSIDE THE VEHICLE •
— check the — make
•
loose supports. Be aware of a sudden noise change
a reputable shop, or the Toyota dealer.
to
smooth operation and free-play check for any brake pull
THE ENGINE COMPARTMENT Washer
•
literature.
Here are a few
for
location,
on the dipstick
case you do not
These checks and inspections can be done
need
check
• Brake and clutch
it
section, in
-
•
upper
when was origirecommended maintenance
copies are usually available from the dealer.
a safe
in
electrolyte levels
be invaluable.
this literature,
—
Brakes —
•
of
the event of a
provided with your vehicle
nally delivered includes the factory If
case
these receipts are the only proof you have that
warranty problem, these receipts
schedule.
in
Brake pedal
•
the
determine operating expenses. As a do-
the required maintenance
The
referred to
•
IN
how
receipts for such items as engine
may be
so that they
problems or
related
self
Keep your own
the parts cost you, the date, and the exact odometer
reading at the time. oil
later.
services you performed,
for
for
of
for
REMOVAL & INSTALLATION
they are securing properly
INSIDE THE VEHICLE • Lights •
— make
sure
all
the lights are
Reminder indicators — ensue
all
in
I See Figures 50, 51 and 52
working order
the warning lights and
The air filter element should be replaced at the recommended intervals shown in the Maintenance Intervals chart
buzzers function properly • Horn
— toot the
horn to
make
sure
it
works when needed
Automatic transmission
Engine
oil
fluid
level dipstick
Engine
oil
ftHer
cap
fHter
Clutch
Hmd
reservoir
Power fluid
steering
reservoir
Ignition
Engine coolant reservoir
Fig.
43 View of the engine compartment maintenance components
— 22R-E
shown
coil
GENERAL INFORMATION AND MAINTENANCE Engine Engine
oil
filler
oil
level dipstick
cap
Clutch
fluid
reservoir
Automatic transmission fluid
level dipstick
Battery
Engine coolant reservoir
Windshield washer
fluid
tank
Engine
oil
filter
86821231
Fig.
44 View of the engine compartment maintenance components
Engine
oil
filter
— 3VZ-E
Engine
oil
shown
level dipstick
Automatic transmission fluid
level dipstick
Battery
Power
Fig.
45 View of the engine compartment maintenance components
— 1FZ-FE
steering fluid reservoir
shown
AUTOMATIC TRANSMISSION FLUIO LEVEL OlPSTlCK
CONNECTOR BOX FOR CHECKING ENGINE SYSTEM
ENGINE
OH
LEVEL OlPSTlCK
SPARK PLUGS BRAKE FLUIO RESERVOIR BRAKE BOOSTER
WIN0SHIE10 WASHER FlUIO TANK
ELECTRIC UN0ERH000
COOLING FAN
HEAOllGHT CLEANER FLUIO TANK
ENGINE OIL FILTER
Fig.
46 View of the engine compartment maintenance components
DISTRIBUTOR
— 3F-E
1989-90
shown
1-25
GENERAL INFORMATION AND MAINTENANCE
1-26
Automatic transmission
Engine
oil
Mud
leva! dipstick
level dipstick
Windshield and back r
I
Engine
Engma coolant
reservoir
oil
fdkr
cap
Radiator cap
Engine
oil
filter
Power steermg ftwd
Fig.
window
and headlight cleaner
tank
47 View of the engine compartment maintenance components
reservoir
— 3F-E
1991-92
shown
Windshield washer
fluid
tank
Fuse block
Battery
Engine
Power Engine
oil
filler
oil
level
dipstick
steering fluid reservoir
cap Engine coolant reservoir 86821233
Fig.
48 View of the engine compartment maintenance components
— 3RZ-FE
shown
GENERAL INFORMATION AND MAINTENANCE Windshield washer
fluid
1-27
tank
Fuse block
Battery
Engine coolant reservoir
Power
steering fluid reservoir
/ Engine
oil
level dipstick
86821234
Fig.
49 View of the engine compartment maintenance components
later in this section.
your truck
If
is
operated under severely
— 5VZ-FE On
3.
fuel injected engines, simply release the clips holding
dusty conditions or severe operating conditions, more frequent
the top of the
changes
clips
certainly
will
be necessary. Inspect the element
least twice a year. Early spring
times for inspection.
Remove
perforations or tears
in
signs of
dirt
element or
one side If
in
signs of
dirt
fall
are always good
Check the cleaner housing
filter.
may have
leaked through the
element and look through the
of light
replace the
early
the element and check for any
through the snorkel tube. Shine a bright
of the
no glow
the
or dust that
and
filter.
at
filter
light
for
holes
in
the
filter
seepage through the
at the light.
element are apparent or
filter
box and
air in
are evident, replace the
Disconnect
hoses, ducts and
all
would block removal For round
2.
air
vacuum tubes which
of the top of the air cleaner
assembly.
cleaner housings, remove the top cover
wing nut and grommet,
if
present. Most models
will
Remove
the
bly.
Pull the wire tab lift
out the
filter
and release the
clip.
Remove
lid.
Note that some of these
filter
clips.
element. Clean or replace as needed.
Wipe clean all surfaces of the air cleaner housing and cover. Check the condition of the mounting gasket and replace it
the cover
To
install:
Reposition the
5.
filter
element
in
the case and
install
cover, being careful not to overtighten the wingnut(s).
the
On
round-style cleaners (carbureted engines), be certain that the
The and
of the air
lid fit
lid
and the snorkel match up
snugly. Air leaks around the top can
bypass the
filter
»»Filter
properly.
cleaner housing must be correctly installed
and allow
dirt into
cause
air to
the engine.
fuel injected engines have a TOP and be sure they are inserted correctly.
elements on
BOTTOM
side,
element.
86821050
Fig.
if
appears worn or broken.
also use
three or four side clips to further secure the top of the assem-
and
the
ponents; don’t pry or force the
arrows on the cover
filter.
1.
lift
close quarters against bodywork or other com-
it
on
can be seen through the element material, If
may be
4.
filter
shown
50 Release the clips securing the
lid
.
.
.
86821051
Fig. 51
.
.
.
then
lift
the
lid
and remove the
filter
1-28
GENERAL INFORMATION AND MAINTENANCE
86821052
Fig.
52 Exploded view of a
common
air
cleaner assembly found on Toyota trucks
GENERAL INFORMATION AND MAINTENANCE Connect
6.
•Never
hoses, duct work and
all
vacuum
operate the engine without the
Fuel Injected Engines
lines.
air filter
1-29
element
in
place.
> See Figures 54, 55 and 56
The which
fuel filters is
located
on injected engines are a metal cylinder the rear frame
in
under You may find models. Each model varies. partment.
Fuel Filter
1.
it
fuel
or
in
the engine
com-
some
Unbolt the retaining screws and remove the protective
shield from the fuel 2.
rail
the injection manifold on
filter.
Place a pan under the delivery pipe to catch the dripping
and
pressure.
SLOWLY The
fuel
loosen the union bolt to bleed
system
is
off
the fuel
under pressure. Release pressure
slowly and contain spillage. Observe ‘”no smoking/no open
Never smoke when working around or near gasoline. Make sure that there are no active ignition sources (heaters,
motors or fans, welders, anything with sparks or open flame.) in the area. Have a fire extinguisher within electric
arm’s reach at
all
times.
Carbureted Engines > See Figure 53
The rail,
for the fuel.
near the
1.
on carbureted engines
fuel filter
two ports
filter,
2.
pull
slide the
3.
in
the
Pull the filter
install:
4.
Install
the
filter
from the
new
filter
clip
twist
to
and discard.
The arrow must
filter
point
pipes, then slide the
into position.
Start the
them gently
to the carburetor.
Push the hoses onto the
clamps back
down the hose, Remove the
pipe.
into the clip.
towards the hose that runs
6.
further
pipe extends.
same manner.
free from the
To
5.
clamp
filter
Grasp the hoses near the ends and
them
a plastic cylinder with
expand the hose clamp on one
of pliers,
and
past the point to which the other clamp
is
usually located on right rear frame
is
fuel tank.
Using a pair
side of the
It
engine and check
for leaks.
flame precautions”. 3.
Remove
4.
Disconnect and plug the
5.
Unbolt and remove the fuel
the union bolt
and drain the remaining inlet line. filter.
fuel.
GENERAL INFORMATION AND MAINTENANCE
1-30
Cap Gasket
Fuel
REMOVAL & INSTALLATION I
See Figure 57 vehicles require the replacement of the fuel
All
gasket at 60,000
tniles
filler
(96,558 km). The gasket
cap
important
is
in
neck and keeping the vapors from the tank routed through the vapor emission system. On 1989 Land
sealing the
filler
Cruisers the gasket
is
retaining plate which
held
in
with 4 small screws
must be removed. The
later
and a models
nate the screws and retainer; gently pry the gasket
your fingers or a it
is
^•When
the
new gasket and make
filter,
you
must use a torque wrench. The tightening torque is very important, as under or over tightening may cause fuel leakage. Insure that there is no fuel line interference and that there is sufficient space between the fuel lines and other components.
certain
Valve
See Figure 58 The PCV valve regulates crankcase
tightening the fuel line bolts to the fuel
elimi-
with
not twisted or crimped.
PCV >
tool. Install
off
ventilation during various
engine operating conditions. At high vacuum partial load throttle)
it
range)
will
open
it
will
fully.
open
slightly
and
at
(idle
speed and
low vacuum
(full
This causes vapor to be removed
from the crankcase by the engine vacuum and then sucked into the
combustion chamber where
it
is
burned alonq with the
fuel.
6.
Coat the
engine
22
Hand-tighten the
8.
Install
9.
lbs.
the fuel
inlet line to
filter
and then
threads with
the fuel
filter.
tighten the inlet line nut to
Reconnect the delivery pipe using new gaskets and then
Run
22
ft.
lbs.
*-The PCV system will not function properly unless the oil cap is tightly sealed. Check the gasket on the cap and be certain it is not leaking. Replace the cap or gasket or both
if
necessary to ensure proper sealing.
(29 Nm).
REMOVAL & INSTALLATION
the engine for a short period and check for any fuel
> See Figures 59 and 60
leaks. 11.
bolt
(29 Nm).
tighten the union bolt to 10.
all
filler
7.
ft.
union nut and
flare unit,
oil.
Install
the protective shield. 1.
ging.
Check
the ventilation hoses and lines for leaks or clog-
Clean or replace as necessary.
86821062
Fig.
57 A seal pick can be used to remove the cap
gasket
GENERAL INFORMATION AND MAINTENANCE
1-31
Normal Operation
Engine not Running or Backfiring Intake Manifold Side
oPCV VALVE
IS
OPCV VALVE IS OPEN. OVACUUM PASSAGE IS LARGE
CLOSED.
Cylinder Head Side Acceleration of Heavy Load
Idling or Decelerating
OPCV VALVE IS OPEN OVACUUM PASSAGE IS SMALL
Fig.
58 The
Locate the
2.
remove
it
FULLY
valve regulates crankcase ventilation according to engine running conditions
PCV
by pulling
IS
it
valve
in
the cylinder head cover and
upward.
Test the valve by attaching a clean tube to the crank-
3.
case end free
PCV
oPCV VALVE OPEN
of the valve, then
passage
4.
Move
of air
blow through
it.
There should be
through the valve.
the tube to the other end of the valve. Blow into
the tube. There should be
little
or
no passage
of air
through
the valve. 5.
If
checks, 6.
To 7.
the it
PCV
will
Pull the
valve failed either of the preceding two
require replacement.
PCV
valve
off
the hose.
install:
Slip the
hose back onto the proper end
of the
PCV
valve. 8.
Press the valve
into the retaining
grommet
in
the cylin-
der head cover. 86821071
Fig.
59 Locate the
and remove
it
PCV
valve
by pulling
it
in
the cylinder head cover
upward
GENERAL INFORMATION AND MAINTENANCE
1-32
is
simply the reverse of the removal process. To check the
canister:
vacuum lines leading to the vacuum lines attached to
1.
Label the
2.
Remove
3.
Unfasten the retaining bolts from the canister.
4.
Lift
the
the canister up and
canister.
the canister.
remove the lower hose attached
to the unit. 5.
Inspect the case for any cracking or
damage.
6.
Using low pressure compressed
blow
pipe (flanged end) and check that
air
air,
into the
tank
flows freely from the
other ports.
Blow
into the purge pipe (next to tank pipe) and check does not flow from the other ports. If air does flow, the check valve has failed and the canister must bp replaced. 8. Never attempt to flush the canister with fluid or solvent. 7.
that air
Low pressure
air
43
psi
(294 kPa)
maximum may be used to When applying the
evaporate any vapors within the canister. 86821072
Fig.
60 Pull the
PCV
air,
hold a finger over the purge pipe to force
all
the air out
the bottom port.
valve off the hose
Evaporative Canister (Charcoal Canister)
SERVICING > See Figures 61, 62, 63, 64, 65 and 66
The
canister cycles the fuel vapor from the fuel tank and,
carbureted, the carburetor float fold
and eventually
chambers
into the cylinders for
if
into the intake
mani-
combustion. The
acti-
vated charcoal element within the canister acts as a storage device
for the fuel
vapors
at
when
times
the engine operating
conditions do not allow efficient burning of the vapors.
The only
required service for the canister
intervals specified in the
section.
If
is
Maintenance Chart
the charcoal element
is
inspection at the
at the
end
of this
saturated (possibly from
carburetor flooding), the entire canister
will
require replace-
86821076
ment. Label and disconnect the canister purge hoses, loosen Fig.
the retaining bracket bolt(s) and
lift
62 Label the vacuum lines leading to the canister
out the canister. Installation
86821077
86821075
Fig. 61
The evaporative canister also known as the
charcoal canister
Fig.
63
canister
Remove
the
vacuum
lines attached to the
GENERAL INFORMATION AND MAINTENANCE No carbon should come
9.
Loose charcoal
is
out of the
filter
a sign of internal failure
at
1-33
any time.
the canister.
in
Battery
GENERAL MAINTENANCE All
batteries, regardless of type, should
by a battery hold-down device. terminals or casing
may
A
leaking corrosive acid can also eat
86821078
Fig.
64 Unfasten the retaining bolts from the canister
A
battery that
is
ically for electrolyte level.
it
is
not secured
discharge faster; such
away components under
not sealed must be checked period-
You cannot add water
maintenance-free battery (though not .
done, the battery
battery which
allow acid to leak out, making
the hood.
be carefully secured
this is not
crack from stress applied to the bat-
tery during vehicle operation.
may
If
to a sealed
maintenance-free bat-
all
.
teries are sealed), but for
a sealed battery must also be checked
proper electrolyte level as indicated by the color of the
built-in
hydrometer “eye.”
Keep
the top of the battery clean, as a film of
completely discharge a battery that ods.
A
solution of baking
can
dirt
not used for long peri-
is
soda and water may be used
for
DO
cleaning, but be careful to flush this off with clear water.
NOT
let
any
of the solution into the
neutralizes battery acid
and
will
filler
holes. Baking
de-activate a battery
soda
cell.
•-CAUTION Always use caution when working on or near the battery. Never allow a tool to bridge the gap between the negative and positive battery terminals. Also, be careful not to allow a tool to provide a ground between the positive cable/terminal and any metal component on the vehicle. Either of these conditions will cause a short circuit leading to sparks and possible personal injury. 86821079
Fig.
65
... then
lift
the canister up and
lower hose attached to the unit
remove the
Batteries
basis can
vehicles' which are not operated
in
on a regular
victim to parasitic loads (small current drains
fall
which are constantly drawing current from the parasitic loads
may
battery).
on a vehicle that
drain a battery
is
Normal in
storage and not used for 6-8 weeks. Vehicles that have additional
accessories such as a cellular phone, an alarm system
or other devices that increase parasitic load
battery sooner.
If
the vehicle
is
to
be stored
secure area and the alarm system,
if
may
present,
sary, the negative battery cable should
discharge a
for 6-8 is
weeks
be disconnected
Remember
that constantly discharging life.
Take care
needlessly discharged.
a
at the
onset of storage to protect the battery charge.
shorten battery
in
not neces-
and recharging
not to allow a battery to
will
be
GENERAL INFORMATION AND MAINTENANCE
1-34
BATTERY FLUID
should require
> See Figures 67, 68 and 69
Fluid Level
Check the battery electrolyte level at least once a month, or more often in hot weather or during periods of extended vehi-
^CAUTION Battery electrolyte contains sulfuric acid.
If
you should
checked
medical help immediately.
level in
in
fluid (sulfuric
acid solution) contained
you many things about the condition
Because the fluid level in
cell
plates
in
must be kept submerged below the
order to operate, maintaining the
fluid level is
extremely important. And, because the specific gravity of the acid
is
an
be an aid battery
in
indication of electrical charge, testing the fluid in
determining
if
the battery must be replaced.
can
cell
caps on opaque-cased
types.
cell
should be kept
the
If
or the line
cell,
the level
low,
is
ing until the level
is
can be
The
electrolyte
inside
split ring
marked on the outside of the case. add only distilled water through the opencorrect. Each cell is separate from the individually. Dis-
filled
water should be used, because the chemicals and miner-
tilled
als found
most drinking water are harmful
in
could significantly shorten If
filled to
each must be checked and
others, so
A
a vehicle with a properly operating charging system
level
case on translucent batteries or by
each
the battery cells
of the battery.
non-sealed batteries, the
either through the
removing the
each
The
On
cle operation.
your eyes, flush the affected area with plenty of clear water. If it lands in your eyes, get
splash any on your skin or
will tell
maintenance, but careful, periodic inspec-
little
should reveal problems before they leave you stranded.
tion
water
added
is
its
to the battery
and
life.
freezing weather, the vehicle should be
in
driven several miles to allow the water to mix with the electro-
Otherwise, the battery could freeze.
lyte.
Although
some maintenance-free
cell
caps
for
access
and
level
on
all
have removable
batteries
to the electrolyte, the electrolyte condition
sealed maintenance-free batteries must be
checked using the
hydrometer “eye.” The exact type
built-in
of
eye varies between battery manufacturers, but most apply a sticker to the battery itself explaining the possible readings.
When
doubt, refer to the battery manufacturer’s instructions
in
hydrometer.
to interpret battery condition using the built-in
••Although the readings from in
sealed batteries
may
hydrometers found
built-in
vary, a green eye usually indicates
A
a properly charged battery with sufficient fluid level.
dark eye
normally an indicator of a battery with
is
one which may be low
cient fluid, but light or
yellow eye
is
charge.
in
And
a
usually an indication that electrolyte
supply has dropped below the necessary (and hydrometer) operation. teries with
suffi-
an insufficient electrolyte
level for battery
case, sealed bat-
In this last
must usually be
level
discarded. Specific Gravity
As level
stated earlier, the specific gravity of a battery’s electrolyte
can be used as an indication
once a year, check the be between
1
and
.20
1
of battery charge. At least
specific gravity of the battery.
.26
should
It
on the gravity scale. Most auto
supply stores carry a variety of inexpensive battery testing
hydrometers. These can be used on any non-sealed battery to test the specific gravity in
The
end and a nozzle into the
cell.
gravity
is
until
the float
is
lifted
in
one or more
cells,
up. Generally,
tween any two battery should
its
seat.
The
if
float.
the battery should be
slowly charged and checked again to see
come
from
one
at
sucked
then read by noting the position of the
is
low
squeeze bulb
at the other. Battery electrolyte is
hydrometer
specific gravity If
each
battery testing hydrometer has a
if
the’ gravity
has
after charging, the specific gravity be-
cells varies
more than 50
be replaced as
it
points (0.50), the
can no longer produce
suffi-
cient voltage to guarantee proper operation.
On of
sealed batteries, the
checking specific
manufacturer readings.
for
built-in
gravity. Again,
hydrometer
is
the only
check with your
proper interpretation of
its
built-in
way
battery’s
hydrometer
GENERAL INFORMATION AND MAINTENANCE
BATTERY TOP
1-35
BATTERY TOP
BATTERY TOP
OR BRIGHT ii
MAT
i
BE
JUMP STARTED
INOCATOR.
NO OREEN DOT do NOT JUMP START
of the charge Indicator on top of the battery before attempting a jump atari; If It’s not green or dark, do not jump start the car
Ch*ck the appearance
tccsl253
Fig.
69
A
hydrometer
typical sealed (maintenance-free) battery with a built-in
between battery manufacturers; always
— NOTE that the
hydrometer eye may vary
refer to the battery’s label
CABLES See Figures
70, 71, 72, 73,
Once a year
(or
I
74 and 75
as necessary), the battery terminals and the
cable clamps should be cleaned. Loosen the clamps and
move on
the cables, negative cable
top, the
use of a
re-
On batteries with posts made for this purpose is
first.
puller specially
recommended. These are inexpensive and
available
in
most
auto parts stores. Side terminal battery cables are secured with a small bolt.
Clean the cable clamps and the battery terminal with a wire brush,
metal
until all is
shiny.
corrosion, grease, etc., It
is
is
removed and the
especially important to clean the inside of
the clamp (an old knife
is
useful here) thoroughly, since a
small deposit of foreign material or oxidation there
a sound electrical connection and
will
prevent tecs 1207
inhibit either starting or
The underside
charging. Special tools are available for cleaning these parts,
Fig. 71
one type
wire brush to clean post terminals
for
conventional top post batteries and another type
of this special battery tool
has a
for side terminal batteries.
tecs 1206
Fig. 70 Maintenance is performed with household items and with special tools like this post cleaner
tecs 1208
Fig.
72 Place the tool over the terminals and twist to
clean the post
GENERAL INFORMATION AND MAINTENANCE
1-36
Fig.
73 A special tool
is
available to pull the
clamp
from the post
^CAUTION The chemical reaction which takes place in all batteries generates explosive hydrogen gas. A spark can cause the battery to explode and splash acid. To avoid serious personal injury, be sure there is proper ventilation and take appropriate
fire
safety precautions
when connecting, diswhen using jumper
connecting, or charging a battery and cables.
A
battery should be charged at a slow rate to
plates inside from getting too hot. However,
if
nance-free batteries are allowed to discharge
almost “dead,” they Fig.
74 Clean the battery terminals
until
the metal
bring
is
Before
installing the cables,
loosen the battery hold-down
remove the battery and check the battery tray. Clear of any debris, and check for soundness (the battery tray can be cleaned with a baking soda and water solution). Rust should be wire brushed away, and the metal given a couple coats of anti-rust paint. Install the battery and tighten the hold-down clamp or strap securely. Do not overtighten, as clamp or
may have
to “life.”
turer’s instructions
shiny
to
be charged
until
at
mainte-
they are
a high rate to
Always follow the charger manufac-
on charging the
battery.
REPLACEMENT
strap,
it
it
this
them back
keep the
some
can crack the battery case.
After the
last;
it
reinstall
DO NOT hammer
becomes necessary
installed. Deterioration
cables, starter motor, in
the clamps onto
and just plain aging of the battery and associated wires makes the battery’s
successive years. The slow increase
resistance over time
the
to replace the battery, select
with a rating equal to or greater than the battery originally
job harder
clamps and terminals are clean,
cables, negative cable
When one
makes
it
prudent to
install
in electrical
a new battery
with a greater capacity than the old.
post batteries. Tighten the clamps securely, but do not distort
them. Give the clamps and terminals a thin external coating of
grease
Heat Insulator
after installation, to retard corrosion.
Check the cables cleaned.
If
at the
same
the cable insulation
is
time that the terminals are
cracked or broken, or
if
the
SERVICING
ends are frayed, the cable should be replaced with a new cable of the
same
length
and gauge. >
See Figure 76 The
fold
or heat insulator
and
sensor
is
is
the covering over the exhaust mani-
secured by three or four
electrical
connection
if
bolts.
Remove
the
02
equipped. Unfasten the bolts
GENERAL INFORMATION AND MAINTENANCE Remove any gasket
securing the insulator to the manifold. material
and check the
a new gasket
Install
1-37
insulator for leaks, cracks or corrosion.
to the manifold,
then attach the insulator.
Tighten the mounting bolts as folldws: • • •
—
71 inch lbs. (8 Nm) 5VZ-FE engines 48 inch 2RZ-FE and 3RZ-FE engines 14 ft. lbs. 22R-E and 1FZ-FE engines
—
—
Check the
condition of the drive belts
Nm) Nm)
lbs. (6
(19
and check the
belt
tension at least every 15,000 miles (24,000 km). Inspect the belts for signs of glazing or cracking.
perfectly
slight texture of fabric visible.
inner first
A
glazed belt
smooth from slippage, while a good
edge
of the belt
Cracks
will
will
generally start at the
and run outward. Replace the
sign of cracking or
if
the glazing
is
be
have a
belt will
belt at the
severe.
Belt tension does not refer to play or droop. By placing your should be possible thumb midway between the two pulleys, to depress the belt V4-V2 in. (6-1 3mm). If any of the belts can it
be depressed more than
this,
or cannot be
much, adjust the tension. While
this is
depressed
an inaccurate
provides a quick reference. Inadequate tension sult in
will
slippage or wear, while excessive tension
pulley bearings
should be just
this
test,
always
will
it
re-
damage
and cause belts to fray and crack. A belt enough to perform without slipping or
tight
squealing. Its
not a
bad idea
to replace
all
drive belts at 60,000 miles
(96,000 km) regardless of their condition.
ADJUSTMENT tccsl214
I
See Figure 82 Fig.
Toyota measures
mined by a
pounds of force as deterThe Nippondenso and Bur-
belt tension in
belt tension tester.
78 An example of a healthy drive belt
GENERAL INFORMATION AND MAINTENANCE
1-38
80 The cover of this belt
Fig.
is
worn exposing the
cords to excessive wear
critical reinforcing
3VZ-E Engine • lbs.
•
Alternator:
(136
Power
lbs.
ft.
•
(108
Steering:
ft.
lbs.
(108
New
— 125
New
— 125
Nm)
Air Conditioning:
lbs.
ft.
— 160
New
(217
Nm) Used
— 100
ft.
Nm) ft.
ft.
lbs.
lbs.
(169
Nm) Used
— 80
(169
Nm) Used
— 80
Nm)
5VZ-E Engine • lbs.
•
•
100
— 160
New
(140
Steering:
lbs.
(217
Nm) Used
— 100
(136
lbs.
New
— 158
New
— 160
ft.
lbs.
ft.
(214
Nm) Used
— 103
(217
Nm) Used
—
Nm)
Air Conditioning: ft.
ft.
Nm)
Power
lbs.
ft.
/
Alternator:
(136
ft.
lbs.
Nm)
tccsl217
2RZ-FE and 3RZ-FE Engines Fig. 81
Too wide a
belt’s side
as well
on a narrow pulley can groove as damage the cover and seat belt
• Alternator: lbs.
roughs testers are available through dealers or
may be
setting tension
and purchase
of this tool or
its
equivalent
is
recommended.
new
Specifications for
A new
belts.
for
belt is
belts are slightly higher than for
is
a used
•
100
• Alternator with air
—
ft.
lbs.
(108
ft.
lbs.
(108
Steering:
ft.
lbs.
(108
Steering:
Air Conditioning: ft.
(136
lbs.
New
— 125
ft.
lbs.
— 125
New
— 125
ft.
lbs.
• lbs.
lbs.
— 158
New
— 160
ft.
lbs.
Nm) Used
ft.
lbs.
Nm)
(169
Nm) Used
— 80
(169
Nm) Used
— 80
ft.
(214
Nm) Used
— 103
(217
Nm) Used
—
Alternator:
(136
— 145
New
ft.
lbs.
(196
Nm)
Nm) Used
— 100
— 145
lbs.
ft.
—
(169
— 115
Nm)
Power Steering and air pump: New Nm) Used 100 ft. lbs. (136 Nm) lbs.
ft.
(108
New
— 125
ft.
lbs.
(169
ft.
(196
Nm) Used
— 80
Nm)
1FZ-FE Engine •
ft.
New
(224
•
belt.
Nm)
New
lbs.
Nm)
• Air conditioning:
pump:
Nm)
• Air Conditioning:
(140
ft.
3F-E Engine
22R and 22R-E Engines
Used 80 • Power
— 165
New
Nm)
Power
lbs.
ft.
used
one which has not been run under tension
more than 5 minutes. Anything else
•
found
The tester slips over a short section of the drive belt, and, when tightened, reads the deflection pressure on a dial. This is one of the most exact ways of at retail auto parts stores.
(156
(91
Nm)
Alternator:
New
— 110
Nm)
• Air Conditioning: ft.
lbs.
(108 Nm)
New
ft.
lbs.
— 125
(149
ft.
lbs.
Nm) Used (169
— 67
Nm) Used
ft.
lbs.
— 80
GENERAL INFORMATION AND MAINTENANCE REMOVAL a INSTALLATION >
See Figures
When critical
83, 84, 85, 86,
buying replacement
87 and 88
remember
belts,
width of the
V shape. The
shape
of the pulley; belts that are not
belt
shape should exactly match the
cause noise, slippage and premature a
an exact match can failure.
must be replaced, the driven
belt
and moved it
is
fit
the depth of the belt and the angle or profile
belt,
of the
If
that the
according to the length of the belt (“diameter”), the
to
extreme loosest
its
unit
must be loosened
position, generally
by moving
toward the center of the motor. After removing the old
check the pulleys
for dirt or built-up material
belt,
which could affect
new belt, remembering that may appear to be just a little too small
belt contact. Carefully install the is
to
new and
unused-it
over the pulley flanges.
fit
the belt over the largest pulley (usually the crankshaft
Fit
pulley at the bottom center of the motor)
the smaller one(s). Gentle pressure is
it
Some
helpful.
belts run
acts as an additional pivot
around a
are changing,
it
then work on
first,
the direction of rotation
which
third or idler pulley,
the belt’s path.
in
It
may be
possi-
as well as the main component,
ble to loosen the idler pulley
making your job much
in
Depending on which
easier.
may be necessary
to
interfering belts to get at the one(s)
belt(s)
1FZFE
you
loosen or remove other
you want.
new belt is installed, draw tension on by moving away from the motor and tighten its mounting bolts. This is sometimes a three or four-handed job; you may find an assistant helpful. Make sure that all the bolts you After the
it
the driven unit
loosened get re-tightened and that any other loosened belts
A new
also have the correct tension. stretch
new
a
belt,
if
belt
can be expected
so be prepared
bit after installation
needed, within the
first
to re-adjust
to
your
hundred miles/kilometers
of
use.
Fig.
86 Belt routings on the 1FZ-FE engine
VP
Van° Pump
AL CK
Alternator
CC CORRECT
WRONG
WRONG
Cranksha^ Cooler Compressor
IP
Idle Pulley
WP
Water Pump
AP
Air
Pump 86821126
Fig.
83
When
installing a
new
or used belt,
certain the belt is installed in the
make
grooves correctly
Fig.
84 Listing of pulley abbreviations
1-39
GENERAL INFORMATION AND MAINTENANCE
1-40
Fig.
88 Belt routings on the 3VZ-FE and 5VZ-FE
engines
Timing Belts INSPECTION >
See Figures
89, 90, 91, 92,
93 and 94
Toyota recommends that the timing cles that are
used
in
extensive
be replaced on vehi-
belt
idling or
low speed driving for
long distances. Police, taxi and door-to-door deliveries are
commonly used
manner. The timing
in this
replaced every 60,000 miles (96,000 km)
in
belt
should be
these cases.
Toyota trucks do not have interference engines; where engine
damage
will
milage, you
occur
if
the belt snaps.
may want
to
the possibility of having
it
If
your vehicle has high
consider replacing the belt to prevent snap. Or
if
your engine
overhauled, inspect the belt for wear and replace
is if
being
needed.
In
the event the belt does snap while you are driving, turn the
engine tion
OFF
immediately. Section 3 has removal and installa-
procedures available.
GENERAL INFORMATION AND MAINTENANCE
1-41
Hoses See Figures
I
95, 96,
Upper and lower
97 and 98
radiator
hoses along with the heater hoses
should be checked for deterioration, leaks and loose hose
clamps
every 15,000 miles (24,000 km).
at least
check the hoses periodically
to
beginning of the
maintenance.
A
fall
or winter
Whenever you
left
you stranded
is
if
it
also wise
of the
when squeezing
had
make sure
re-
the en-
cold. Visually inspect for cracking,
collapsed hoses, replace as necessary.
hand along the length noted
is
at the
are performing other
are checking the hoses,
gine and cooling system
is
when you
It
and
early spring
quick visual inspection could discover a weak-
ened hose which might have mained unrepaired.
rotting or
in
hose.
If
a
weak
Run your
or swollen spot
the hose wall, the hose should be
replaced.
REMOVAL & INSTALLATION >
See Figures
99, 100, 101, 102, 103
and 104
•-CAUTION Never remove the pressure cap while the engine is running or personal injury from scalding hot coolant or steam may result. If possible, wait until the engine has cooled to remove the pressure cap. If this is not possible, wrap a thick cloth
around the pressure cap and turn
the stop. Step back while the pressure
When you
the cooling system.
has been released,
still
is
are sure
it
slowly to
released from
all
the pressure
using the cloth, turn and remove
the cap.
1.
Remove
2.
Position a clean container under the radiator and/or en-
the radiator pressure cap.
gine petcock or plug, then open the drain and allow the cooling
system
to drain to
hoses only a
little
an appropriate
level.
coolant must be drained.
For
some upper
To remove hoses
tecs 12 19
Fig.
95 The cracks developing along this hose are a age and hardening
result of
1-42
GENERAL INFORMATION AND MAINTENANCE
tecs 1220
96 A hose clamp that is too hoses to separate and tear Fig.
tight
can cause older
Fig.
99
When
the engine
is
cool,
remove the
radiator
cap positioned lower on the engine, such as a lower radiator hose, the entire cooling system must be emptied.
**CAUTION When
draining coolant, keep in mind that cats and dogs
are attracted by ethylene glycol antifreeze, likely to drink in
any that
puddles on the ground. This
quantity.
Always drain coolant
Coolant
may be reused unless
eral
will
prove
fatal in sufficient
into a sealable container. it
is
contaminated or sev-
years old.
3.
Loosen the hose clamps
ing replacement.
Clamps are
at
or of the
each end
Fig.
97 Check for
soft,
spongy hoses like this is hose will eventually burst
— this
requir-
squeeze the tabs and loosen)
screw tension type (which require screw or hex
ers to loosen). Pull the clamps back on the hose
(swollen at the clamp)
hose
of the
usually either of the spring ten-
sion type (which require pliers to tccal221
and are quite
an uncovered container or
is left in
driv-
away from
the connection.
86821111
Fig. 98 Debris or contaminants in the cooling system can cause a hose to weaken from the inside out
Fig.
100 Attach a short length of hose to the petcock
before loosening the nut
GENERAL INFORMATION AND MAINTENANCE
1-43
86821112
Fig. 101
Using a pair of
pliers,
squeeze the tabs to
loosen the upper hose
10.
Twist, pull
4.
damage
not to
hose
and
slide the
the neck of the
the
fitting
hose
is
an
To
taking care
component from which the
stuck at the connection, do not try to
of
effort to free
it,
as the connection and/or hose
may
especially
the hose
is
installation.
7.
a clamp shows signs of any
If
thumb
Slide the
deep so as to prevent damaging the connection. The hose can then be peeled from the connection and
8.
Position
the raised 9.
tem
hose clamps and replace them,
if
necessary.
damage (bent, too loose, now is the time to replace A good rule a new hose is always worth new clamps. it.
If
of the hose.
bead
slide the
into position.
and secure the clamps
Make sure
at least ’A
(6.35mm)
in.
they are located inside
of the connector.
Reinstall the petcock
and properly
refill
the cooling sys-
with the clean drained engine coolant or a suitable mixture
ethylene glycol coolant and water. If
Clean both hose mounting connections. Inspect the con-
clean engine coolant
clamps over the replacement hose, then
from the ends
of
discarded.
dition -of the
that
into
etc.)
hose ends over the connections
cut
5.
is
to
be replaced, use a single-edged razor blade to make a slice along the portion of the hose which is stuck on the connection, perpendicular to the end of the hose. Do not
new hose
ease
hard to tighten,
sharp tool under the hose
may become damaged. Heater connections be easily damaged by such a procedure. If
install:
Dip the ends of the
6.
to
insert a screwdriver or other in
off
being removed.
is
**lf the
end
hose
available, install a pressure tester
a pressure tester
is
and check
not available, run the engine
for leaks.
until
normal
GENERAL INFORMATION AND MAINTENANCE
1-44
operating temperature rally
is
reached (allowing the system
check
pressurize), then
to natu-
for leaks.
**CAUTION If
you are checking
for leaks with the
system
at
normal
BE EXTREMELY CAREFUL not to hot engine parts. Once temperature
operating temperature,
touch any moving or
has been reached, shut the engine OFF, and check for leaks around the hose fittings and connections which were
removed
earlier.
CV-Boots INSPECTION I See Figures 105 and 106
The CV (Constant
be checked changed and any other time the vehicle is raised for service. These boots keep water, grime, dirt and other damaging matter from entering the CVjoints. Any of these could cause early CV-joint failure which can be expensive to repair. Heavy grease thrown around the inside of the front wheel(s) and on the brake caliper can be an for
damage each
Velocity) boots should should
time the
indication of a torn boot. ing
clamps and
tears.
If
oil
is
Thoroughly check the boots the boot
is
damaged, have
for miss-
it
replaced
two electrodes (measured
in
dredths of a millimeter)
called the spark plug gap.
The spark plug does
is
thousandths of an inch or hun-
not produce a spark but instead pro-
duces anywhere from 20,000
to
coil pro-
50,000 volts (depending on
the type and application) which travels through the wires to the
spark plugs. The current passes along the center electrode
and jumps the gap
to the side electrode,
and
in
doing so,
combustion chamber.
ignites the air/fuel mixture in the
immediately.
The
vides a gap across which the current can arc.
SPARK PLUG HEAT RANGE
Spark Plugs > See Figure 107
» See Figure 108
A
typical
ceramic
spark plug consists of a metal shell surrounding a
insulator.
A
metal electrode extends downward through
the center of the insulator
Located
at the
end
outer metal shell
bends
in at
is
and protrudes a small distance.
of the plug
and attached
the side electrode.
a 90° angle so that
its
to the tip of the center electrode.
The
to the side of the
side electrode
tip is just
past and parallel
The distance between these
Spark plug heat range heat.
The longer the
engine), the hotter the plug
Fig.
105 CV-Boots must be inspected periodically for
damage
the ability of the plug to dissipate
will
extends
it
the cooler
it
operate.
will
remains too cool it
is
will
A
plug that absorbs
little
enough
to
burn them
off.
passages)
heat and
quickly accumulate deposits of
not hot
into the
operate; the shorter the insula-
tor (the closer the electrode is to the block’s cooling
carbon since
TCCS101
is
insulator (or the farther
oil
and
This leads
GENERAL INFORMATION AND MAINTENANCE Disconnect the negative battery cable, and
1.
has been run
THE SHORTER THE PATH THE FASTER THE HEAT IS DISSIPATED ANO THE COOLER THE PLUG
recently, allow the
engine
to
1-45 the vehicle
if
thoroughly cool.
Carefully twist the spark plug wire boot to loosen
2.
pull
upward and remove the boot from the
pull
on the boot and not on the Using compressed
3.
wire, otherwise the
may become
located inside the boot
then
it,
Be sure
plug.
to
connector
separated.
blow any water or debris from the
air,
spark plug well to assure that no harmful contaminants are allowed to enter the combustion chamber is
removed.
compressed
If
when
the spark plug
not available, use a rag or a
air is
brush to clean the area.
(Remove HEAVY LOADS HIGH SPEEDS
the plugs
when the engine damage to the threads.
the spark plugs
possible, to prevent
is If
cold,
if
removal of
apply a few drops of penetrating
is difficult,
oil
or silicone spray to the area around the base of the plug,
Short Insulator Tip Fast Heat Transfer
LOWER
and allow
Heat Range
Using a spark plug socket that
4.
COLO PLUG
few minutes to work.
a
it
equipped with a rubber
is
spark plug counter-
insert to properly hold the plug, turn the
clockwise to loosen and remove the spark plug from the bore.
WARNING Be sure not
use a
to
plied to the plug.
extension on the socket. Use
flexible
may
of a flexible extension
A shear
allow a shear force to be ap-
force could break the plug off
in
the cylinder head, leading to costly and frustrating repairs.
To
install:
Inspect the spark plug boot for tears or
5.
damaged boot
SHORT TRIP STOP-AND-GO
LONG Slo
See Figures 118 and 119 Every 36,000 miles (58,000 km) or so, the resistance of the
wires should be checked with an sive resistance will difficult to start in
the cables
To check
is
cause
damp
ohmmeter. Wires with exces-
misfiring,
and may make the engine
weather. Generally, the useful
life
of
36,000-50,000 miles (58,000-80,000 km).
86821151
remove the distributor cap, leaving the wires attached to the cap but removing them from the spark plugs. Look at each contact inside the cap for any sign of cracking or burning. A small amount of discoloration is normal but there should be no heavy burn marks or contact marks. Connect one lead of an ohmmeter to an electrode within the
Fig.
cap; connect the other lead to the corresponding spark plug
cracks or wear
terminal.
25,000.
resistance,
Replace any wire which shows a resistance over
ohms.
118 Check the inside of the cap for burning,
GENERAL INFORMATION AND MAINTENANCE
1-50
Test the high tension lead from the
ohmmeter between
the center contact
coil in
by connecting the
the distributor cap
either of the primary terminals of the coil.
and
resistance
If
more than 25,000 ohms, remove the cable from the check the resistance
ohms
is
cause
resistance
for
of the
cable alone. Anything over 15,000
replacement.
should be remembered that
It
also a function of length; the longer the cable,
is
the greater the resistance. Thus,
if
the cables on your truck
are longer than the factory originals, resistance quite possibly outside these limits. Toyota
25,000
ohm
is
and
coil
limit
be observed
in all
will
be higher,
recommends
the
cases.
REMOVAL & INSTALLATION I
See Figure 120 At every tune-up, visually inspect the spark plug cables for
burns, cuts, or breaks
in
aged coil
wiring.
Check
the insulation.
the nipples on the distributor cap and
coil.
Always replace spark plug wiring
wire as well. Length
is
the boots
and
Replace any damsets, with
in
a
important; get the correct set for
your vehicle.
When
installing
new
cables, replace
them one
at
avoid mix-ups. Start by replacing the longest one
a time to
first.
Install
the boot firmly over the spark plug. Route the wire over the
same
path as the original. Insert the nipple firmly into the
tower on the cap or the
Distributor
coil.
Cap and Rotor
REMOVAL & INSTALLATION > See Figures 121, 122, 123 and 124
for
1.
Disconnect the negative battery cable.
2.
Remove
3.
Loosen the screws securing the cap on the
4.
Usually
easy
the distributor cap rubber boot
it
is
if
equipped. distributor.
helpful to tag the wires leading to the
identification
on
installation.
cap
GENERAL INFORMATION AND MAINTENANCE
1-51
INSPECTION
When
inspecting a cap and rotor, look for signs of cracks,
burns and wear. The inside
cap may be burnt or have
of the
wear on the carbon ends. On the burning and excessive wear.
rotor look at the tip for
Timing
Ignition
GENERAL INFORMATION Ignition timing is the
measurement
degrees
in
of crankshaft
rotation at the instant the spark plug fires while the piston
on
its
adjusted by loosening the distributor locking
Ignition timing is
device and turning the distributor mixture
Ideally, the air/fuel 5.
Lift
the cap
off
the distributor. Pulling from the wire boot,
6.
Once
the cap and wires are
off,
lift
the rotor
off
the
install:
7.
Install
the rotor onto the distributor shaft.
The
goes on one way so there should be no mix-up
rotor only
and the inside
of the
grease on the
tip
of
Attach the tagged wires to their proper locations on the
mixture
This the cap
10.
Fit
1 1
Make
spark plugs. 12.
sure
onto the distributor, then tighten the bolts. all
Install
the wires are secure on the cap the negative battery cable.
Start the vehicle
and check
for
any misses.
ignited by
of the
compression
be beginning the power
will
mixture starts to burn
air/fuel
takes a fraction of a second for the spark from the plug to
completely ignite the mixture the spark plug must
cap carbon ends.
cap.
.
compressed
be
and expand. The expansion (explosion) of the air/fuel mixture will then force the piston down on the power stroke and turn
It
Apply a small amount of dielectric
the rotor 9.
happens, the piston
this
will
rapid expansion as the
its
the crankshaft.
in
replacement. 8.
If
stroke just as the
To
mount.
its
passes Top Dead Center (TDC)
stroke.
shaft.
in
the cylinder
in
the spark plug and just beginning piston
remove the plug wires from the cap.
is
compression stroke.
and
be completely
to
is
measurement
ignited
given
is
Because of TDC,
the cylinder.
in
before the piston reaches
fire
means
your engine
must
that the spark plug
piston for that cylinder
is
engine
As the engine accelerates from
the speed of the engine
idle,
The increase
(rpm, or revolutions per minute) increases.
means
that the pistons are
faster.
Because
sooner
if
now
is
to
in
rpm
up and down much
traveling
spark plugs
of this, the
the mixture
will
have
to fire
even
be completely ignited as the piston
to
passes TDC. To accomplish
means
its
holds true while your
this only
speed.
at idle
is
(7°)
the
fire at
the igni-
If
BTDC, this time when the
seven
is
7° before reaching the top of
compression stroke. However,
the
of crankshaft rotation
before the piston reaches top dead center (BTDC). tion timing setting for
if
as the piston passes TDC.
degrees
in
this,
this,
advance the timing
the distributor incorporates
of the
spark as engine speed
increases.
The
distributor in
advancing the
and
is
called
your Toyota has
actuated by weights
at least
is
is
of
advance
The other
is
controlled by that larger circular
many
of the distributor. In
vacuum advance
two means
called centrifugal
is
the distributor.
in
vacuum advance and
housing on the side the
One
ignition timing.
replaced by
full
later
models,
computerized control,
thanks to the Engine Control Unit or ECU. This function
and
is
is
known as
Electronic Spark
monitoring the rpm, intake throttle position
and other
cides the correct
moment
The system
is
addition,
volume, engine temperature,
air
variables, the microprocessor deto trigger the
operating condition from cold
In
Advance (ESA) of the ECU. By
accomplished by Toyota’s programming
idle
simple, non-adjustable
some
mechanism which
is
early distributors
contained
in
spark for any engine
through wide open
the
and
throttle.
reliable.
have a vacuum retard same housing on the
GENERAL INFORMATION AND MAINTENANCE
1-52
vacuum advance. The
side of the distributor as the this
mechanism
function of
spark
to retard the timing of the ignition
is
under certain engine conditions. This causes more complete burning of the
air/fuel
mixture
in
vacuum advance and
have vacuum hoses connected
retard
them mixed up during removal. Because these mechanisms change essary to disconnect and plug the one
briefly) to find
the
from the distributor If
when
of the air/fuel
down
force the piston
in
vacuum
lines
advanced (BTDC), the
mixture
the cylinder
in
the cylinder while
is still
it
uum
ignition
timing
into
an empty
too far retarded (after, or
is
down on
already started
mixture ignites. This only a portion of
ance and lack
its
the
tin
can.
the distributor. Both must be disconnected and plugged.
traveling
ATDC), the
cause the piston
will
piston
power stroke when the
travel, resulting in
to
will
6. 5.
Be sure
moving
Keep
poor engine perform-
fingers, clothes, tools, hair,
all
INSPECTION AND ADJUSTMENT
instrument
is
checked with a timing
connected
inductively
The
This
light.
timing light flashes every time an electrical current 1
Except
for the
mark
is
When
On Land it
same
at the rear of
in
is
aligned with the 0
the No.
1
cylinder
is
TDC
of
scopic flashes from the timing
light will
ignition timing setting of the engine.
every time the spark plug
in
the No.
its
seem
stationary for a
timing light flashes
cylinder of the engine
makes the crankmoment you will be able to
Since the flash from the timing
read the exact position of the piston
light
in
the No.
cylinder
1
on
the timing scale on the front of the engine.
Because your Toyota has
plug wire, eliminating any adapters.
susceptible to crossfiring or false triggering, which with a conventional
It
is
may
not as
occur
light.
8.
a tachometer
If
the timing
(hold-down
advance or
is
idle,
in
the chart
timing should be at
not at the specification, loosen the pinch
bolt) at
the base of the distributor just
retard the timing as required.
marks are seen
down
enough
to align, timing is correct.
Once
to
the proper
Tighten the hold-
bolt.
^Remember
that
you are using metal tools on a running
engine. Watch out for moving parts and don’t touch any of the spark plug wires with the wrench.
Recheck the
9.
timing.
chometer and timing the
light.
vacuum
Stop the engine; disconnect the Except
for
line(s) to
ta-
engines equipped with
the distributor
vacuum
unit.
10.
On
HAC
engines with
after setting the
the distributor.
1 1
the engine, then turn the ignition
to both battery terminals
marks indicated
With the engine at
so that the distributor can be turned. Turn the distributor
the
Warm-up
if
initial
(identified in the
NOTE
earlier),
vacuum hose at should now be about 13°
timing, reconnect the
Recheck the
timing.
It
BTDC.
22-R Engine 1.
idle
the specification given on the “Tune-Up Specifications” chart.
HAC, connect
electronic ignition, always use a
timing light with an inductive pickup. This pickup simply clamps 1
speed and adjust the
allow you to check the
The 1
illustrations.
bolt
mark on the at
Point the timing light at the
7.
is lo-
compression stroke. With the engine running, and the timing light aimed at the timing pointer and timing scale, the strobo-
onto the No.
idle
Be sure that the parking brake is set and that the front wheels are blocked to prevent the vehicle from rolling.
and
side of the engine as the spark plugs.
the timing pointer
shaft pulley
check
to
**CAUTION
Cruisers with the 3F-E, the timing
meets the transmission. The plug
timing scale, the piston
fires.
shift
3F-E engine, the crankshaft pulley and the
where
cated on the
speed with the gear
idle
is
spark plug wire to
found be removing the small rubber plug
the engine
of
a well ventilated area.
in
Use the tachometer
cover of the engine are marked with a timing pointer and
a timing scale.
and wiring leads clear you are running the
(No. 1)
the spark plug.
front
that
necessary.
number one
to the
sent from the distributor through the No.
Be sure
parts.
Neutral (manual) and Park (P) with automatic transmission.
spark plug of the engine as well as to the two battery terminals.
moving
Allow the engine to run at in
is
wires are clear of the fan and
i-CAUTION the
adjustment
all
be forced down
engine
Ignition timing
that the
belts, pulleys etc. Start the engine.
have
air/fuel
power.
of
the engine run poorly.
systems, there are two vacuum hoses which connect to
will try to
the ignition
If
golf tees are excellent for
(^•On 22R engines with High Altitude Compensation (HAC)
upward. This causes engine “ping”, a sound which resembles
marbles being dropped
position very
from the distributor vac-
line(s)
Clamp or plug the line(s); Any vacuum leak will make
unit.
this job.
setting the basic ignition timing.
ignition timing is set too far
and expansion
or two
START
according to the manufacturer’s
light
Disconnect the vacuum
4.
nec-
is
it
excellent
is
the engine around
instructions.
get
ignition timing,
bump
the pulley marks.
Connect a timing
3.
them. Don’t
to
purpose. You might have to
with the starter (just touch the key to the
the cylinder and consequently
lowers exhaust emissions. Both the
vacuum
using chalk or paint. Fluorescent (dayglow) paint for this
and
OFF. Connect
to the service
con-
.
If
the advance
HAC
is
still
about 8°, pinch the hose between
valve and the three
about 13°.
If
not, the
HAC
way
connector.
It
should
now be
valve should be checked for proper
operation.
nector coming from the distributor.
Clean
off the timing marks. The marks are on the crankand timing cover. The timing notches in the crankshaft pulley are normally marked at the factory with red or white paint. You may want to retouch them if they are dark,
2.
shaft pulley
22R-E, 3VZ-E and 3F-E Engines I See Figures 125, 126, 127 and 128 1.
Warm
light to
up the engine, then turn
it
OFF. Connect a
timing
the engine following the manufacturer's instructions.
GENERAL INFORMATION AND MAINTENANCE Connect a tachometer
2.
both battery terminals. Connect
to
the tachometer probe to the IG-terminal
The check connector box
box.
is
in
the check connector
located next to the un-
derhood fuse and relay box on trucks and 4Runner’s; Cruisers, the
check connector box
correct adapter to insure a tight
fit
is
on the
Land
for
Use
firewall.
on the terminal. Not
3.
Start the
Read
6.
instructions for your unit before using.
engine and run
on the tachometer; adjust 4.
it
it
at idle.
Check the
to specification
if
idle
speed
T or TE1 and terminal El, of the DLC1 as shown. Special service tool (SST) 09843-18020 or equivalent can be used for this also. will
be used repeatedly during diagnostics
sections. Take the time to
with correct terminals or probes. tool for
its
make
It’s
distributor pinch bolt just
can be turned. Aim the timing
turn the distributor until the correct timing
enough
light at
that the
the marks on
mark
aligns with the
pointer. Tighten the distributor pinch bolt. 7.
the connector at terminal
in later
Loosen the
the crankshaft pulley (or the drive plate on 3F-E) and slowly
necessary.
At the check connector, use a small jumper wire to short
f*This jumper
at idle.
distributor
tachometers, particularly older ones are electrically compatible with this system.
5. Check the idle speed, then check the ignition timing. The 22R-E should read 5° BTDC, 3VZ-FE should read 10° BTDC and the 3F-E should read 7° BTDC. All of these readings are
the
all
1-53
Remove
the jumper wire or special service tool (SST)
from the DLC1. 8. Check that the ignition timing advances. At idle the 22RE should read 10°-14° BTDC, 3VZ-FE should read 8° BTDC, and the 3F-E should read 12° BTDC. 9. Shut the engine OFF and remove the timing light and
tachometer leads.
a proper jumper
a valuable special
very low cost.
1FZ-FE Engine I See Figures 129, 130 and 131
^Toyota’s hand-held tester or an equivalent OBD-II scan must be used for this procedure.
tool
1.
Warm
2.
Connect an OBD-II compliant scan
the engine to normal operating temperature. tool to the
DLC3
located under the dash on the driver’s side. Refer to Section 4
Tachometer
more information. Connect the timing light to the engine. 4. Race the engine to 2500 rpm for approximately 90 seconds. Check the idle speed. It should read 600-700 rpm. 5. Using SST 09843-18020 or its equivalent jumper wire,
for
3.
connect terminals TE1 and El 6.
With the transmission
the timing. 7.
It
should read 3°
Loosen the hold-down
distributor.
in
of the
neutral
BTDC bolt,
DLC1 under and the A/C
the hood. off,
check
at idle.
and adjust
Tighten the hold-down bolt to 13
it
ft.
by turning the lbs.
(18 Nm),
then recheck the ignition timing again. 8. 9. idle.
Fig.
125 Attach the tachometer as shown
Remove the jumper wire from the DLC1. Check the timing, the reading should be 2°-13° BTDC The timing mark will move in this range.
10.
Disconnect the timing
11.
Disconnect the scan
light
tool.
from the engine.
at
1-54
GENERAL INFORMATION AND MAINTENANCE
2RZ-FE and 3RZ-FE Engines >
See Figures
129, 132
and 133
'•Toyota’s hand-held tester or an equivalent OBD-II scan
must be used
tool 1
.
2.
Warm
for this procedure.
the engine to normal operating temperature.
Connect an OBD-II compliant scan
tool to the
DLC3
located under the dash on the driver's side. Refer to Section 4
more information. Connect the timing light to the engine. 4. Using SST 09843-18020 or its equivalent jumper wire, connect terminals TE1 and El of the DLC1 under the hood. 5. After the engine speed is kept at about 1000 rpm for 5 for
10.
3.
seconds, check that 6.
Check
BTDC
it returns to idle speed. the ignition timing, the reading should be 3°-7°
at idle.
7.
Remove
the jumper wire from the
8.
Recheck
the timing, the
DLC1. mark ranges from 7°-18°
at idle. 9.
Disconnect the scan
tool.
Disconnect the timing
light.
BTDC
GENERAL INFORMATION AND MAINTENANCE
1-55
2.
Remove
Turn the engine OFF. along with the hot
ing,
air
and cold
the air cleaner and hous-
air intake ducts.
**CAUT!ON Components
be
will
hot.
The engine head, block and
radi-
ator will be very hot.
3.
Remove any
the valve cover. the
other hoses, cables, or wires attached to
The valve cover
(or cylinder
domed steel item with the oil filler in 4. Remove the small nuts holding the
the cover
head cover)
valve cover, then
Retrieve the rubber gasket and put
off.
damaged
it
aside;
can be reused
if
ware
dripping from the inside of the cover.
5.
of hot
oil
Use a
not
until
lift
it
or crushed out of shape. Be-
wrench on the crankshaft pulley
large
the engine clockwise
is
it.
bolt to turn
the timing mark on the pulley to 0
on the scale. Turning the engine plugs are removed, but this
be easier
will
if
the spark
not required.
is
^CAUTION Valve Lash Adjustment >
Do not attempt
See Figures 134 and 135
everything
As
in
will
splash hot
oil
onto
the area, including you.
part of every major tune-up or service interval, the valve
clearance should be checked and adjusted
necessary. For
if
Cruisers, the requirement
is
engine
months. the valve clearance will
thus the valves
too large, part of the
is
be used up
not be
will
lift
of the
opened
far
enough. This condition
the valve train noisy as they take up the excessive
clearance, and the engine
amount
4
closest to the firewall.)
is
will
of air/fuel mixture will
exhaust valves
not
will
open
far
enough
to the cylinders.
entry of the next air/fuel charge. small, the intake
cylinder
If
head when they
will
restrict
the valve clearance
and exhaust valves close. This
will
not
causes
fully
off.
will
screw
will
felt
when
loose than slightly
have the valve adjustment tight,
as burnt valves
may
until
the feeler
Repeat the procedure
the clearance
is
correct. Tighten
for
gauge
No
1
is
pulled through the gap.
exhaust,
No 2
intake
and No.
3 exhaust. 8.
run
the
til
Turn the crankshaft pulley one
full
rotation clockwise un-
the marks align at 0 and for the remaining valves. 9.
Clean the valve cover thoroughly with a
Wipe any
oil
off
the cylinder head
edges
in
lint-free rag.
the area of the
valve cover gasket. Fit
better to
arm on the No. 1 intake valve. To on the end of the rocker arm and
drag
valve adjustments must be as accurate as pos-
all
is
a feeler gauge and check
clearance between the top of the valve stem and
the gasket into the valve cover, making sure
crimped or twisted. it
(0.20mm) intake and
in.
Insert
adjust, loosen the locknut
cylinder head).
'•While
recheck the rockers.
at zero;
the bottom of the rocker
some
in
is
it
too
is
overheat and warp (since they cannot
transfer heat unless they are firmly touching the seat
If
and
revolution clockwise
full
the locknut and recheck the clearance; there should be a slight
internal cylinder
Therefore, the engine
mark
(0.30mm) exhaust.
in.
turn the adjusting
poorly (due to gases escaping from the combustion chamber),
and the valves
0.012
closest to the
the
seat on the
leakage and prevents the hot valve from transferring heat to the head and cooling
The
to vent the cylinder
completely; retained pressure (back pressure)
sible,
one
Adjust the clearance 0.008
for10. proper
perform poorly, since a smaller
be admitted
7.
is
this is true, the
If
aligned with No.1 piston at top dead center.
is
realign the timing
removing the excessive clearance,
in
on No.1 cylinder are loose and
that the rockers
not true, turn the engine
camshaft
makes
Check
the rockers on No.4 are under tension. (No.1 radiator; No.
15,000 miles (24,000 km) or 18
is
6.
all
and 4Runner’s covered by this book, the specification every 30,000 miles (48,000 km) or 36 months. For all Land
trucks
If
to align the engine by using the ignition
switch to turn the engine. Doing
If
the valve cover, clean
the half-moon rubber plugs
them and apply sealant
came
not
is
it
out of
to the part of
slightly
the plug contacting the valve cover; result
install
the half-moon plug.
from
•*The use of sealants on the valve cover gasket recommended.
overly tight adjustments.
ADJUSTMENT
11.
Install
the valve cover onto the head.
Make
is
not
certain
is
squarely seated and not pinching any adjacent wires or cables.
them to more than finger-tight; overtightening will deform the cover and cause leaks. 13. Connect the lines, hoses and cables which were removed for access. Make certain electrical and ignition wires 12.
22R and 22R-E I
See Figures 136, 137, 138 and 139 1
.
Start the
temperature.
engine and
Install
43-60 inch
warm
it
up to normal operating
the valve cover retaining nuts. Tighten
lbs. (5-7
Nm)
This
is
little
are firmly held by their clips or brackets.
1-56
GENERAL INFORMATION AND MAINTENANCE
Adjusting Shim Selection Chart (Intake)
New Shim
No
Intake valve clearance (Cold): 0.18 - 0.28 (0.007 - 0.011
mm
EXAMPLE:
The 2.800 is
0 450
mm
(0.1
measured clearance Replace the 2 800
mm
(0.1102
mm
102
in.)
(0.0177
in.)
in.)
shim in
is
installed,
and the
a
new No
1
7
shim
(in.)
Shim Thickness
No
Thickness
No
1
2
200 (0 0866)
10
2
650
(0 1043)
19
3 100 (0 1220)
2
2
250 (0 0886)
11
2
700 (0 1063)
20
3
1
3
2
300 (0 0906)
12
2
750 (0 1083)
21
3
200 (0 1260)
4
2
350 (0 0925)
13
2
800 (0 1102)
22
3
250
5
2
400 (0 0945)
14
2
850 (0 1122)
23
3 300 (01299)
6
2
450 (0.0965)
15
2
900 (01142)
24
3
350 (01319)
7
2
500 (0 0984)
16
2
950 (0.1161)
25
3
400
8
2
550 (0 1004)
17
3000
9
2
600 (0.1024)
18
3
shims have the thickness
in
HINT:
).
shim with
mm
shim thickness Shim
Thickness
New
50 (0
1
240)
(0 1280)
(0 1339)
(0.1181)
050 (0 1 201 millimeters
imprinted on the lace. 86821167
Fig.
134 Adjusting shim chart for the intake valves
GENERAL INFORMATION AND MAINTENANCE
1-57
Adjusting Shim Selection Chart (Exhaust) 7)1
'^Installed shtm thickness
mm
(tn.)
Measured clearance^^^^
mm
(in.)
0 ooo - 0 030
10
0 031 - 0 050
10
OOOO - 0 00121 0012 - 0 0020)
0 051 - 0 070
10
0020 - 0 0028t
0071 - 0 090
(0
0028 - 0 00351
0.110
I0
00J6 - 0 00431 0044 - 0 005H 0052 - 0 00591
0 091
-
0H1
- 0 130 (0
0 131 - 0.150
(0
0.171 - 0 190
10
0 191 - 0 210
(0
0059 - 0 0067t 0067 - 000751 0075 - 0 00831
(0
0083 - 0 009H
10
0091 - 0 00981
0.151 - 0 170
0 211 - 0 230
0 231
-
0 249
10
0098 - 0 0'38t 0 351 - 0.370 iOO'38 - 0 0'46t 0 371 - 0 390 10 0146 - 0 0154) 00161) 0 391 - 0410 (00154 - 0 430 |0.0'62 - 0 0189) 0.41 0.250 - 0 350
« «* § s 2 2 5 8 * S s 5 5 s a 5 = 1 s 5 a £ - £ s 0 s § 5 - s s 8 | I s S 8 s 1 s s S I I 8 8 1 S i S i o o g i i 1 1 1 o o o o o o o o o o o o o o o o o o 0 0 O 0 O 0 O 0 0 O 0 0 O 0 0 0 0 0 0 0 0 O O O O 0 0 0 0 0 0 0 0 0 0 O 0 0 0 0 0 0 0 0 o ° ° O 8 8 ° Sj s 0 2 2 2 8 = 5 8 s o 2 s 2 5 2 2 $ 2 § 1 8 8 8 2 2 § 1 8 8 1 1 s 1 • • 1 § S 1 3 1 « • 1 8 8 1 I § O § i i § 1 >06
i!
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2
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3
3
3
5
5
5
5
6
6
6
6
6
7
7
7
8
8
a
8
1
1
1
2
2
2
2
2
3
3
3
3
3
4
4
4
4
4
5
5
5
5
5
6
6
6
6
6
7
7
7
7
7
8
8
8
9
9
9
9
1
1
2
2
2
2
2
3
3
3
3
3
4
4
4
4
4
5
5
5
5
5
6
6
6
6
6
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7
7
7
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8
8
8
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9
9
9
9
10 10
1
2
2
2
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3
3
3
3
3
5
5
5
5
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6
6
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8
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9
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2
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7
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4
4
4
4
4
5
5
5
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5
6
6
6
6
8
7
7
7
7
7
8
8
8
8
8
9
9
9
9
9
10 10 10 11 11 11
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9
9
9
9
9
10 10 10 10 10 11 11 11 12 12 12 13 13 13 14 14 14 15
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1
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2
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4
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6
6
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7
7
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7
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8
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9
9
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l
’
2
2
2
3
3
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6
6
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6
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7
7
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7
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8
8
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9
9
9
9
9
9
10 10 10 10 10
3
3
2
3
3
4
4
4
4
4
4
5
5
5
5
5
6
6
6
6
6
7
7
7
7
7
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9
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3
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7
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8
8
8
8
9
9
9
9
9
10 10 10 10 10
3
3
4
4
5
5
5
5
6
6
6
7
7
7
7
8
8
8
8
8
9
9
9
9
9
1 1
1 1
4
4
4
5
5
5
6
6
6
7
7
7
7
7
8
8
8
8
8
9
9
9
9
9
10 10 10 10 10 11
4
5
5
5
6
6
6
7
7
7
7
e
8
8
9
8
9
9
9
9
9
10 10 '0 10 10
9
9
4
4
'7
10 10 10 10 10
3
4
4
4
5
5
5
6
6
6
7
7
7
8
8
8
8
8
9
9
9
(0
4
4
5
5
5
5
8
6
7
7
7
7
8
8
8
8
9
9
9
9
9
(0
0170 0178
7 71
0 470
0.0185)
4
5
5
5
5
6
8
7
7
7
7
8
8
8
9
9
9
9
9
10 10 10 10 10
0 471 - 0 490
tO
O' 85 - 00193)
5
9
9
0 491 - 0 510
(0
0193
0 01
5
6
6
6
7
7
7
8
8
8
9
9
9
5
6
6
6
7
7
7
8
8
8
9
9
9
9
10 10 10 10 10
7
7
7
8
8
8
9
9
9
10 10 10 10 10
10 10 10 10
0 0201)
5
6
6
6
0 531 - 0 550 0.551 - 0 570
(0
0209
- 0 0217)
6
6
7
7
7
7
8
8
9
9
9
9
(0
0217 - 0 0224)
8
7
7
7
7
8
8
9
9
9
9
10 10 10
0 571 - 0 590 0 591 - 0 610
(0
0225 0233
0 0232)
7
7
7
8
8
8
9
9
9
10 10 10
(0
630
(0
0 631 - 0 650
(0
6'0
tO
0 671
-
0 02401
7
7
8
e
8
9
0241 - 0 0248) 0748 - 0 0256)
7
8
6
8
9
9
8
8
9
9
9
9
-
10 10 10 11
9
9
9
10 10 10
10 10
1
1
1
1 l
1
1
1
1
1
10 10 10 10 10
10 10 10 10 10
5
5
- 0 5 30 (0 0201 - 0.0209)
- 0
0 690
10 10
02 72 - 0 0280)
10
0 731 - 0 750
10
0280 - 0 0287) 0788 - 0 02951
11
1
1
1
1
1
11
1
1
1
11
1
1
11
1
1
1
1
1 1
11
1
1
1
1
tO
0304 -
(0
0311 - 0 03191
0811 - 0
8 30 10
0 831 - 0 850
10
10
0335 - 0 03431
0 871 - 0 800
10
0343
0351 - 0 0358)
0 891
-
0 910
10
0.91
-
0 930
10
0931 - 0 950
10
0 970
10
0 951
OH
-
1
030
tO
031 -
I
050
tO
1
051 -
1
Q7Q
|0
1
071 -
1
1
091
1
-
-
1
1
12 12 12 13 13 13 13 14 14 15 15 15 15 16
1
1
1
1
1
1
1
.
1
1
1
1
12 ’2 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 16 16 17 17 17
1
1
1
1
1
11 11 12 12 12 12 12 13
1
1
1
12 12 12 12 12 '3 13 '3 13 13 14 14 14 14 14 15 15 15 15 16 16 16 17 17 17 17
1
12
1
2
12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15 16 16 16 17 17
1
1
11
1
11
1 1
12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15 16 16 16 16 17 17 17 17 17
1
1
1
12 12 12 12 12 13 13 13 13 ’3 14 14 14 14 14 15 15 15 15 15 16 16 '6
15 15 15 15 15 16 16 16 16 16 17 17
12 12 12 12
i
2
1 1
11
1
12 1? 12 12 12 13
1
3 13
1 1
12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15 16 16 16 16 16
13 13 13 1
1
3 13 14 14
1
4 14 14 15
15 15 15 15 16 16 16 16 16
12 12 12 12 13 13 13 13 13 14
7
1
7
1
7
1
7
1
7
1
7
17
1
1
7
15 15 15 15 15 16 16 16 16 18
1
7
1
7
17 17
1
7 17 17
1
7 17 17 17
1
7
7
1
1
7 17
1
7
1
17 17 17 1
7
7
17 17 17 17 17
7
12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15 18 18 16 16 18 17 17 17
1
7
1
15 15 15 '5 16 16 '6 16 16 17 17 17 17 17 17
1
3 13 14 14 14 14 14 15 15 15 15 15 18 16 16 16 16 17 17 17 17 17 17
11
1 1
1
12 12 '2 12 12 13 13 13 13 13 14 14 14 14 14 >5 15 15 15 15 16 16 16 16 16 17 17 17 17 17
11
1 1
7 17
11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15 16 16 16 16 16 17 17 17 17 17
'2 ’2 12 12 12 13 13 13 13 13
11
1
1
3 13 13 13 14 14 14 14 14 15 15 15 16 16 16 17 17 17 17 17
1
1
1
1
1
1 1
1
7
17
New Shim
10 10
130
10
0430 - 0 0437) 0437 - 0 0445)
150
10
044 5 - O 04
Exhaust valve clearance (Cold): 0.25 - 0.35 mm (0 010 - 0.014 in.) EXAMPLE: The 2.800 mm (0. 1 102 in.) shim is installed, and the measured clearance is 0.440
mm
(0.01
73
in.)
Replace the 2 800
mm
(0.
1
1
02
mm
shim thickness
Thickness
No.
0 03901
0 0 3981 0398 - 0 04061 0406 - 0 04 131 0414 - 0 04711 0422 - 0 Q4291
090
I
1
11
1
0 0350i
-1110 I
1
11
1
0359 - 0 03661 0367 - 0 0374) 0374 - Q Q3821
- 0 990 10 0382 0 991 - 1010(0 0390
0 971
1
12 12 12 12 13 13 13 14 14 14 15 15 15
1 1
1
0319 - 0 0 3271 0327 - 0 0335)
0 8 51 - 0 8 70
1
12 12 13 13 13 13 14 14
11
1
12 12 12 13 13 13 14 14 14 15 15
1
11 11
QQ31H
- 0 790
0 791 - 0 610
71
1
1 1
1
11
12 12 12 12 12 13 13 13 13 13 14 14 14 14 14
11
1
1 1
1
10 10 10 10 10
0 751 - 0 770 >0.0296 - 0 0303) 7
1
11
12 12 13 13 13 13 14
1
0256 - 0 0264) 0264 - 0 02721
0 691 0 /IQ 0 711 - 0 >30
0
11
1
10 10 10 10 11 11 11 12 12 12 13 13 13
10 10 10 10 11
10 10 10 10 11 11
3
-
0 65'
7
1
- 0 450
- 0
5
10
1
1
5
2
3
12 12 12 13 13
i
2
2
3
12 12 12 13
1
2
3
1
1
1
3
12
12 12
11
2
2
3
10 10 10 11 11
1
1
n
1
1
i
3
10 10 10 11 11
1
1
1
1
1
l
3
1
i
1
2
10 10 10 10
10 10
i
1
9
9
i
1
•
1
7
'
0 45'
0 61
5
1
0.431
0 511
3
1
1
1
9
1
1
1
1
i
1
i
1
Shim No.
(in.)
Thickness
1
2.500 (0.0984)
10
2.950
(0.1
161)
2
2.550 (0.1004)
1
3.000
(0.1
181)
3
2.600 (0.1024)
12
3.050 (0.1201)
4
2.650 (0.1043)
13
3.100 (0.1220)
5
2.700 (0.10631
14
3.150 (0.1240)
6
2.750 (0.10831
15
3.200 (0.1260)
7
2.800
(0.1
102)
16
3.250 (0.1280)
8
2.850
(0.1
122)
17
3.300 (0.1299)
9
2.900 (0.1142)
HINT:
New
shims have the thickness
in
milli-
131
in.)
shim with a No. 10 shim
meters imprinted on the face. 86821168
Fig.
135 Adjusting shim chart for the exhaust valves
1-58
GENERAL INFORMATION AND MAINTENANCE
First
Front
Fig.
136 Adjust the clearance of half the valves, do the
arrowed ones
first
14.
Install
15.
If
the in
still
air
cleaner with the hoses and duct work.
remove the wrench and socket from the
place,
crankshaft pulley.
3VZ-E Engines
See Figures 140, 141,
t
142, 143, 144, 145, 146, 147, 148,
149 and 150
The valves should be checked
means the Use a longer
ally, this
hours.
with the engine cold. Gener-
vehicle has not
been driven
interval for hot climates.
in at
least 3
Overnight cold
is
best.
~
The use
86821170
Fig.
137 Use a gauge to measure the distance between
the stem and the rocker arm
of valve
shim removing tools and a micromelists both shim
required for this procedure. Toyota
ter is
removing tools as a set, SST 09248-55010; equivalent tools may be purchased through retail outlets. A micrometer is a precision measuring device. Do not attempt the procedure
if
the tools are not available.
1.
Disconnect the spark plug wires, then remove the plugs.
2.
Remove
the air intake
chamber by tagging and
disconnecting: a. b. c.
The throttle position sensor. The canister vacuum hose from the throttle body. The vacuum and fuel hoses from the pressure
regulator. d. e.
The PCV hose at the union. The No. 4 water by-pass hose from
the union of the
intake manifold. f.
The No. 5 water by-pass hose from
the water by-pass
pipe. g. h. i.
move j.
k.
The cold start injector wire. The vacuum hose at the fuel
Remove
filter.
the union bolt and two gaskets and then re-
the cold start injector tube.
EGR gas temperature sensor wire. EGR vacuum hoses at the air pipe
The The
and vacuum
modulator. Fig.
138 Hold the adjusting screw
tighten the locknut
l.
in position,
then
On
California vehicles,
remove the
EGR
gas sensor
connector.
m.
Remove
the nut, bolt
and intake chamber
stay.
GENERAL INFORMATION AND MAINTENANCE Remove
n.
the 5 nuts,
EGR
valve with the pipes
connected and the 2 gaskets. o. Disconnect the No. 1 air hose
Remove
p.
at the reed valve.
the six bolts and two nuts and
lift
off
the
air
chamber and gasket.
intake
Disconnect the following wiring:
3.
Knock sensor
a. b.
No. 2 water temperature switch
c.
Start injector time switch
d.
Water temperature switch
e.
Right side ground strap Injector connectors.
f.
After the connectors are
4.
move
bracket bolts and
way location. Remove the
the
still
5.
left
removed, unfasten the two
the engine wire harness to an out of
and
right
valve covers (cylinder head
covers).
Use a wrench and
6.
notch
turn the crankshaft clockwise until the
the pulley aligns with the timing
in
mark 0
of the
lower
(No. 1) timing belt cover.
(Check
that the valve lifters
on the No.
loose and those on No. 4 cylinder are
1
cylinder are
tight.
If
not, turn the
crankshaft one complete revolution clockwise and realign the marks. 7.
Using a
flat
tween the bottom
feeler gauge, of the
measure the clearance be-
camshaft lobe and the top surface
of
measurement should correspond to the one given in the Tune-Up Specifications chart. Check only the No. 6 intake valve and the
the valve
lifter (It is
the top surface of the shim). This
No. 2 exhaust valve.
If
measurement
the
next step.
If
individual valve.
They
go on to the measurement taken for each
within specifications,
is
not, record the will
be used
later to
determine the
required replacement shim sizes. 8.
Turn the crankshaft
revolution
The No.
intake
1
'h of
a revolution (120°). One-third
the equivalent of from 12 to 4 on a clock face.
is
and the No. 3 exhaust valves should not be cam lobes. Measure the clearances for
under tension from the
these 2 valves only. Record any measurement that
is
out of
specification. 9.
Turn the crankshaft
'A of
a revolution (120°) and mea-
sure the clearance at the No. 2 intake and the No. 4 exhaust valves. 10.
Record any measurement
Turn the crankshaft
’A of
that
is
out of specification.
a revolution (120°) and mea-
sure the clearance at the No. 3 intake and the No. 5 exhaust valves. 11.
Record any measurement
Turn the crankshaft
'h of
that
is
out of specification.
a revolution (120°) and mea-
sure the clearance at the No. 4 intake and the No. 6 exhaust valves. 12.
Record any measurement
Turn the crankshaft
’A of
that
is
out of specification.
a revolution (120°) and mea-
sure the clearance at the No. 5 intake and the No. valves.
If
Record any measurement
the
that
is
1
exhaust
out of specification.
measurements for the six sets of valves are within you need go no further; the procedure is
specifications, finished.
If
any clearance
tinue with the next step.
is
not within specification, con-
1-59
1-60
GENERAL INFORMATION AND MAINTENANCE Turn the crankshaft clockwise
13.
until
the camshaft lobe of
the valve to be adjusted faces upward, taking tension
off
the
valve.
Using a small awl, turn the valve
14. is
lifter
so that the notch
easily accessible. 15.
Install
SST 09248-05410
the
sors-type tool on the the tool presses lifter
down
lifter,
down
(A) or
its
equivalent scis-
then squeeze the handle so that
the valve
lifter
evenly. Hold the valve
SST 09248-05420 (B) or its tool. Remove tool (A) or equivalent.
with the other
equivalent single-bladed
»^For easy removal of the shim, set the SST (B) or equivalent on the lifter so there is adequate space in the removal direction. Using a small flatbladded
16.
tool
and a magnet, remove the
valve shim. 17.
Carefully
measure the thickness
of the old
micrometer. Locate that particular measurement stalled
Shim Thickness” column
of the
shim with a in
the “In-
accompanying
charts,
then locate the recorded clearance measurement (from Step
Fig.
147
on the
When
lifter
direction
setting tool (B) or
so there
is
its
a wide space
equivalent, set in
the removal
it
GENERAL INFORMATION AND MAINTENANCE Place a
23.
new gasket on
chamber
intake
evenly to 13
lbs.
ft.
Connect the No.1
25.
Place two
air
the
Nm). Tighten bolts (B)
Connect the
27.
On
the
Install
air
them
nuts. Tighten
EGR
chamber and
right-
valve with the pipes to
chamber
stay.
Refer to the
Tighten bolts (A) to 22
to
EGR
reed valve.
to the
the intake
manifold.
air intake
tion for bolt designation.
modulator.
the
Install
chamber and
Install
hose
new gaskets on
side exhaust chamber.
26.
and 2
(18 Nm).
24.
the intake
the intake manifold.
with the 6 bolts
1-61
13
lbs.
ft.
hoses
ft.
illustra-
(29
lbs.
(18 Nm).
to the air pipe
California vehicles, connect the
and the vacuum
EGR
tempera-
ture sensor connector.
Use a new gasket and
28.
install
tighten the union (banjo) bolt to 13
29.
Install
the
vacuum hose
the cold start injector; ft.
(18 Nm).
lbs.
to the fuel
filter
and connect the
cold start injector wiring connector. 30.
148 With the aid of a magnet and a small
Fig.
flatbladded tool,
Install
the No. 5 water by-pass hose to the water bypass
Connect the No. 4 water bypass hose
pipe.
remove the shim
to the union at the
intake manifold.
6-11) for that, valve
in
the
“Measured Clearance
’’
column
31
of
the charts. Index the two columns to arrive at the proper
replacement shim thickness.
^Replacement shims ments 0.133 18.
of 0.002 in.
in.
are available in 25 sizes,
(0.05mm), from 0.0866
in.
the
new
Connect the
PCV
hose. Connect the
vacuum and
fuel
regulator.
32.
Connect the canister vacuum hose
33.
Attach the wiring connector to the throttle body.
to the throttle
body.
in incre-
(2.200mm) to
(3.400mm).
Install
.
hoses to the pressure
2RZ-FE and 3RZ-FE Engines > See Figures 151, 152, 153, 154 and 155
shim, remove the special tool and then
^Adjust the valve clearance when the engine
is cold.
recheck the valve clearance.
for
as you face the
the spark plugs.
21.
Install
the valve covers. Place the gasket on the cover
small
amounts
of sealant. Attach the covers, then
tighten the 11 bolts only to 4-5
lbs. (5-7
ft.
Nm). Do not
4.
are
Install
the engine wire harness with the two bolts. Attach in
Step
in
alignment with the marks on the No. 4 timing cover.
and
149 A micrometer
is
used
to
measure the
If
complete revolution (360°). lifter
and the
Measure the exhaust valves at the 1 and 3. The intake valve clearance cold is 0.006-0.010
2.
(0.15-0.25mm).
Fig.
1
Measure the clearance between the valve
a.
thickness of shims
groove with the
camshaft. Record the measurements on the intake valves No. 1
2.
its
mark 0 of the No. 1 timing cover. Check that the timing marks on the camshaft sprockets
5.
every connector removed
the cylinder head covers.
not, turn the crankshaft
overtighten. 22.
Turn the crankshaft pulley and align
timing
Install
install
Remove
3.
front of the motor.
20.
Disconnect the negative battery cable.
.
2.
any other valve needing adjustment. Always
turn the engine clockwise
and
1
Consult the clearances recorded earlier and perform
19.
Steps 12-17
in.
1-62 b.
GENERAL INFORMATION AND MAINTENANCE The exhaust valve clearance cold
is
0.010-0.014
the groove with the timing
revolution (360°)
1
mark 0
of the No.
1
and
align
timing belt
cover.
Measure the clearance between the valve lifter and the camshaft. Record the measurements on the intake valves No. 3 and 4. Measure the exhaust valves at the 2 and 4. a. The intake valve clearance cold is 0.006-0.010 in. (0.15-0. 25mm). b. The exhaust valve clearance cold is 0.010-0.014 in. (0.25-0. 35mm). 8. To adjust the intake valve clearance: 7.
a.
Remove
b.
Using a small flatbladded
the intake camshaft.
the adjusting shim.
ei-
ther using the chart or the following formula:
Turn the crankshaft pulley
6.
Determine the replacement adjusting shim size by
c.
in.
(0.25-0.35mm).
tool
Exhaust
•
T=Thickness
•
of removed shim A=Measured valve clearance N=Thickness of new shim
new
shim.
d.
Install
a
e.
Install
the intake camshaft.
Recheck the valve clearance. To adjust the exhaust valve clearance:
f.
a.
Turn the crankshaft
camshaft on the valve b.
and a magnet, remove
Intake
•
•
9.
— N=T+(A-0.008 in./0.20mm) — N=T+(A-0.01 3 in./0.32mm)
•
Turn the valve
to the c.
to
lifter
to position
of the
so that the notch
is
perpendicular
camshaft and facing the spark plug side. Using
SST 09248-55040
equivalent, hold the camshaft d.
on the cam lobe
be adjusted, upward.
Using
SST 09248-55040
equivalent, press
down
(valve in
(valve
the valve
lifter
press) or
place. lifter
lifter
press) or
and place the SST
GENERAL INFORMATION AND MAINTENANCE
—
Check
12.
and the No.
on the No.
that the valve lifters 1
exhaust are
tight.
1
1-63
intake are loose
not, turn the crankshaft
If
one
complete revolution (360°).
(All measurements should be written down. These recorded measurements will need to be used in conjunction with a mathematical formula to determine the thickness of
the replacement shims.
Measure the clearance between the valve
13.
lifters
camshaft. Record the measurements on valves No. intake; a.
1
and the and 6
2 and 3 exhaust.
The
intake valve clearance cold
is
0.006-0.009
in.
(0.15-0.23mm). b.
The exhaust valve clearance
cold
is
0.011-0.014
in.
(0.25-0.37mm). 14.
Turn the crankshaft
%
of a revolution (240°).
measurements on valves No. 2 and 3 155
Fig.
Remove
the adjusting shim with a small
flatbladded tool and a
15.
Turn the crankshaft another
%
intake;
of
a revolution (240°).
Record the measurements on valves No. 4 and 5
magnet
and 6 exhaust.
09248-05420 (valve
lifter
camshaft and the valve
Remove
e.
stopper) or equivalent between the
lifter.
the tool 09248-44040 or equivalent.
Using a small bladed
f.
tool
and a magnet, remove the
adjusting shim. 10.
Determine the replacement adjusting shim size by either
using the chart or the following formula:
— N=T+(A-0.008 in./0.20mm) — N=T+(A-0.01 3 in./0.32mm)
•
Intake
•
Exhaust
•
T=Thickness
• •
of removed shim A=Measured valve clearance N=Thickness of new shim
new
shim.
11.
Install
a
12.
Install
the intake camshaft.
13.
Recheck the valve clearance. the cylinder head covers.
14.
Install
15.
Connect the negative battery cable.
5VZ-FE Engine I
Fig.
See Figures 156, 157, 158 and 159
Adjust
the valves
when
the engine
is
cold.
1.
Disconnect the negative battery cable.
2.
Disconnect the
3.
Remove
the
air
throttle
cable from the linkage.
cleaner cover,
air flow
meter, and the air
duct assemblies.
6.
Remove Remove Remove
7.
Disconnect the engine harness from the injectors and
4. 5.
the V-bank cover. the emission control valve set. the air intake chamber.
the ignition coils. 8.
Detach the
ignition coils
and keep them
in
order for
reassembly.
10.
Remove Remove
11.
Turn the crankshaft pulley and align
9.
timing
mark 0
the spark plugs. the cylinder head covers.
of the
No.
1
timing cover.
its
groove with the
156 Adjust these valves
in
Record the
4 and 5 exhaust.
the 1st step
intake;
1
GENERAL INFORMATION AND MAINTENANCE
1-64
22.
Recheck the valve clearance. Install the cylinder head covers. Install the spark plugs and the ignition
23.
Connect the engine wiring harness
20. 21.
coils.
to the injectors
and
the coils. 24.
Install
the intake chamber.
25.
Install
the emission control valve set.
26.
Install
the V-bank cover.
27.
Install the. air
flow meter, air duct,
and the
air
cleaner
cover. 28.
Connect the accelerator cable
29.
Connect the negative battery cable.
to the throttle linkage.
3F-E Engine
See Figures 160 and 161
>
1
6
6
158 Adjust these valves
in
it
to
the 3rd step
Remove any
Stop the engine.
2.
Fig.
engine and allow
Start the
.
reach normal operating
temperature.
86821194
which are attached
to the valve
cables, hoses, wires, etc.,
cover and remove the valve
cover.
Remove the adjusting shim by turning the position the cam lobe of the camshaft in the up 16.
crankshaft to position
valve to be adjusted. Using a small thin flatbladded the valve
so that the notches are perpendicular
lifters
camshaft. Press
down
the valve
(A) or equivalent. Place
lifter
between the camshaft and the valve 17.
Remove
with
SST 09248-55010 lifter.
the adjusting shim with a
to the
SST 09248-55010
Components
Once
4.
T=Thickness
0
Check
5.
in
17 sizes
(0.050mm) from 0.06984 (3.300mm). in.
in.
in
increments of 0.0020
(2.500mm) to 0.1299
is
useful.
the timing marks are aligned, check the two rocker
in.
the clearance between each of the rocker
and valve stems
for the first set of valves,
feeler gauge. Hot the intake should
exhaust 0.014
arms
as shown, using a
be 0.008
in.
(0.20mm) and
(0.35mm).
in.
and
turn
the adjusting screw as required to gain correct clearance.
The
If
the clearance
incorrect, loosen the locknut
is
gauge should pass with just the the locknut and recheck the clearance. feeler
When
7.
valves
all
crankshaft one
full
to the firewall or
the measuring
second
set,
back
ft.
the
first
slightest drag. Tighten
set are adjusted, turn the
The two rockers
closest
motor should be loose. Repeat
of the
and adjusting procedure
for
each valve
in
the
as shown.
gasket on the cover. bolts to 6
in
rotation clockwise.
After adjusting
8.
lbs. (8
all
of the valves, install
Nm).
a new valve cover
the valve cover, tightening the
Install
Install
were removed during Step
2.
any other components which
Make
certain
all
wires and
cables are properly held by the clamps or brackets. 9.
Recheck the engine
idle
speed and adjust
1FZ-FE Engine >
See Figures
162, 163, 164, 165, 166
'•Adjust the valves when the engine
and 167 is
cold.
Drain the engine coolant from the vehicle.
1.
Remove
2.
a.
n
Since the timing marks
0.
.
6.
are available
clockwise
to turn the crankshaft pulley bolt
the timing marks are aligned at
until
•
•Shims
ra-
arms (No. 1) closest to the front of the motor; they should be loose. The No. 6 rocker arms should be tight. If not, rotate the engine one full rotation (360°) and realign the timing marks at
— N=T+(A-0.008 in./0.20mm) Exhaust — N=T+(A-0.01 3 in./0.32mm) Intake
of removed shim A=Measured valve clearance • N=Thickness of new shim 19. Select a new shim with the thickness as close as possible to the calculated value. Install the new replacement shim.
•
The cylinder head, block and
hot.
are at the back of the engine, an assistant
using charts or the following formula:
•
be
Use a wrench
3.
part (A).
magnet and a small
Determine the replacement adjusting shim size by either •
will
diator will be very hot.
(B) or equivalent,
Remove
flatbladded tool. 18.
^CAUTION
on the
tool, turn
the throttle body:
Disconnect the
PCV
hose.
if
necessary.
f
GENERAL INFORMATION AND MAINTENANCE
First
Front
1
w)
tt EX IN IN
EX
160 Adjust the
Fig.
mv
first
w EX
IN
set of valves to specifications
Second Front
EX
Fig. 161
EX
IN
IN EX
IN
The second set of valves can be checked
a adjusted
after the first set is
cleaner hose.
b.
Detach the
c.
Disconnect the control cables from the
d.
Remove
throttle
body.
the throttle position sensor connection.
Disconnect the
e. 3.
air
idle air control
valve wiring.
Disconnect the engine wiring harness and heater valve
from the cowl panel. 4.
Tag and disconnect the spark plug
5.
Remove
6.
Set the No.
wires.
the valve cover. 1
cylinder to
turning the crankshaft pulley,
TDC/compression stroke by
and
aligning
its
groove with the
mark 0 of the timing chain cover. 7. Check that the timing marks (one and two dots) of the camshaft drive and driven gears are in a straight line on the
timing
cylinder
head surface.
revolution (360°) 8.
and
If
they are not, turn the crankshaft
1
align the marks.
Inspect the valve clearance by using a thickness gauge.
Measure the clearance between the valve
lifter
and the
camshaft. 9.
Record the out
ments. These
will
of specification valve
be used
later to
clearance measure-
determine the replacement
1-65
GENERAL INFORMATION AND MAINTENANCE
1-66
adjusting shims. Intake
exhaust
is
0.010-0.014
is in.
0.006-0.010
Turn the crankshaft pulley
10.
groove with the timing mark
its
(0.15-0.25mm) and
in.
1
16.
Remove
the adjusting shim with a small flatbladded tool
and a magnet.
(0.25-0.35mm). revolution (360°)
and
align
17.
Determine the replacement shim size by following the or, charts. Using a micrometer, measure the thickness removed shim. Calculate the thickness of the new shim
formula
0.
11.
Check only the valves shown
12.
Adjust the clearance except for rear valves of the No. 6
in
the
first illustration.
of the
so that the valve clearance comes within specifications.
Remove the adjusting shim by turning the crankshaft position the cam lobe of the camshaft on thew adjusting
— N=T+(A-0.008 in./0.20mm) — N=T+(A-0.01 3 in./0.32mm)
cylinder.
•
Intake
to
•
Exhaust
Position the notch of the valve
13.
plug side. Using lifter
3ST
(B) or equivalent lifter
flange.
down
the valve
between the
Remove
the
•
SST
18. (A) or
ble to
possi-
shim.
equivalent.
14.
Apply
marked
it
toward the spark
lifter
(A) or equivalent, press
and place the SST
camshaft and the valve its
of removed shim A=Measured valve clearance • N=Thickness of new shim Select a new shim with the thickness as close as the calculated value. Install the new replacement
T=Thickness
•
valve upward.
SST
(B) or equivalent at
with “11”, at the position
15.
When
will
get pinched by the shim.
insert
it
the
SST
a
shown
slight in
angle on the side
thew
this
illustration.
from occurring,
shallowly from the outside of the cylinder head, at a
slight angle.
available in 17 sizes in increments of 0.0020
(0.050mm) from 0.06984 (3.300mm). in.
(B) or equivalent are inserted too deeply,
To prevent
••Shims are
19.
valve
Install lifter.
down on
new
a
Using
(2.500mm) to 0.1299
adjusting shim. Place the
SST
the valve
in.
(A)
lifter
in.
new shim on
the
09248-06020 or equivalent, press
and remove the SST
(B)
09248-55050
or equivalent. 20.
Recheck the valve clearance.
21
For the rear valves of cylinder No.
.
6,
remove the
distributor.
23.
Remove Remove
24.
Determine the replacement adjusting shim size by follow-
22.
the camshafts. the adjusting shim with a small flatbladded
tip.
ing the formula or charts.
25.
Using a micrometer, measure the thickness
moved
shim. Calculate the thickness of the
the valve clearance Intake
•
Exhaust
•
T=Thickness
•
of removed shim A=Measured valve clearance N=Thickness of new shim
Select a
new shim
with the thickness as close as possi-
ble to the calculated value. Install the
••Shims are in.
that
within specifications.
— N=T+(A-0.008 in./0.20mm) — N=T+(A-0.01 3 in./0.32mm)
•
•
26.
comes
of the re-
new shim so
shim.
available in 17 sizes in increments of 0.0020
(0.050mm) from 0.06984
(3.300mm).
new replacement
in.
(2.500mm) to 0.1299
in.
GENERAL INFORMATION AND MAINTENANCE 27.
new
a
Install
valve
new shim on
adjusting shim. Place the
the
lifter.
5.
Disconnect the hose from the
6.
Hold the
28.
Install
the camshafts, then recheck the valve clearance.
29.
Install
the distributor.
of the carb) closed.
30.
Install
the valve cover using gasket sealant.
throttle plate.
31.
Attach the spark plug wires to the plugs.
32.
Reconnect the heater valve and the engine wire
open and
slightly
to the
34.
Refill
35.
Check and
10.
the radiator with engine coolant and water mixture.
Check
for coolant leaks.
Hold the choke closed while releasing the
engine but
running at high
3000 rpm and
idle
DO NOT idle,
as
The screw
regulations, the mixture adjusting
on the carbureted 22R engine
is
preadjusted and plugged by
not part of routine maintenance.
is
screw requires removal
of the carburetor. Full
details of re-setting the air/fuel mixture after a carburetor over-
haul are covered
mixture screw
engine is
is
Section
in
NOT
cases, the
In virtually all
5.
the cause of a problem. Even
Remove
if
air/fuel
the
air
cleaner assembly.
speed on the
idle
Speed
Idle
proper
idle
engines are electronically
fuel injected
Module (ECM) computer. The
Control (ISC) system electrically oversees the
speed
for all operating conditions. This
news/bad news arrangement. The bad news
a good
is
you can’t
that
is
the good news is that rarely, ever, needs adjustAny roughness or uneven idle is almost always due to
adjust ing.
it;
if
it
other causes such as a clogged injector,
corroded terminals
air
leaks
in
in
air
leak or loose,
the wiring harness.
the system or faulty
Air Conditioning
internal carburetor parts (clogged jets, mis-adjusted floats,
We recommend
professional
all
mixture adjustments be handled by a
mechanic equipped with the proper emissions
test
^Be
sure to consult the laws
in
your area before servic-
ing the air conditioning system. In
equipment.
On
the tachometer. Connect
tested with an emissions analyzer, incorrect mixture
is
almost always caused by
etc.).
started cold.
if
to the correct locations.
controlled by the Engine Control
to the
touch the accelerator. The
would
Fuel Injected Engines
MIXTURE ADJUSTMENT
Access
it
2600 rpm.
California,
the
Install
Toyota. Adjusting this screw
accomplished
easily
speed by adjusting the lower screw on
Turn the engine OFF.
vacuum hoses
the
Speed And Mixture Adjustments
To meet emissions
is
the carburetor. Correct idle speeds are: 49 State and Canada,
9.
idle
is
Set the fast
8.
adjust the timing.
of the carburetor)
time push the choke plate (top
This sounds tricky but
Start the
7.
engine Reinstall the throttle body.
same
at the
valve.
with a thin tool.
cowl. 33.
EGR
bottom
throttle plate (in the
1-67
the fuel injected engines, fuel mixture
handled by the
is
computer, based on signals from the oxygen sensor
many
exhaust system and
in
the
other engine sensors. By having a
“picture” of the engine operating conditions at
any given mo-
most areas,
is illegal
it
work is done by a certified technician. Also, it is quite likely that you will not be able to purchase refrigerant without proof
to perform repairs involving refrigerant unless the
of certification.
ment, the computer determines the exact amount of fuel to maintain proper combustion and signals the injectors accord-
Any
ingly.
investigation of the air/fuel mixture
engine requires the use of an is
well out of the reach of the
on a
HC/CO emissions home mechanic.
SAFETY PRECAUTIONS
fuel injected
tester,
which
There are two major hazards associated with
systems and they both
gas (R-12 or R-1 34a)
refrigerant
ADJUSTMENT
IDLE
When exposed
stance.
face
it
comes
in
hazard relates to
Carbureted Engines
to air,
it
is
an extremely cold subinstantly freeze
will
contact with, including your eyes. fire
(if
conditioning
air
relate to the refrigerant gas. First, the
your vehicle
is
any
The
sur-
other
equipped with R-12.
Although normally non-toxic, the R-12 gas becomes highly poiBefore attempting to set the tions
must be met:
idle
speed, the following condi-
Air cleaner installed with
warmed and choke accessories switched OFF, all vacuum
etc. intact, tric
engine
transmission
in
fully
NEUTRAL
all
ducts, hoses,
plate open, lines
all
elec-
connected,
and parking brake set and engine
running at normal temperature. 1
.
2.
Connect a tachometer Set the curb
idle
to the engine.
3.
is
idle
700 rpm.
Turn the
and plug the hoses
system.
Because
of the inherent
for
OFF. Remove the
air
cleaner.
Remove
both the Hot Air Intake (HAI) and
Mixture Control (MC) systems.
followed.
• Avoid contact with a charged refrigeration system,
when working on another part vehicle. a heavy tool comes
of the air conditioning
tubing or a heat exchanger,
can easily cause the
it
into contact with
even
system or
a section of relatively
soft material to rupture.
•
When
it
is
necessary
Disconnect the hose from the choke opener diaphragm and plug the hose end. This shuts off the choke opener
contains refrigerant, as
system.
the
4.
dangers involved with working on
conditioning systems, these safety precautions must be
If
ignition
open flame. One good whiff of fatal. Keep all forms
of fire (including cigarettes) well clear of the air conditioning
strictly
speed by turning the adjusting screw
the presence of an
in
the vapor formed by burning R-12 can be
air
on the side (not the bottom) of the carburetor. Correct
speed
sonous
to apply force to
when checking
plings are securely tightened, fitting
involved,
if
that
a all
fitting
which
system cou-
use a wrench on both parts
possible. This
will
of
avoid putting torque on
GENERAL INFORMATION AND MAINTENANCE
1-68
refrigerant tubing.
^R-12
working on before attempting to add
also advisable to use tube or line
is
(It
wrenches when tightening these
the
flare nut fittings.)
when
refrigerant is a chlorofluorocarbon which,
ozone
layer in the upper atmosphere.
The most important aspect of air conditioning of a pure and adequate charge of
Ozone
not attempt to discharge the system without the proper
Precise control
tools.
possible only
is
gauges and a proper A/C
when connecting
protective gloves
when
Wear
A
Discharge the system only
testing or soldering, this
When
as toxic gas
particularly important,
is
• Never start a system without
first
verifying that both ser-
and
that
all
fittings
through-
any
may be aided by using to warm the refrigerant
refrigerant storage container to
out
sit
water heated to less than
Never allow a
container.
the sun, or near any
in
•
Always wear goggles
all
cases •
to protect
your eyes when working
refrigerant contacts the eyes,
If
it
is
advisable
•
use.
Always keep
jelly.
the valve,
make
A
drum
sure the cap
Never carry a drum
in
is
when
place
in
is
or from banging a
it,
in
heavy
it.
recovery unit before painting the vehicle
•
much
on), or before welding
When
the paint
is
dirt
as moisture or
is
open
to
be
refrigerant lines.
servicing the system, minimize the time that
refrigerant line or fitting
moisture or
(if
anywhere near
any
to the air in order to prevent
from entering the system. Contaminants such dirt
can damage
Always replace O-rings on
internal
which are discon-
as the valve
be expelled, the pressure available
restriction for
orifice will
prove
result. Eventually,
and
it,
air will
in
air
be drawn
moisture
will
of the
into the sys-
the low side.
contains at least
enter the system mixing with the of
some
moisture,
and
refrigerant
cause sludging
of the
oil,
corrosion of the system. Saturation and clogging of the
and freezing
As
tually result.
extent,
will
it
fills
interfere
expansion valve
oil.
and
fil-
orifice will
even-
the system to a greater and greater
more and more
with the normal flows of
and heat.
refrigerant
From
air
of the
of
the operating pres-
be lower than the pressure
will
atmospheric
all
drop, and a marked by freeze-up
will start to
cooling capacity,
in
coil, will
Trace amounts
ter/drier,
be
to
adequate flow even with the
tem wherever there are leaks will
to
continue to
will
withdrawn.
fully
severe reduction
system components.
lines or fittings
a
of
Because
a suitable
little
to
force the liquid through the expansion valve
water into
the stream of
in
compensate for its presence. As the quantity of liquid in the condenser decreases, the operating pressure will drop there and throughout the high side of the system. As the
the passenger compartment of a
Always completely discharge the system
baked
opens
atmosphere surrounding
tool against
the level of
in
begin to appear
will
the capacity of the expansion valve very
sure of the evaporator
not
con-
and so
refrigerant,
nears the bottom of the vessel, some
vapor bubbles
the evaporator
to protect
the can
flow of refrigerant
appear there as a reduction
this level
At this point, low side pressure
vehicle.
•
extreme operating
supplied to the expansion valve. This vapor decreases
needle
being used. Avoid sudden shock to the drum, which might
occur from dropping
will first
As
liquid
any excess
receiver/drier stores
liquid.
too
first
capped when not
fittings
equipped with a safety cap
is
The
a loss
physician should be consulted.
refrigerant
the container
If
a
operated with a continuous leak.
decrease, and, eventually, the valve’s
be treated by
gradually warming the area with cool water, and then gently
applying petroleum
is
it
refrigerant continues to
in
a physician immediately.
to consult
Frostbite from liquid refrigerant should
system as
to the
refrigerant
refrigerant line or storage ves-
other source of heat, such as a radiator or heater.
on a system.
if
common
Leaks are
lost.
to thp evaporator, the level of refrigerant there is fairly
out the system are snugly connected. • Avoid applying heat to
pens
stant.
vice valves are properly installed,
Charging
is
Because the expansion valve regulates the
leak
formed when R-12 contacts any flame.
125°F (50°C)
charge
The problem can be understood by considering what hap-
a well ventilated area, as
in
can exclude oxygen and act as an anesthetic.
sel.
of the
pressures of the system to force refrigerant out.
high concentrations of the gas which might accidentally escape
is
the
is
refrigerant in
system cannot function properly
refrigeration
percentage
significant
of the air conditioning fittings; allowing, the
or disconnecting service
gauge hoses. •
of
because the severe vibration encountered underhood in an automobile can easily cause a sufficient cracking or loosening
using the service
refrigerant recovery station.
Use
to the
service
maintenance the system.
Do
•
refrigerant.
cause damage
system.
out harmful radiation from the sun.
filters
refrigerant or oil will
re-
leased into the atmosphere, can contribute to the depletion of the
wrong
this description,
repairman’s focus
in
it
should be obvious that
much
of the
on detecting leaks, repairing them, and
nected. Prior to installation coat, but do not soak, replacement
then restoring the purity and quantity of the refrigerant charge.
O-rings with suitable compressor
A
oil.
list
of general rules
should be followed
in
addition to
all
safety precautions:
GENERAL SERVICING PROCEDURES
•
Keep
•
Thoroughly purge the service gauges/hoses
all
tools
as clean and dry as possible. of air
and
moisture before connecting them to the system. Keep them
•It
is
recommended, and possibly required by
law, that a
qualified technician perform the following services.
capped when not necting
•-WARNING Some
covered by this manual may be equipped with R-134a refrigerant systems, rather than R-12. Be ABSOLUTELY SURE what type of system you are of the vehicles
in
use.
• Thoroughly clean it,
in
any
refrigerant fitting before discon-
order to minimize the entrance of
dirt into
the
system. •
Plan any operation that requires opening the system be-
forehand,
exposed
in
to
order to minimize the length of time
open
air.
Cap
or seal the
the entrance of foreign material.
open ends
it
will
be
to minimize
GENERAL INFORMATION AND MAINTENANCE When
•
adding
not use
oil
that
Purchase
•
pour
oil,
Keep
dry tube or funnel.
it
1-69
through an extremely clean and
capped whenever possible. Do has not been kept tightly sealed. the
oil
refrigerant intended for
use only
automatic
in
air
conditioning systems. • Completely evacuate
and
vacuum pump for
for at least
one
up
for
has been opened
draw and moisture
air
hour.
If
a considerable length of time
evacuate the system •
that
sufficiently to
This requires evacuating
air.
open
any system
has leaked
for service, or that
moisture
in
with a
good
a system has been it
may be
advisable to
12 hours (overnight).
to
Use a wrench on both halves
of
a
fitting
that
is
to
be
disconnected, so as to avoid placing torque on any of the refrigerant lines.
•
When
overhauling a compressor, pour
a clean glass and inspect
it.
particles, or both, flush
refrigerant
all
If
if
is
some
of the
evidence of
components
oil
into
metal
dirt,
with clean
and recharging the system.
refrigerant before evacuating
addition,
there
In
metal particles are present, the compressor should
be replaced. •
Schrader valves
pressure. Therefore,
for leaks
from
when under
leak only
leakage
is
all
full
operating
CONDENSATION DRAIN TUBE
suspected but cannot be
system with a
located, operate the
and look
may if
full
charge
This single molded drain tube expels the condensation,
of refrigerant
Schrader valves. Replace any
faulty
which accumulates on the bottom into the
valves.
engine compartment.
evaporator housing,
of the
this
If
tube
is
conditioning performance can be restricted
Additional Preventive Maintenance
buildup can
spill
over onto the vehicle’s
obstructed, the
air
and condensation
floor.
USING THE SYSTEM
SYSTEM INSPECTION The easiest and most important preventive maintenance for your A/C system is to be sure that is used on a regular basis. Running the system for five minutes each month (no
^R-12
matter what the season)
leased into the atmosphere, can contribute to the deple-
it
components remain
internal
help assure that the seals and
will
all
filters
ditioning In
order to prevent heater core freeze-up during A/C operait
is
necessary
Use a hand-held
to maintain
a proper antifreeze protection.
antifreeze tester (hydrometer) to periodically
check the condition
of the antifreeze in
your engine’s cooling
system.
the upper atmosphere.
in
most important check
often
system consists
of
refrigerant leaks,
drive belt tension
and
fins,
up dust or
RADIATOR CAP
dirt
in
system, the radiator cap should have a holding pressure which
meets manufacturer’s specifications. A cap which
fails to
hold
heavy
dirt
con-
clutch,
compressor
disconnected or broken wires, blown
and poor
insulation.
appear as an
the system.
The
oily
oily
will
build
residue at
residue soon picks
particles from the surrounding air
greasy. Through time, this
For efficient operation of an air conditioned vehicle’s cooling
for the air
condition, plugged evaporator drain tube,
refrigerant leak will usually
the leakage point
turer specifies.
Ozone
conditioning system for
air
damaged compressor
blocked condenser
A
re-
a visual inspection of the system
components. Visually inspect the
fuses, corroded connections
^Antifreeze should not be used longer than the manufac-
when
out harmful radiation from the sun.
The easiest and
See Figure 168
tion,
ozone layer
tion of the
lubricated.
ANTIFREEZE >
refrigerant is a chlorofluorocarbon which,
and appears
up and appear
to
be a
impregnated grease. Most leaks are caused by
damaged or missing O-ring seals at the component connections, damaged charging valve cores or missing service gauge port caps.
these pressures should be replaced.
For a thorough visual and operational inspection, check the
CONDENSER
following: 1
Any will
tion.
obstruction of or
restrict It
is
damage
the air flow which
therefore a
good
is
to the
condenser configuration
essential to
rule to
its
efficient
opera-
this unit
clean and
of the radiator
and condenser
for kinks in
hoses and
lines.
for dirt,
air flow.
Check
the system
in'
screens which are mounted in front of the condenser (unless they are original equipment) are regarded as obstructions.
Check
2.
keep
proper physical shape.
^Bug
Check the surface
.
leaves or other material which might block
for leaks.
Make
3.
sure the drive belt
is
When
the
belt
free of noise or slippage.
is
air
conditioning
is
under the proper tension.
operating,
make
sure the drive
GENERAL INFORMATION AND MAINTENANCE
1-70 Make
4.
sure the blower motor operates at
check
positions, then
for distribution of the air
all
appropriate
from
all
outlets
wiper pattern
and most sensible
est
(Keep
mind
in
under conditions of high humidity, may not feel as cold as
that
air
discharged from the A/C vents expected, even
the system
if
working properly. This
is
is
because the vaporized moisture in humid air retains heat more effectively than does dry air, making the humid air more difficult to cool.
Make
5.
sure the
passage selection
air
make
temperature, then
warm
engine and
correctly. Start the
smeared
is
it
to
lever
is
If
any
type blade or
is
as the original equipment. Here are
refill
The Anco® type uses a release back
slides
down
a
system
of
recommend
you take your vehicle
that
repairs on the vehicle,
take your vehicle
When you
type
for the
necessary equipment,
to the
have the work done.
station to
standards
If
you
to
still
we
a reputable service
the
refill
perform the necessary work.
are finished, return the vehicle to the station for
evacuation and charging. Just be sure to cap
ALL A/C system
fittings
immediately after opening them and keep them pro-
tected
until
the system
Press
refills
have two metal tabs which are
A new
filler
frame jaws and
into the front
is
refill
can installed
sliding
it
rearward to engage the remaining frame jaws. There are usu-
gaged into
when
jaws; be certain
in all of
installing that the
them. At the end of
travel, the
its
Another type of
made from
is
refill
has a simple locking device
tabs
at
en-
will
polycarbonate. The
one end which
flexes
out of the groove into which the jaws of the holder
easy release. By
sliding the
pushing through the of
is
refill
lock
place on the front jaws of the wiper blade frame.
its
travel, the
about
1
in.
new
refill
slight resistance
refill
wiper blade. This
Windshield Wipers
strip.
from the retaining tab.
refill
through
when
it
all
refill
downward
fit,
allowing
the jaws and
reaches the end
lock into position.
will
To replace the Tridon®
recharged.
is
wider. Insert a small screw-
is
refill
then be withdrawn from the frame jaws. refill
refill
place.
in
unlocked by squeezing them together. The rubber
wish to perform
have them discharge the system, then
home and
pushed down
between the frame and metal backing
to release the
ally four
you don’t have access
If
SAE
meets
that
be serviced.
to
is
are removed by locating where the
refills
strip or
by inserting the
equipped with refrigerant recov-
facility
equipment
ery/recycling
certified
available for
yoke jaws. The new
frame and locks
into the
Other types of Trico®
system must be performed by a properly trained and
may be
all
button that
to slide out of the
refill
driver blade
Discharging, evacuating and charging the air conditioning
and your vehicle might have
refills
your vehicle:
Some Trico®
DISCHARGING, EVACUATING AND CHARGING
easi-
is
It
in pairs.
blades and arms rarely use the exact
typical aftermarket blades; not
to allow the
normal operating
the
If
the blade chatters
equipped with aftermarket blades, there are
is
kind. Aftermarket
same some
operating
sure the hot/cold selection lever
your vehicle
metal backing
in
about one year. if
elements
to replace the
several different types of
operating correctly.
mechanic
to
life
or streaked, or
across the glass, the elements should be replaced.
HIGH.
with the blower on
deterioration usually limits element
refill,
has a
necessary
is
it
backing
plastic
to
remove the
strip with
a notch
the end. Hold the blade (frame) on a
(25mm) from
hard surface so that the frame
is
bowed. Grip the
tightly
tip of
the backing strip and pull up while twisting counterclockwise.
ELEMENT
CARE AND REPLACEMENT
(REFILL)
The backing
strip will
the remaining tabs length of these
See Figures 169, 170, 171, 172, 173, 174, 175, 176, 177, 178 and 179
I
effectiveness and longest element
windshield and wiper blades should be kept clean. sap, road tar and so on
will
blade deterioration
on the glass.
if
left
the
life,
Dirt,
tree
cause streaking, smearing and It
is
advisable to
wash
the windshield carefully with a commercial glass cleaner at least
once a month. Wipe
rag afterwards.
Do
To
will
off
the rubber blades with the wet
not attempt to
windshield by hand;
nism
damage
move wipers across
to the
the
motor and drive mecha-
result.
inspect and/or replace the wiper blade elements, place
the wiper switch switch
in
the
in
ACC
the
LOW
position.
speed
When
position
and the
ignition
the wiper blades are ap-
proximately vertical on the windshield, turn the ignition switch to
OFF. Examine the wiper blade elements.
If
they are found to be
cracked, broken or torn, they should be replaced immediately.
Replacement
Regardless
is
the
of the retaining tab.
refill
molded
is
intervals will vary with usage, although
ozone
Do this The
for
free of the blade.
end and they should
into the
identical types.
of the type
used, be sure to follow the part
manufacturer's instructions closely.
maximum
For
refills
be replaced with
snap out
until
frame jaws are engaged as the
Make
refill
is
sure that
all
of the
placed and locked.
the metal blade holder and frame are allowed to touch the
glass during wiper operation, the glass
will
be scratched.
If
GENERAL INFORMATION AND MAINTENANCE
1-71
tecs 1224
tecs 1228
Fig. Fig.
170 Lexor® wiper blade and
fit
kit
173 To remove and
refill,
a
install
Lexor® wiper blade in a new one
out the old insert and slide
slip
tecs 1225
tccsl229
Fig. Fig. 171
Pylon® wiper blade and adaptor
174
On Pylon®
inserts, the clip at the
be removed prior to sliding the insert
end has
to
off
tecs 1230
Fig.
175
the blade
On Trico® wiper
blades, the tab at the end of
must be turned up
.
.
.
GENERAL INFORMATION AND MAINTENANCE
1-72
BLAOC REPLACEMENT 1
CYCLE ARM AND BLADE ASSEMBLY TO UP POSlTtONWl NO SHIELD WHERE REMOVAL OF BLADE ASSEMBLY CAN BE PERFORMED WITHOUT DIFFICULTY TURN lONITtON KEY OFF AT OESIREO
ON THE
POSITION 2
TO REMOVE BLADE ASSEMBLY. INSERT SCREWDRIVER IN SLOT. PUSH OOWN ON SPRING LOCK AND PULL BLADE ASSEMBLY FROM PIN (VIEW A)
3
to install, push the Blade assembly on the SO THAT the SPRING LOCK ENGAGES THE PIN A) BE SURE THE BLADE ASSEMBLY IS SECURELY ATTACHEO TO PIN PIN
(VIEW
VIEW A
NOTE INSERT SCREWORIVER 3 2
mm
(1/8
INCH)
OR LESS PAST
TWIST CLOCKWISE
ELEMENT REPLACEMENT 1
INSERT SCREWDRIVER BETWEEN The EDGE OF ThE SUPER STRUCTURE AND The BLADE BACKING ORiP (VIEW B) TWIST SCREWORIVER SlOwly until ELEMENT CLEARS ONE SlOE OF Th£ SUPER STRUC
4
ture Claw the element into the super structure Claws
2 Slide
INSERT ELEMENT INTO ONE SlOE OF THE END Claws (view 0) and with a rocking motion push element upward until it snaps in (view E)
VIEW B
*
ELEMENT STOP
slide element starting AT This point 3
VIEW 0
iboth ends)
‘
'
SLIDE The ELEMENT into THE SUPER STRUCTURE CLAWS. STARTING with SECOND SET FROM EITHER ENO (VIEW C) ANO CONTINUE TO SLIDE THE BLAOE ELEMENT INTO ALL THE SUPER STRUCTURE CLAWS TO THE ELEMENT STOP (VIEW C)
VIEW C
VIEW e tccs!236
Fig.
176 Trico® wiper blade insert (element) replacement
GENERAL INFORMATION AND MAINTENANCE
BLADE REPLACEMENT 1
2
Cycle arm and blade assembly to a position on the windshield where removal performed without difficulty. Turn ignition key off at desired position
of
blade assembly can be
To remove blade assembly from wiper arm. pull up on spring lock and pull blade assembly from pin (View Be sure spring lock is not pulled excessively or it will become distorted.
A).
3
To
install,
the blade
push the blade assembly onto the pin so assembly is securely attached to pin
that the spring lock
engages the
pin (View A).
Be sure
ELEMENT REPLACEMENT 1
In
the plastic backing strip which
notch located approximately 2
Place the frame
ol
is
part of the rubber blade assembly, there
one inch from
the wiper blade
an
is
1 1
1 1
mm (7/16 inch) long
either end. Locate either notch
assembly on a
firm surface with either
notched end
of the
backing
strip
visible.
3
Grasp the frame portion
of the wiper
blade assembly and push
down
until
the blade
assembly
is tightly
bowed. 4
With the blade assembly twisting
C.C.W.
at
the
in
the
bowed
position,
same time The backing
grasp the
strip will
tip of
the backing strip firmly, pulling
then snap out
ol the retaining tab
up and
on the end
of
(he
frame
assembly from the surface and slide the backing strip down the frame until the notch up with the next retaining tab. twist slightly, and the backing strip will snap out Continue this operation with the remaining tabs until the blade element is completely detached from the frame 6 To install blade element, reverse Ihe above procedure, making sure all six (6) tabs are locked to the backing strip before installing blade to wiper arm 5.
Lift
the wiper blade
lines
Fig.
177 Tridon® wiper blade insert (element) replacement
1-73
GENERAL INFORMATION AND MAINTENANCE
1-74
TIRE ROTATION I See Figures 180 and 181 Tires must be rotated periodically to equalize
wear patterns
on the vehicle. Tires
that vary with a tire’s position
also
will
wear in an uneven way as the front steering/suspension system wears to the point where the alignment should be reset. Rotating the tires
so you
set,
ensure
will
maximum
not have to discard a
will
only part of the tread. Regular rotation
for the tires
life
early
tire
due
as a
wear on
to
required to equalize
is
wear.
When ways the
rotating “unidirectional tires,”
roll
in
same
the
direction. This
make means
sure that they
al-
used on
that a tire
side of the vehicle must not be switched to the right
left
side and vice-versa.
These
tires
are marked on the sidewall as
tccal‘231
observe the mark when
to the direction of rotation;
178 ... then the insert can be removed. After installing the replacement insert, bend the tab back
the
Fig.
reinstalling
tire(s).
Some
“mag" wheels may have
styled or
used up
and vice-versa. Furthermore,
front
equipped with unidirectional less the
different offsets
these cases, the rear wheels must not be
front to rear. In
remounted
tire is
•The compact
if
these wheels are
tires,
they cannot be rotated un-
for the
proper direction of rotation.
or space-saver spare
emer-
for
is strictly
gency use. It must never be included in the placed on the vehicle for everyday use.
tire
rotation or
TIRE DESIGN >
See Figure 182
maximum
For four.
must be avoided.
belted) turer
satisfaction, tires should
Mixing of different types In
has designated a type
perform best. Your
first
be used
in
sets of
(radial, bias-belted, fiberglass
most cases, the vehicle manufacwhich the vehicle
of tire ori
choice
when
will
replacing tires should be
tecs 1232
to
Fig.
179 The Tripledge® wiper blade insert
and
installed using a securing clip
is
removed
use the same type
of tire that the
manufacturer
recommends.
When
'
radial tires are used, tire sizes
and wheel diameters
should be selected to maintain ground clearance and capacity equivalent to the original specified
Tires
and Wheels
Common
sense and good
should always be used
Fast starts, sudden stops and hard cornering are hard
on
and
tires
will
shorten their useful
life
span.
Make
sure that
you don’t overload the vehicle or run with incorrect pressure the
tires.
Both of these practices
Be
Inspect your tires frequently.
bubbles
for
tion.
in
will
tires with
bubbles
deep cuts in
or underinfla-
the sidewall.
If
so deep that they penetrate to the cords, discard the cut for is
in
the sidewall of a radial
tire
uneven tread wear patterns
renders
that
may
it
cuts are tire.
Any
unsafe. Also look
indicate the front
out of alignment or that the tires are out of balance.
load
sets of four.
Radial tires should never be used on only the front axle.
in
increase tread wear.
especially careful to watch
the tread or sidewall,
Replace any
tire
Radial tires
•-CAUTION
maximum
driving habits will afford
tire life.
in
tire.
end
When selecting tires, pay attention to the original size as marked on the tire. Most tires are described using an industry size code sometimes referred to as P-Metric. This allows the exact identification of the manufacturer.
If
tire
specifications, regardless of the
selecting a different
ber to check the installed
tire
size or brand,
any sign
tire for
the body or suspension while the vehicle
remem-
of interference with is
stopping, turning
sharply or heavily loaded.
Snow
Tires
Good
radial tires
weather, but
in
can produce a big advantage
snow, a street
cient tread to provide traction of a street tire quickly
radial tire
slippery suffi-
The small grooves snow and the tire behaves
and
pack with
in
does not have
control.
GENERAL INFORMATION AND MAINTENANCE
1-75
tecs 1259
Fig.
180
Common
tire rotation
patterns for 4 and 5 wheel rotations
like
a
billiard ball
tread of a
much To
snow
on a marble
The more open, chunky
floor.
self-clean as the tire turns, providing
tire will
on snowy surfaces.
better grip
satisfy municipalities requiring
emergencies, most snow
snow
tires carry either
during weather
tires
an
M
+ S designa-
stamped on the sidewall, or the designageneral, no change in tire size is neces-
tion after the tire size tion “all-season.” In
when buying snow
sary
tires.
Most manufacturers strongly recommend the use on
tires fitted
reasons of
their vehicles for
stability.
If
of
snow
4 snow tires
are
only to the drive wheels, the opposite end of the vehicle
may become
very unstable
when
braking or turning on slippery
surfaces. This instability can lead to unpleasant endings driver can’t counteract the slide
Note that snow
tires,
in
if
the
time.
whether 2 or
4, will affect
vehicle
The stiffer, heavier snow tires will noticeably change the turning and braking characteristics of the vehicle. Once the snow tires are installed, you must re-learn the behavior of the vehicle and drive accordingly. handling
in all
non-snow
situations.
^Consider buying extra wheels on which to mount the snow tires. Once done, the “snow wheels” can be installed and removed as needed. This eliminates the potential damage to tires or wheels from seasonal removal and installation.
Even
if
your vehicle has styled wheels, see
if
inexpensive steel wheels are available. Although the look of the vehicle will change, the
protected from
TIRE
If
curb
hits
expensive wheels will be and pothole damage.
STORAGE
they are mounted on wheels, store the
inflation If
salt,
pressure.
they are stored
All tires in
stand on a concrete
should be kept
is
of
tires at
proper
a cool, dry place.
the garage or basement, do not floor; set
them on
or a large stack of newspaper. Keeping
moisture
in
strips of
let
them
wood, a mat
them away from
paramount importance. Tires should not be
stored upright, but
in
a
flat
position.
direct
GENERAL INFORMATION AND MAINTENANCE
1-76
INSPECTION I See Figures 183, 184, 185, 186, 187, 188, 189 and 190
The importance
A
sized.
tire
cannot be overempha-
of proper tire inflation
employs
as part
air
around the supporting strength
of
structure.
its
It
designed
is
of the air at a specified pres-
sure. For this reason, improper inflation drastically reduces the
in
A
perform as intended.
tires’s ability to
lose
tire will
day-to-day use; having to add a few pounds of
a sign
cally is not necessarily
Two
depth gauge. Check the
because
when ture.
it
air
hose
suffers too
at
every glove
pressure (including the spare)
Too
regularly with a pocket type gauge.
the end of the
in
pressure gauge and a tread
tire
tire
air
of a leaking tire.
items should be a permanent fixture
compartment: an accurate
some
air periodi-
often, the
your corner garage
gauge on
not accurate
is
much abuse. Always check
pressure
tire
the tires are cold, as pressure increases with temperaIf
you must move the vehicle
to
check the
tire inflation,
do not drive more than a mile before checking. A cold generally
one
that
has not been driven
for
Fig.
184 Tires with deep cuts, or cuts which show
bulging should be replaced immediately
tire is
more than three
hours.
A
plate or sticker
is
normally provided
somewhere
vehicle (door post, hood, tailgate or trunk
proper pressure for the
tires.
sure build-up by bleeding out).
This
will
cause the
lid)
in
the
which shows the
Never counteract excessive pres-
off air
tire to
pressure
(letting
run hotter and
some
wear
air
quicker.
^CAUTION Never exceed the tire!
This
maximum
is
maximum
pressure embossed on the
tire
the pressure to be used
loading, but
it
is rarely
when
the
tire is at
the correct pressure for
everyday driving. Consult the owner’s manual or the pressure sticker for the correct tire pressure.
Once you’ve maintained weeks,
you’ll
be
the correct
tire
tire
pressures for several
familiar with the vehicle's braking
and han-
dling personality. Slight adjustments in tire pressures
can
fine-
tune these characteristics, but never change the cold pressure specification by
more than 2
psi.
A
slightly softer tire
pressure
PROPERLY INFLATED
IMPROPERLY INFLATED
RADIAL TIRF tecs 1263
Fig.
186 Radial
tires
bulge; don’t try to tire.
Use
a quality
have a characteristic sidewall
measure pressure by looking air pressure gauge
at the
GENERAL INFORMATION AND MAINTENANCE
•HAVE
TIRE
INSPECTED FOR FURTHER USE. tccs!267
Fig.
will
Common
187
tire
wear patterns and causes
A
give a softer ride but also yield lower fuel mileage.
slightly
harder
tire will
give crisper dry road handling but can
cause skidding on wet surfaces. Unless you’re the vehicle, stick to the
made
All tires
recommended
since 1968 have
inflation
built-in
tread
fully
attuned to
pressures.
wear
indicator
show up as V2 in. (13mm) wide smooth bands across the tire when Vie in. (1 ,5mm) of tread remains. The appearance of tread wear indicators means that the tires should be bars that
replaced.
In fact,
tires with less
many
states
You can check your own
or by using a Lincoln
penny
(with Lincoln’s If
tire
has less than
of Lincoln’s Vie in.
manner by using the can see the top
snow
tire(s).
"tails” side of
of the Lincoln
head
in
(1.5mm) tread
should be replaced. You can measure snow
the
of
head penny. Slip the Lincoln head upside-down) into several tread
you can see the top
grooves, the
use
prohibiting the
tread depth with an inexpensive
gauge
grooves.
have laws
than this amount of tread.
tires in
2 adjacent left
the
the Lincoln penny.
memorial,
it's
If
and
same you
time to replace
1-77
GENERAL INFORMATION AND MAINTENANCE
1-78
CARE OF SPECIAL WHEELS
wood. Never store
strips of
may develop
When
•
you have invested money
If
magnesium, aluminum
in
or sport wheels, special precautions should be taken to
sure your investment
wheels look good
for the
check the rims
leaks.
any
If
of
ment
of
•
Use
damaged
damage
installation, balancing, etc. After
hazards;
for
doesn’t take
it
much
to
washing, use a mild soap or non-abrasive dish de-
possible,
If
sand used
in
in
mind
that detergent tends to
remove wax).
Make
•
the wheels during removal,
wheels.
winter. Salt
snow removal can severely damage
exceeded
certain the
recommended
may
or the wheel
crack.
special wheels; severe scratching
removal of the wheels from
the vehicle, place them on a mat or other protective surface.
for
for special
remove the wheels during the
and
the finish of
a wheel.
the costly replace-
a special wheel, observe the following precautions:
damage
watch
There are many cleaners and polishes •
or air
these are found, replace the wheel. But
extra care not to
When
•
tergent (keeping
and/or scratched. Occa-
damage and
driving,
Avoid cleansers with abrasives or the use of hard brushes.
impact
for cracking,
order to prevent this type of
make
your special
that
upright; the tread
crack a wheel.
alloy
of the vehicle.
life
Special wheels are easily sionally
and
not wasted
is
and wheels
tires
spots.
flat
lug nut torque
is
never
Never use snow chains on occur.
will
If
they are to be stored for any length of time, support them on
FLUIDS AND LUBRICANTS Fluid Disposal Used
fluids
and brake
such as engine
Before draining any
of properly.
authorities; in
transmission
oil,
fluid,
antifreeze
are hazardous wastes and must be disposed
fluid
many
fluids,
areas, waste
oil,
consult with your local
being accepted as
etc. is
a part of recycling programs. A number
of service stations
and
auto parts stores are also accepting waste fluids for recycling.
Be sure
any been
of the recycling center’s policies before draining
many
as
fluids,
not accept different fluids that have
will
mixed together, such as
oil
and
Fuel and Engine Oil
antifreeze.
Recommendations
DON’T POLLUTE. CONSERVE RESOURCES. RETURN USED OIL TO COLLECTION CENTERS
GENERAL INFORMATION Fig. 191 Look for the API choosing your engine oil
Oils
> See Figures 191, 192 and 193
The SAE
you choose when changing the
indicates the viscosity of the engine
lighter the
SAE ity
oil.
to
SAE 80
These
cants.
oil;
its
resistance to flow
The lower the SAE grade number, the
For example, the mono-grade
5 weight, which
up
number
(Society of Automotive Engineers) grade
at a given temperature.
or
a
is
thin, light oil,
in
known as
viscos-
meaning
“straight weight”,
the
is
oil
changed again. Refer
recommendations according the classification of engine
oil,
make
to the
sure you are
be operating
will
oil
Institute)
designation indicates
designated
for
use “Service SG” or
SG
type perform a variety
Only
oils
engine
addition to the basic function
as a lubricant. Through a balanced system
adaptable to temperature extremes. These tions in
such as 10W-40, 20W-50,
oil,
that
of high
and
and low temperature deposits and also keeps sludge
particles of dirt in suspension. Acids, particularly sulfuric
as well as other by-products of combustion, are neutral-
ized.
Both the
Once
bottle
however, the
nents.
have designa-
of metallic deter-
prevents the formation
acid,
“W”
in
the designation) the
offering rapid lubrication.
good
oils
The “10W-40” means
oil
allowing the engine to spin easily
winter (the
weight
etc.
in
gents and polymeric dispersants, the
being
oil
used under certain given operat-
temperature. of
until
to temperature.
of functions inside the
advantage
antici-
in
viscosity chart for
oil
they are of a single viscosity, and do not vary with engine
Multi-viscosity oils offer the important
when
greater should be used. Oils of the
ing conditions.
lubri-
identification label
pating the temperatures your engine
The API (American Petroleum
begin with
oils
and continue
90 weight, which are heavy gear
are also
oils
oil
acts
oil
lubrication
oil
the
like
a thin 10
when cold and engine has warmed up,
for the engine’s internal
would therefore be
ideal in cold
acts
a straight 40 weight, maintaining
and protection
A 20W-50
and not as
like
oil
slightly
compo-
ties,
can. For
recommended
oil
viscosi-
SYNTHETIC OIL
weather as the 10W-40, but would
rpm and temperatures because a 50 weight oil. Whichever oil viscosity
There are many excellent synthetic
oils currently
can provide better gas mileage, longer service
when warm
some cases
like
oil
heavier than
that
acts
grade number and the API designation
refer to the chart.
offer better protection at higher it
SAE
be found on the
better engine protection.
These
available life,
benefits
and
do not
in
GENERAL INFORMATION AND MAINTENANCE Consider your type of mileage
is
driving.
may be
the
and
oil
warm
in
highway
synthetic
If
oil
last
itself will
in
much
due
driving,
used,
is
as stated
intervals
more expen-
up, accumulating less
putting less stress
it
on the engine over the
may show
long run. Trucks with synthetic oils
economy
your accumulated
a benefit. Extended highway driving
gives the engine a chance to in
of
high speed, highway type driving, the
sive synthetic oils
acids
most
If
1-79
increased fuel
to less internal friction.
should
still
be replaced
at regular
the maintenance schedule. While the
longer than regular
oil,
oil
pollutants such as
soot, water and unburned fuel still accumulate within the oil. These are the damaging elements within a motor and must be drained regularly to prevent damage.
Trucks used under harder circumstances, such as stop-and-
be
go, city type driving, short trips, or extended idling, should
serviced more frequently. For the engines TCCS1901
Fig.
new
192 Before installing a
rubber gasket with clean
oil filter,
much
these trucks, the
in
oils may not be much quicker on
greater cost of synthetic or fuel-efficient
worth the investment. Internal wear increases
coat the
these trucks, causing greater
oil
oil
consumption and leakage.
Fuel
Recommended
viscosity (SAE):
important to use fuel of the proper octane rating
is
It
Octane
truck.
rating
based on the quantity
is
compounds added
to the fuel
which the gas
burn.
will
and
The lower
it
in
your
of anti-knock
determines the speed
at
the octane rating, the faster
The higher the octane, the slower the fuel will burn of compounds in the fuel prevent spark ping (knock), detonation and pre-ignition (dieseling). As the temperature of the engine increases, the air/fuel mixit
burns.
and a greater percentage
ture exhibits a If
*F
-20
80
60
40
20
0
100
Temperature range anticipated before next change
ignition timing of
your truck,
premium
193 Viscosity chart
fuel is
without a few hitches, however; the main one being the
per quart of conventional Synthetic
is
oil
is
ing the
use
not for every truck and every type of driving,
check your
truck’s warranty conditions regard-
new engines and
older, high
engines; most manufacturers is
properly broken
age. Slippery synthetic truck
much
is
leaking
oil
a properly tuned and main-
your engine exhibits any
when
using regu-
removed
for
oils
Vehicles equipped with catalytic converters must use
UNLEADED GASOLINE
oil.
A
synthetic
recommend
that
of
you wait
Use
of
leaded
fuel
EGR
shortens the
valves and can
the catalytic converter. Most converter equipped
designed
to
oil
of
only.
spark plugs, exhaust systems and
els are
3000 miles (4830 km) before using synthetic oil. Older engines with wear have a different problem with synthetics: they leak more oil as they the engine
ignite
super-
the ignition timing should be checked against specifi-
damage
mileage engines
can be so slippery that they can prevent the proper break-in
until
some
decarbonizing.
life
are often the wrong candidates for synthetic
new
if
cations or the cylinder head should be
of synthetic oils.
Both brand
for
that
of
oil.
so you should consider your engine's condition and your type of driving. Also,
no substitution
signs of spark ping, detonation or pre-ignition lar fuel,
three or four times the price
slow the combustion pro-
and smoothly. The use
Chances are
tained engine.
will
spark plug enough time to
sufficiently to allow the
the mixture completely
which
is fired.
used, this
Fuel of the proper octane rating, for the compression ratio
cess
price of synthetic oils,
is
very rapidly.
and
come
spark plug
low for the engine
compression stroke, thereby creating a very high pressure
its
86821236
Fig.
to ignite before the
rating too
allow combustion to occur before the piston has completed
will
oil
tendency
an octane
fuel of
minimum
mod-
operate using unleaded gasoline with a
rating of 91
ratings lower than 91
Use
octane.
of
unleaded gas with octane
can cause persistent spark knock which
could lead to engine damage.
in
get past worn parts easily.
If
your
past old seals you’ll most probably have a
greater leak problem with synthetics.
Light spark ing
up
hills,
knock
may be
particularly with
noticed
when
accelerating or driv-
a carbureted engine. The
slight
may be considered normal (with 91 octane) because maximum fuel economy is obtained under condition of oc-
knocking the
casional
light
spark knock. Gasoline with an octane rating
GENERAL INFORMATION AND MAINTENANCE
1-80
may be
higher than 91
used, but
it
is
not necessary
(in
most
engine’s fuel requirement can change with time,
mainly due to carbon buildup, which changes the compression ratio. If your engine pings, knocks or runs on,
Sometimes just changing brands will cure the problem. If it becomes necessary to retard the timing from specifications, don’t change it more than a few degrees. Retarded timing will reduce power output and fuel mileage and will increase the engine
the
If
horizontally,
below the L mark, add oil of capped opening on the top of
oil
is
head cover.
the cylinder
fuel.
dipstick.
it
should be between the F and L
oil
the proper viscosity through the
Reinsert the dipstick and check the
5.
switch to a higher grade of
The
level.
oil
marks on the
'Your
again and, holding
Pull the dipstick out
4.
read the
cases) for proper operation.
adding any
Be
oil.
imately
one quart
Excess
oil will
oil
level
again after
careful not to overfill the crankcase. Approxof
oil will
generally be
raise the level from the
consumed
at
L
to the F.
an accelerated
rate
as well as hampering engine operation.
temperature.
AND FILTER CHANGE
OIL
Engine I See Figures 195, 196, 197, 198, 199 and 200
OIL LEVEL
CHECK
The
and
oil
filter
should be changed every 7500 miles
(12,000 km). I
See Figure 194
^CAUTION
**CAUTION
Prolonged and repeated skin contact with used engine
Prolonged and repeated skin contact with used engine
oil,
may cause skin cancer. these simple precautions when handling
with no effort to remove the
oil,
Avoid prolonged skin contact with used motor
•
Remove
oil
remove the
oil,
Always follow used motor oil:
Always follow used motor oil: •
oil,
may cause skin cancer. these simple precautions when handling
with no effort to
•
Avoid prolonged skin contact with used motor
•
Remove
oil.
from skin by washing thoroughly with soap
oil
and water or waterless hand cleaner. Do not use gasoline,
oil.
from skin by washing thoroughly with soap
thinners or other solvents.
and water or waterless hand cleaner. Do not use gasoline,
Avoid prolonged skin contact with oil-soaked clothing.
•
thinners or other solvents. •
The
Avoid prolonged skin contact with oil-soaked clothing.
drain plug
oil
pan (bottom Every time you stop
be
Park the truck on
2.
When
minutes after turning
back 3.
from
into the
Open its
oil
oil
level
it
is
best for the engine to
will
off
oil
immedi-
lead to a false reading. Wait a few
the engine to allow the
oil
to drain
pan (crankcase).
it
figures given are the Toyota
assuming normal
tervals
The
truck).
oil
oil filter
usually this
day use
is
recommended
and conditions. Normal
driving
requires that the vehicle be driven fa" oil;
enough
to
about 10 miles (16 km) or so.
in-
driving
warm up If
the
your every-
shorter than this (one way), your use qualifies as
is
severe duty.
the hood and locate the dipstick. Pull the dipstick
tube, wipe
underneath the
located on the side of the engine.
is
The mileage
temperature, although checking the
ately after a stopping
as follows:
oil
level ground.
checking the
at operating
check the engine
for fuel,
1.
located on the bottom, rear of the
is
of the engine,
clean and reinsert
Severe duty includes dusty, polluted or off-road conditions, as well as stop-and-go short haul uses. Regularly towing a
it.
trailer
also puts the truck
category, as does constant
in this
Change the oil and filter 7500 equals 3250 miles (5229
operation with a near capacity load. at
V2 the normal
km); round
Level dipstick
km) Low
others, level
line
Full
level
it
interval.
interval. Half of
down to the easily remembered 3000 mile (5000 some owners, that may be once a month; for
For
may be
it
six
Always drain the
enough
F
the
oil
Too
if
it
to
after the
engine has been running long
normal operating temperature. Hot
oil
more contaminants will be removed along were drained cold. To change the oil and
the engine
until
it
will
with filter:
reaches normal operating
temperature. 2.
Jack up the
front of the truck
and support
it
on safety
stands. 86821235
3. oil
oil
when
Slide a drain
pan
of at least
6 quarts capacity under the
pan. 4.
194 Read the dipstick carefully, add below the L mark; do not overfill
Run
it
oil
full
OK
Fig.
than
oil
1.
Add
to bring
flow easier and
L
(
months.
line
Loosen the drain plug with a wrench. Turn the plug out
by hand. By keeping an inward pressure on the plug as you the
unscrew
it,
oil
won’t escape past the threads and you can
level is
remove
it
without being burned by hot
oil.
GENERAL INFORMATION AND MAINTENANCE
1-81
86821246
Loosen Loosen
Fig.
195 Keeping an upward pressure on the drain plug it will prevent oil leakage until you’re
while unscrewing
ready for
Fig.
it
198
Allow the
5.
plug location
Oil drain
oil
to drain
- 22R-E and
completely and then
that
or a replacement plug for stripped threads.
Using a
6.
it’s
the
install
be buying a
drain plug. Don’t overtighten the plug, or you’ll
new pan
3VZ-E
filter
wrench, remove the
one quart
holding about
comes
the old gasket
off
oil
filter.
of dirty, hot
with the
filter
and
oil.
is
Keep
in
Make
certain
mind
not stuck to the
10. block. 7.
Empty the
old
filter
into the drain
pan and dispose
of the
filter.
8.
Using a clean rag, wipe
off
the
adapter on the
filter
engine block. Be sure that the rag doesn’t leave any could clog an 9.
oil
Coat the rubber gasket on the
onto the engine by hand; surface give the gasket
it
and
when
another it
lint
which
passage.
will
filter
with fresh
oil.
Spin
turn.
No more,
or you’ll
squash
leak.
86821239
Refill
the engine with the correct
See the “Capacities” Fig.
196 Oil drain plug location
— 1FZ-FE
chart.
it
the gasket touches the adapter
amount
of fresh
oil.
GENERAL INFORMATION AND MAINTENANCE
1-82
86821250
Use a wrench
Fig. 201
to
remove the 17mm plug on
the side of the case
Check the
11.
oil
be a
allow
to idle for
it
bit
level
on the
above the
level to
full
dipstick.
is
It
normal
squeeze
for the
mark. Start the engine and
a few minutes.
Install
4.
a nozzle; making additions simple. You
bottle with
can also use a
and check
the
common everyday filler
plug with a
kitchen faster.
new
gasket.
Run
the engine
for leaks.
**WARNING Do
not run the engine above idle speed until
up
oil
pressure, indicated
when
the
oil light
it
has
goes
DRAIN AND REFILL
built
out.
See Figures 205, 206 and 207
>
Shut
12.
OFF
and check the for
any
leaks,
the engine, allow the
oil
level.
to drain for
oil
Check around the
filter
a minute,
The
and drain plug
1
in
oil
is
at
Raise the truck and support
3. oil.
The recommended
types are: API GL-3, GL-4 or GL-5 with the viscosity
75W-90
or
sion.
The It
is
to
drain plug
work
drain plug, then
80W-90.
it
is
drained.
it
is
if
the truck
is
will
probably not
not raised.
located on the bottom of the transmis-
remove
five it.
and
speeds. Place a pan under the
Keep a
slight
upward pressure on
LEVEL CHECK >
See Figures 201, 202, 203 and 204 The
oil
the manual transmission should be checked 7500 miles (12,000 km) and replaced every
in
least every
at
25,000-30,000 miles (40,000-48,000 km). Even more frequently if
driven 1.
filler
deep
water.
With the truck parked on a level surface, remove the plug
gasket 2.
in
If
(17mm) from the
will
also have to be
side of the transmission housing.
A
removed and discarded.
the lubricant begins to trickle out of the hole, there
enough. Otherwise, carefully
insert
sharp threads) and check to see
if
your finger (watch out the
oil
is
is
for
up to the edge
of
the hole. 3.
edge
If
not,
add
of the hole.
oil
through the hole
until
the level
Most gear lubricants come
in
is
86821251
at the
a plastic
If
properly on jackstands so
usually on the passenger side on four speeds,
on the bottom center of
SAE
should be hot before
oil
you can safely work underneath. You
that
vehicles use a multipurpose gear
at
normal operating temperature, the transmission
have enough room
All
changed
should be hot enough. 2.
RECOMMENDATIONS
the manual transmission should be
30,000 miles (48,000 km).
The transmission
.
the engine
Manual Transmission FLUID
oil
least every
and correct as necessary.
Fig.
to
202 A gear
fill
the case
pump
with a nozzle
is
also a type used
GENERAL INFORMATION AND MAINTENANCE
1-83
86821252
Fig. 203 The fill plug and drain plug locations on the 22R-E and the 3VZ-E engines
Fig.
205 Use a short extension to aid
in
removing the
drain plug
86821253
Fig. 206 Quickly remove the plug to avoid getting on your hands
the plug while unscrewing
out
until
the plug
is
it,
this will
keep the
oil
oil
from pouring
removed.
•'CAUTION oil will be HOT. Be careful when you remove the plug so that you don’t take a bath in hot gear oil.
The
to drain completely.
4.
Allow the
oil
5.
Clean
the plug then
off
install
it,
tightening
it
until just
snug. 6.
case.
Remove It
the
filler
plug from the side of the transmission
usually on the driver’s side of four speeds,
is
the passenger side on five speeds. There
underneath
this plug.
Replace
it
will
and on
be a gasket
every time the bolt
is
removed. 7.
Fill
the transmission with gear
oil
through the
filler
plug
hole. 8.
hole.
The oil level should come right up to the edge of the You can stick your finger in to verify this. Watch out for
sharp threads.
Fig.
207 Allow the
fluid to drain
completely into a pan
or container, before reinstalling the plug
GENERAL INFORMATION AND MAINTENANCE
1-84.
the
Install
9.
check
filler
DRAIN AND REFILL
plug and gasket, lower the truck, then
Dispose
for leaks.
of the old
oil
the proper manner.
in
I
See Figure 209
Automatic Transmission The automatic transmission
should be changed
fluid
every 25,000-30,000 miles (40,000-48,000 km).
FLUID
RECOMMENDATIONS
normally used trailer
All
automatic transmissions covered
DEXRON®
or
II
its
superceding
in this
manual use
fluid type.
LEVEL CHECK
fluid level
The
possible.
dipstick
should be checked only when the transmission
The transmission
is
is
Park the truck on a
level surface with the
Shift the transmission into Neutral or Park
and
engine
idling.
2.
item;
removing the pan
dipstick
that
it
the dipstick, wipe
has been pushed
and check the
fluid level
With the engine running, the
second and 3.
.
If
the
third
it
3.
the
way
while holding
fluid level
if
4.
it
5.
firmly.
Remove
in.
the
horizontally.
should be between the
not required or recom-
is
HOT
some
Allow the unit to drain for
fluid.
the flow of Install
plug.
the plug and gasket slowly, and be prepared for
oil
down
is
minutes;
to individual drops.
the drain plug with a
new gasket
Add transmission
fluid
if
used, and
through the dipstick
tube under the hood.
set the parking
clean and reinsert
all
pan below the drain
Remove
a rush of
when
drained without removing
not replaceable as a
is
With the truck safely supported on stands, position a
large catch 2.
pan
during normal transmission maintenance.
Reinsert the dipstick after
and allow
Remove
may be
maintenance
tighten just snug.
brake.
Be sure
will
this.
within the
consid-
ered hot after about 20 miles (32 km) of highway driving. 1.
The
drained; a 20 minute drive
filter
is
The
the rear of the engine compartment.
hot (normal operating temperature).
is
it
The
1
every
fluid level at least
if
the interval should be halved.
the pan, so that fluid
mended
I See Figure 208
in
in
the pan.
Check the automatic transmission 15,000 miles (24,000 km) or more
like,
is
driving,
Toyota automatic transmissions are equipped with a drain plug
usually located
towing or the
accomplish
at least
the truck
severe service, such as stop-and-go
in
should be hot before
fluid
If
it
DO NOT
to idle.
has
After the engine
then start the engine
filling,
race the engine.
idled for
a few minutes,
transmission slowly through the gears, then return
With the engine If
still
idling,
necessary, add more
check the
fluid to raise
fluid level
shift it
the
to Park.
on the
dipstick.
the level.
notches on the dipstick.
fluid level is
below the second notch, add
fluid
PAN AND FILTER SERVICE
with the aid of a funnel. 4. Check the level often as you are filling the transmission. Overfilling will cause Be extremely careful not to overfill slippage, seal damage and overheating. Approximately one pint of ATF will raise the level from one notch to the other. The fluid on the dipstick should always be a bright red color.
>
See Figures 210, 211, 212 and 213
it.
It
if
is
discolored (brown or black), or smells burnt, serious
transmission troubles, probably due to overheating, should be
suspected. The transmission should be inspected by a qualified service technician to locate the cause of the burnt
fluid.
1
.
Jack up the
front
end
of the vehicle
and support
it
on
jackstands. 2.
Place a container under the transmission drain plug and
drain the transmission
fluid.
Remove gasket. On all
A43/A44
3.
of a thin, flat
Fig.
209
but the
bladed
All
removal of
the pan securing bolts and remove the pan and family, this will require the
tool to cut the sealant
bead.
automatics have a drain plug to ease the
fluid
use
Do NOT use
GENERAL INFORMATION AND MAINTENANCE cept 7. the A440F, tighten the bolts to 48 inch the A440F, tighten the
10mm
the
bolts to 7
Install
8mm
bolts to
lbs.
(10 Nm).
ft.
lbs. (6
48 inch
1-85 On Nm) and
Nm).
lbs. (6
the pan, tightening the securing bolts to the
proper torque
in
a crisscrossing pattern. Correct pan
bolt
tightness:
8.
•
A43D and A44D
•
A340E, F and H
•
A440F
— 61
— 48 inch — 65 inch
lbs. (6 lbs. (7
Nm) Nm)
Nm)
inch lbs. (7
^WARNING The pan bolts must be tightened evenly; the bolts break easily
overtightened.
if
the transmission to the correct level with the speci-
Fill
fied fluid.
Transfer Case a screwdriver
(you’ll
tool straight into the will
result.
deform the pan
seam;
if
Work on an angle
and do
lip)
to the
NOT
drive the
internal
damage
pan and tap the
tool just
goes too
it
far,
deeply enough to cut the sealer. 4.
The pan may be washed
must be absolutely dry when out with a rag; the
lint
sion. Additionally, the
units contain
in is
it
for the
RECOMMENDATIONS
• Trucks
solvent for cleaning but
Do not wipe damage the transmisA43D, A44D and A440F
reinstalled.
and 4Runner’s w/MT
GL-3, GL-4 or GL-5; it
from the rag can
pans
FLUID
magnets; clean any shavings from the magnets
• Trucks
perceding •
and 4Runner’s w/AT
fluid
— multipurpose gear
SAE 75W-90
or
oil
API
80W-90
— ATF
DEXRON®ll
or
its
su-
type
Land Cruiser
— multipurpose gear
oil
API GL-4 or GL-5;
SAE 90 W.
and make certain the magnet(s) are correctly positioned before reinstallation. 5.
Remove
all
traces of the old gasket or sealer from the
pan and from the transmission.
new gasket on units,
apply a
On A43/A44
the pan but do not use any sealer.
thin,
even bead
of sealant
On
all
other
pan flange. 6.
Inspect, clean or replace the transmission
strainer at this time,
if
necessary.
ready for an additional rush of
If
fluid.
the
For
> See Figures 214, 215 and 216
around the pan,
and roughly centered on
staying inboard of the screw holes the
LEVEL CHECK
series, install a
filter is all
filter
or
removed, be
transmissions ex-
The oil in the transfer case should be checked at least every 7500 miles (12,000 km) and replaced every 25,000-30,000 miles (40,000-48,000 km), even more frequently if driven in deep water. 1. filler
With the truck parked on a level surface, remove the plug from the side of the transfer housing.
GENERAL INFORMATION AND MAINTENANCE
1-86
3.
86821263
Fig.
214
When removing
the
plug,
filler
remember there
2.
If
the lubricant begins to trickle out of the hole, there
enough. Otherwise, carefujly
Fig.
insert
sharp threads) and check to see
if
your finger (watch out the
oil
is
up
to the
edge
The
is
If
edge
add
Install
check
oil
the
through the hole
until
the level
Most gear lubricants come
bottle with
can also use a 4.
usually
a long container with
in
drain plug
is
usually located on the bottom of the
pan under the drain plug and remove
in
is
at the
a plastic
a nozzle; making additions simple. You
common everyday filler
The oil will be HOT. Be careful when you remove the plug so that you don’t take a bath in hot gear oil.
kitchen faster.
plug and gasket, then run the engine and
4. install
for leaks.
DRAIN AND REFILL
Allow the it,
oil
tightening
5.
Remove
6.
Fill
the
to drain completely. it
until
filler
it
is
just
Clean
off
the plug and
snug.
plug from the side of the case.
the transfer case with the correct
oil
through the
filler
plug hole as detailed previously. Refer to the “Capacities”
amount of oil needed to refill your transfer case. The oil level should come right up to the edge of the You can stick your finger in to verify this.
chart for the
I See Figures 217 and 218
7.
hole.
The
1. If
transfer
the engine
is
at
case
oil
should be hot before
it
is
normal operating temperature, the
drained. oil
should
be hot enough. 2.
that
it.
of
i'CAUTION
not,
of the hole.
squeeze
oil is
transfer case. Place a
for
the hole. 3.
216 The gear
a built-in spout
a gasket, usually metal
is
Raise the truck and support
8.
Install
and check manner.
it
you can safely work underneath.
properly on jackstands so
the
filler
for leaks.
plug with a
new
gasket, lower the truck,
Dispose of the old
oil
in
the proper
GENERAL INFORMATION AND MAINTENANCE
1-87
LEVEL CHECK
Front I See Figures 219, 220 and 221
The
oil
in
the front differential should be checked at least
every 7500 miles (12,000 km). 1
With the truck parked on a level surface, remove the
.
plug from the back of the differential.
filler
"••The plug on the bottom 2.
If
the
oil
begins to
trickle
enough. Otherwise, carefully sharp threads) to the 3.
217 This truck has a bracket/shield where you access the plug through. You may need an extension Fig.
edge
into the hole
bottom edge If
not,
add
of the hole.
bottle with
oil
is
of the
the drain plug. out of the hole, there
insert
and check
filler
to
see
if
the
oil
is
for
up
hole.
through the hole
Most gear
is
your finger (watch out
oils
until
come
in
the level
is
at the
a plastic squeeze
a nozzle, making additions simple.
86821266
Fig.
218 There
will
be just enough room to remove the
plug with your hands. Be careful of the hot
oil
Drive Axles FLUID
RECOMMENDATIONS
Hypoid gear
oil
API GL-5. Below 0°F (-18°C) use
above 0°F (-18°C) use
SAE 80W
or
SAE 90W,
80W-90.
86821267
Fig.
220 Locate the
filler
plug
.
.
.
GENERAL INFORMATION AND MAINTENANCE
1-88
DRAIN AND REFILL
Front I
See Figures 223, 224 and 225 The gear
oil
in
the front axle should be
changed
at least
every 25,000-30,000 miles (40,000-48,000 km) or immediately if
driven 1
in
deeR water.
Park the vehicle on a
.
level surface.
Set the parking
brake.
4. is
2.
Clean the area around the drain plug.
3.
Remove
large
the
enough
filler
(upper) plug. Place a container which
to catch
all
of the differential
under the
oil
drain plug.
Remove
4.
the drain (lower) plug and gasket,
equipped. Allow Install
5.
but
the
filler
tance. Stop the truck
plug and drive the truck for a short dis-
and check
of the
oil
if
so
to drain into the container.
the drain plug. Tighten
it
so that
it
will
not leak,
do not overtighten. 6.
Install
all
with the proper grade
Refill
cant.
Be sure
plug.
DO NOT
that the level
and
viscosity of axle lubri-
reaches the bottom of the
filler
overfill.
for leaks. 7.
Install
the
filler
plug and check for leakage.
Rear Rear > See Figure 222 I
The
oil
in
the rear differential should be checked at least
The gear
every 7500 miles (12,000 km). 1
With the truck parked on a level surface, remove the
.
plug from the back of the differential.
driven 1.
^The 2.
plug on the bottom If
the
oil
begins to
is
trickle
enough. Otherwise, carefully
the drain plug.
into the hole
to
see
in
changed
at least
deep water.
Park the vehicle on a
level surface.
Set the parking
Clean the area around the drain plug.
3.
Remove
your finger (watch out for
and check
the rear axle should be
2. is
is
sharp threads)
in
brake.
out of the hole, there
insert
oil
every 25,000-30,000 miles (40,000-48,000 km) or immediately if
filler
See Figures 226, 227, 228, 229 and 230
if
the
oil
is
large
the
enough
filler
(upper) plug. Place a container which
to catch
all
of the differential
oil
under the
up drain plug.
to the
bottom edge of the
filler
hole. 4.
3.
edge
If
not,
add
oil
of the hole.
through the hole
Most gear
oils
until
come
in
the level
a
plastic
is
at the
squeeze 5.
bottle with 4.
a nozzle, making additions simple.
Install
the
filler
plug and drive the truck for a short dis-
tance. Stop the truck and check for leaks.
Remove
the drain (lower) plug and gasket,
equipped. Allow Install
all
of the
oil
the drain plug. Tighten
but do not overtighten.
if
so
to drain into the container. it
so that
it
will
not leak,
GENERAL INFORMATION AND MAINTENANCE
Fig. 224 Remove the drain (lower) plug and gasket, so equipped
if
Fig.
227 Unscrew the
filler
plug
86821268
Fig.
225 Slide a the pump’s tube (shown) into the
hole, or
use bottled
filler
fluid with a built-in funnel
86821279
228 you
Fig.
to
If
you move quick enough,
86821277
Fig.
226 Clean the area around the drain plug
axle
shown
1-89
— rear
this won’t
happen
86821280
Fig.
229
Install
the
filler
(shown) and drain plugs along
with the gaskets, securely
GENERAL INFORMATION AND MAINTENANCE
1-90 Refill
6.
with the proper grade
cant.
Be sure
plug.
DO NOT
7.
viscosity of axle lubri-
bottom
of the
filler
have a high alkaline content or
gency
filler
situations. Drain
as possible
overfill.
the
Install
and
that the level reaches the
The
plug and check for leakage.
after using
radiator
be checked which are
Cooling System
and
is
very hard, except
flush the cooling
in
emer-
system as soon
such water.
hoses and clamps and the radiator cap should
at the
brittle,
same
time as the coolant level. Hoses
cracked, or swollen should be replaced.
Clamps should be checked for tightness (screwdriver tight Do not allow the clamp to cut into the hose or crush the fitting. The radiator cap gasket should be checked for any only.)
RECOMMENDATIONS
FLUID
obvious tears, cracks or swelling, or any signs of incorrect seating
When
additional coolant
is
required to maintain the proper
always add a 50/50 mixture
level,
freeze/coolant and water. or additives
is
inhibitors
recommended.
neither required nor
**Do not use alcohol type
supplementary
of
in
the radiator neck.
50/50 mix of coolant concentrate and water
will
usually
may be checked by using a cooling system hydrometer. Inexpensive provide protection to -35°F (-37°C). Freeze protection
of ethylene glycol anti-
The use
A
hydrometers
may be
obtained from a local auto supply store.
Follow the directions packaged with the coolant hydrometer antifreeze or plain water alone.
when checking
protection.
LEVEL CHECK I
See Figures 231, 232 and 233 Dealing with the cooling system can be a tricky matter un-
less the proper precautions are observed. All vehicles
use a
coolant reservoir tank (expansion tank) connected to the radiator
by a small hose. Look through the
FULL and
should be between
level
FULL
line is
expansion.
If
below the very top the level
in
lines.
Note that the
of the tank, allowing
the tank
the tank and add coolant to the
plastic tank; the fluid
LOW
is
low,
FULL
room
remove the cap
for
of
line.
^CAUTION Never remove the radiator cap to check fluid level; there is a high risk of scalding from escaping hot fluid.
If
the coolant level
glycol
based
is
low,
add an equal amount
antifreeze. Avoid using water that
is
86821282
Fig. 231 of ethylene
known
checking
The engine coolant reservoir can be used fluid level and adding coolant
to
86821281
Fig. Fig.
230
Refill
the axle with the proper gear
oil
for
232
If
the coolant
is
low,
add an equal amount
ethylene glycol based antifreeze
of
GENERAL INFORMATION AND MAINTENANCE
1-91
86821110
Fig.
234
When
the engine
is
cool,
remove the
radiator
cap
>
See Figures 234, 235, 236, 237, 238 and 239
^CAUTION When
draining coolant, keep
mind
in
that cats
and dogs
are attracted by ethylene glycol antifreeze, and are quite
drink any that is left in an puddles on the ground. This will quantity. Always drain coolant into Coolant may be reused unless it is likely to in
eral
uncovered container or prove fatal in sufficient a sealable container.
contaminated or sev-
years old.
Completely draining and two years
will
the cooling system every
refilling
remove accumulated
rust,
scale and other 86821111
deposits. 1.
Make
at least
certain the engine
3 hours from
Overnight cold
COLD.
is
last operation,
Generally, this
longer
in
means
Fig.
235 The petcock or plug can be removed by it clockwise
turning
hot weather.
is best.
Remove the and coolant. Open 2.
radiator cap. Drain the existing antifreeze
the radiator and engine drain petcocks, or
22R-E engine
disconnect the bottom radiator hose at the radiator outlet. Set the heater temperature controls to the
full
HOT
position.
'•Before opening the radiator petcock, spray
it
with
some
penetrating lubricant. 3.
Close the petcocks or reconnect the lower hose and
the system with the correct mixture of antifreeze the correct amount.
It
will
take a
bit of
fill
and water
in
time for the level to
stabilize within the radiator. 4.
Double check the petcocks
5.
Install
6.
Flush the reservoir with water, empty
coolant mixture to the 7.
for closure.
the radiator cap.
FULL
then
it,
install
fresh
line.
Start the engine, allowing
it
to idle.
As
it
warms
Radiator drain plug
keep
up,
86821284
a close watch on the petcocks and/or hose drain the system.
and
fix
the leak.
If
any leakage
is
fittings
used
to
seen, shut the engine
OFF Fig.
236 Radiator and engine coolant plugs
— 22R-E
GENERAL INFORMATION AND MAINTENANCE
1-92
After the engine
8.
Check the 3VZ-E engine
Engine drain plugs
has warmed up, shut the engine OFF.
level in the reservoir tank
and adjust the
fluid level
as needed.
'Fresh
antifreeze has a detergent quality. Fluid in the
may appear muddy or discolored due to the new coolant. If the system has been neglected for a period of time, it may be necessary to
reservoir
cleaning action of the
redrain the system to eliminate this sludge.
FLUSHING AND CLEANING THE SYSTEM
Several aftermarket radiator flushing and cleaning
be purchased
that the radiator
Radiator 86821285
rust build-up
use, Fig.
at
237 Radiator and engine coolant plugs
- 3VZ-E
your local auto parts store.
It
is
kits
can
recommended
be cleaned and flushed of sludge and any
once a year. Manufacturers
and safety precautions, come
in
directions for proper
each
kit.
CLEAN RADIATOR OF DEBRIS Periodically clean
3RZ-FE engine
etc.,
any debris such as leaves, paper,
from the radiator
fins.
Pick the large pieces
The smaller pieces can be washed away
off
insects,
by hand.
with water pressure
from a hose. Carefully straighten dle
nose
pliers.
Be
any bent
radiator fins with a pair of nee-
careful, the fins are very soft. Don’t wiggle
the fins back and forth too much. Straighten not to
move them
them once and
try
again.
Master Cylinder (Brake and Clutch) I En3 Radiator drain ping
™
'
See Figures 240 and 241 models have the brake master cylinder reservoir on the
All
),a,n pl " 3
left
with
side of the firewall under the hood. Trucks and 4Runner’s
manual transmissions use a hydraulic
clutch.
Fig.
238 Radiator and engine coolant plugs
— 3RZ-FE
The
clutch fluid reservoir
is
located
(fluid in
actuated)
same area as same fluid same time as
the
brake reservoir. The clutch master cylinder uses the
as the brakes, and should be checked
at the
the brake master cylinder.
86821287 86821291
Fig. Fig.
239 Radiator and engine coolant plugs
— 1FZ-FE
240 The brake master cylinder
booster
is
attached to the
GENERAL INFORMATION AND MAINTENANCE
1-93
86821292
Fig.
242 Check the
reservoir.
Use
only
J1703
Heavy Duty Brake
meeting
fluid
DOT
3 or
If
fluid level
necessary,
lift
on the side of the
the cap
.
.
.
SAE
specifications.
LEVEL CHECK See Figures 242, 243, 244 and 245
I
The
the brake and/or clutch master cylinders should
fluid in
be checked every 6 months or 6000 miles (9600 km). Check the fluid level at the side of the reservoir.
If
fluid is required,
thoroughly wipe the top of the reservoir and the sides of the plastic
housing with a rag before opening. The
kept free from the reservoir.
fluid must be and grit. Fill the reservoir to the MAX line Never overfill the reservoir. Install the reservoir dirt
cap, making sure the gasket
is
properly seated
in
in
86821294
the cap. Fig.
i-WARNING Brake
It
damages painted
fluid
spilled,
243
then
fill
to the appropriate line with
DOT
3 fluid
immediately clean
surfaces.
off
it
If
any
fluid is
with plenty of clean water.
also absorbs moisture from the
air;
never leave a
container of fluid or the master cylinder or the clutch cylinder uncovered any longer than necessary.
It
is
normal
for the fluid level to
wear. However,
if
you should check the system cylinder, or
fall
as the disc brake pads
the master cylinder requires for leaks in the
filling
frequently,
hoses, master
wheel cylinders.
Power Steering Pump FLUID
RECOMMENDATIONS 86821295
Use
only
DEXRON®ll
transmission
fluid in
the
or
its
superceding type automatic
power steering system.
Fig.
244 As you can see on this brake master cylinder
reservoir the level
is slightly
low
GENERAL INFORMATION AND MAINTENANCE
1-94
Steering Gear
RECOMMENDATIONS
FLUID
3
Use standard hypoid-type gear refilling
FLUID LEVEL
CHECK
See Figure 247
>
Each year
will
be
little
or
no mess
plug
filler
is
on
and requires a 14mm wrench for removal. should be A-1 inch (18-28mm) from the top on 2WD
level
models and 9/16-11/16 inch
(14-1
7mm)
from the top on
4WD
models.
FLUID LEVEL
CHECK
Chassis Greasing >
I
The
oil.
top of the housing
The 245 With the aid of a funnel, there
Fig.
km) you should check
or 15,000 miles (24,000
the steering gear housing lubricating 86821296
SAE 90W when
GL-4,
oil
the steering gear.
See Figures 248, 249, 250 and 251
See Figure 246 Complete chassis greasing should include an inspection
Check the power
months or 6000
steering fluid level every 6
Park the vehicle on a
level surface.
normal operating temperature
Turn the steering
2.
all
the
to the right several times.
shut
off
way
and wipe the
5.
6.
and then
all
the
Center the steering wheel and
level
Add
fluid
arm bushings. To provide
correct operation, the chassis should
be greased with every
and
If
you wish
pose the
power steering
fluid reser-
fluid level
Add mark
(in
the
indicated on the dipstick.
should be at any point below the the
HOT
as necessary. Do not
or
Full
COLD
mark,
ranges).
246 Remove the
filler cap on the power steering and wipe the dipstick clean
filter
change
or
7500 miles
fitting to
this
operation yourself, purchase a
gun and several cartridges
Push the nozzle Force
cause some old grease
rag to wipe
off
of multipur-
grease gun down
of the
and while applying pressure, force the
into the fitting.
sufficient
to
grease
into the
be expelled. Use an old
expelled grease; keep the
fittings
and
joints
free of globs of grease.
Four wheel drive vehicles have several lubrication points within the driveshaft
overfill.
86821297
Fig.
perform
firmly onto the fitting
tucked
fluid reservoir
to
lithium grease.
new grease
Remove
oil
(12,070 km).
cartridge type grease
dipstick clean.
and note the
The
but not below the 7.
to the left
Reinsert the dipstick and tighten the cap.
dipstick
until
the engine.
Open the hood. Remove the filler cap on
4.
voir
Run the engine
reached.
is
way 3.
of
rubber suspension bushings, as well as proper greasing of
the front suspension upper and lower ball joints and control
miles (9600 km). 1.
all
into
and
driveline.
hard to see places;
Some
make
of
these
certain
fittings
each one
is
are
GENERAL INFORMATION AND MAINTENANCE
1-95
EXTERIOR CARE
Keep the scratches
exterior of the vehicle clean. Dirt
the paint and the chemicals
in
in
can cause small
road
can cause paint damage. Frequent washing
mended;
this is particularly
snowy areas, near
Wash
salt
the vehicle
Wash
the touch.
in
when
the shade
in
in
the road.
off
not hot to
is
soap and rinse thoroughly
with mild car-wash
rinse the vehicle
the body
air
recom-
is
important for vehicles used
water or any vehicle used
before the soap dries on the paint.
wash and
and
dirt
pollution
It
may be necessary
to
sections to prevent the soap
from streaking the paint. Never use gasoline or strong solvents to clean painted surfaces.
Use a chamois which
it
may
pick up
dirt
or
grit.
dropped on the ground, rinse
may
carry
grit
which
After the paint
accounted
for.
Additionally,
1989-90 Land Cruisers have lube
the ends of the relay rods
fittings at
in
the steering system.
The 1991-96 Land Cruisers use permanently sealed
joints;
no
Wring
or soft, lint-free rag to dry the exterior.
the drying rag out frequently and keep
will
it
If
it
away from areas
the rag or chamois
thoroughly before continuing;
it
scratch the finish.
may be
completely dry, the bodywork
is
in
is
waxed with any of the commercial car polishes or waxes. Read the can carefully before purchase; use good judgment in deciding the condition of the finish. A wax for older finishes will have more abrasive to remove oxidized paint. A “new car” wax will have much less abrasive. 1
lubrication
necessary.
is
MANUAL TRANSMISSION AND CLUTCH LINKAGE Wheel Bearings On models grease
so equipped, apply a small amount
of
and
to the pivot points of the transmission
chassis
4WD
••Front wheel bearings on Section
clutch
Do not attempt
7.
hubs on these vehicles without
linkage.
vehicles are covered
in
to disassemble the bearings
and
referring to the appropriate
procedures.
AUTOMATIC TRANSMISSION LINKAGE
Only the
front
use
lubricant to
wheel bearings require periodic service. The is
high temperature disc brake wheel bearing
grease meeting NLGI No. 2 specifications. This service
On models gine
oil
to the
so equipped, apply a small amount
kickdown and
shift
of
10W
en-
linkage at the pivot points.
ommended
rec-
is
30,000 miles (48,270 km) on trucks, 4Runner's
and 1991-96 Land Cruisers. On 1989-90 Land Cruisers, the interval is
PARKING BRAKE LINKAGE
at
mileage
26,500 miles (42,638 km).
is
In either
case,
not achieved, the bearings should be
the
if
packed every
36 months or whenever the truck has been driven
water up
in
to the hub.
At yearly intervals or
whenever binding
noticeable
is
in
the
parking brake linkage, lubricate the cable guides, levers and linkage with a suitable chassis grease.
Before handling the bearings there are a few things that you
should remember: •
Remove
all
outside
dirt
from the housing- before exposing
the bearing.
• Treat a used bearing as gently as you would a
Body Lubrication and Maintenance
•
Door handles, hinges, and locks should be lubricated least
once a year. Use a
handles. into
Use spray
door locks;
binding and
stiff
it
grease
light lithium
graphite for door locks.
attracts
and holds
dirt
operation, particularly
in
for
Do
and
at
hinges and
not inject
grit,
oil
causing
cold weather.
amount of grease should be applied to hood and trunk latches and hinges periodically. Other moving components such as seat back pivots or cargo compartments should be attended to on as-needed basis. Additionally, a small
the
•
performing lubrication of any item
in
the passen-
ger area (doors, locks, etc.) apply lubricant sparingly and thoroughly wipe up the excess to prevent lubricant getting
onto upholstery and/or clothing.
new
one.
dry
hands. •
Clean solvents and flushing
•
Use clean paper when
•
Protect disassembled bearings from rust
them • •
fluids
are a must.
laying out the bearings to dry.
and
dirt.
Cover
up.
Use clean rags to wipe bearings. Keep the bearings in oil-proof paper when they are
stored or are not •
•When
Work with clean tools in clean surroundings. Use clean, dry canvas gloves, or at least clean,
in
use.
Clean the inside
bearings.
of the
housing before replacing the
to
be
1-96
GENERAL INFORMATION AND MAINTENANCE
Propeller Shaft
Propeller Shaft
Fig.
249 Grease points on most of the truck and 4Runner’s
Lubricating Positions:
1.
Spider
2. Slide
Yoke 86821300
Fig.
250 Grease points on the Land Cruiser’s 1991-96
!
GENERAL INFORMATION AND MAINTENANCE
Do NOT do •
REMOVAL, PACKING, AND INSTALLATION
the following:
Don’t work
in dirty
•
Don’t use
•
Try not to work on
dirty,
surroundings.
damaged tools. wooden work benches or use wooden
chipped, or
mallets.
Don’t handle bearings with dirty or moist hands.
•
Do Do
1
not use gasoline for cleaning; use a safe solvent. not spin dry bearings with
compressed
air.
They
Do
• •
Do Do
rust at
Loosen the lugnuts. Elevate and safely support the front of the truck on
jackstands. 3.
not spin unclean bearings.
• Avoid using cotton
.
2.
will
be damaged. •
2 Wheel Drive I See Figures 252, 253, 254, 255 and 256
•
•
1-97
waste or
dirty cloths to
to
not to scratch or nick bearing surfaces. not allow the bearing to
come
in
4.
wipe bearings.
contact with
dirt
or
Remove Remove
suspend
the caliper.
any time.
it
the wheels.
the brake caliper from
its
mount. Use
stiff
wire
out of the way; do not loosen the brake hose at
Remove
the brake pads.
•:*CAUTION Brake pads contain asbestos, which has been determined be a cancer causing agent. Never clean the brake surfaces with compressed air. Avoid inhaling any dust from brake surfaces. When cleaning brakes, use commercially to
available brake cleaning fluids.
GENERAL INFORMATION AND MAINTENANCE
1-98 5.
Remove
locknut.
Remove
the grease cap.
Use a socket
and and remove
the cotter pin
of the correct size to loosen
are to be replaced should be taken along to be compared with the replacement part to insure a perfect match.
To pack:
the axle nut. 6.
Remove
the hub and brake disc together with the outer
bearing and thrust washer.
Use your thumbs
pieces inside the hub as the unit
to
to
seal. 8.
Use a small prying tool to remove the inner bearing Once the seal is out, remove the bearing from the hub. Place all both bearings and all the nuts, caps, etc., into
a wide container of cleaning solvent. Cleanliness
wheel bearing maintenance. Use a every
bit of
soft bristle
Inspect the bearings for
same
pitting, flat
conditions.
If
any damage
must be replaced. As a general is
is
essential to
brush to clean
and allow them
clean, lint-free cloth
spots, rust,
damaged, the matching
is
rule,
if
be bought
at
it
the palm of your hand and push
in
with a sliding motion.
The grease must
and
of the bearing
side and through the gaps between the rollers; the bearing
must be completely packed 1 1
Coat the inside
.
Remember
not pack
and
through the center.
it
solid.
of the
with grease.
hub and cap
with grease, but
that the spindle (axle)
To
install:
12.
Clean the spindle thoroughly and inspect
of the
either a bearing or race it
should also be
store.
The
old parts that
between each
in
the grease begins to ooze out the other
until
seen, the components
part that contacts
an auto parts
Continue
to air dry.
replaced. Replacement bearings, seals and other required parts can
There are special
of greasing bearings,
not available, pack the wheel bearings by hand.
is
be forced through the side roller.
with grease.
purpose
hub) for
rough areas. Check the races (inner surfaces the
one
if
the bearing through
grease from every component. Place each cleaned
component on a 9.
but
for the specific
Put a large dab of grease
drop the outer bearing. 7.
made
devices
keep the
removed. Be careful not
is
Pack the wheel bearings
10.
damage. Coat
of
13.
Install
it
diameter to
install
bearing. Reusing the old seal
saves;
may 14.
seize while
Install
nut to 25 16.
may
NEW
in
ft.
flat
do pass
any sign
for
Use a
seal driver
grease seal over the
more money than
cost
fails,
it
the wheel
motion.
Place the hub and disc onto the spindle.
bearing and the 15.
a
the grease leaks out and the bearing
if
to
with a very light layer of bearing grease.
the inner bearing into the race.
of the correct
it
has
Install
the outer
thrust washer.
the locknut and use a torque wrench to adjust the lbs.
(34 Nm).
Turn the hub
in
each
direction several times to seat
snug the bearing. Loosen the locknut
until
hand without the wrench. Don’t loosen
it
it
and
can be turned by
any more than neces-
sary to be finger-loose. (Loosening the nut takes the pre-tension 17.
off
the bearing.)
Use a
spring tension scale to
to turn the hub.
18.
measure the
force
needed
Record the number.
Tighten the nut
until
the force required to turn the hub
is:
19.
— 1.3-4 — 0.9-2.2
•
Single rear wheel vehicles
lbs. (0.6-1. 8 kg)
•
Dual rear wheel vehicles
lbs. (0.4-1
Install
tain the
cap
20.
Install
21.
Install
hicle to the
the locknut, cotter pin and grease cap. is
kg)
Make
cer-
not crooked or loose.
the brake pads and caliper. the wheel and lugnuts (hand-tight).
ground and tighten the lugnuts.
Lower the ve-
GENERAL INFORMATION AND MAINTENANCE
Fig.
253 Exploded view of the
2WD
front
wheel bearing components
1-99
GENERAL INFORMATION AND MAINTENANCE
1-100
TRAILER TOWING See Figure 257
>
General Recommendations Your vehicle was primarily designed cargo.
It
important to
is
remember
to carry
passengers and
that towing a trailer will
place additional loads on your vehicle’s engine, drive
and other systems. However,
steering, braking
cide to tow a
trailer,
may
Local laws
if
using the proper equipment
you is
train,
find de-
a must.
require specific equipment such as trailer
brakes or fender mounted mirrors. Check your local laws.
Weight
Trailer
The weight
most important
of the trailer is the
weight-to-horsepower
ratio is
Combined Weight (GCW)
for
about 35:1, 35
factor.
lbs. of
A good
Gross
every horsepower your engine
develops. Multiply the engine’s rated horsepower by 35 and subtract the weight of the vehicle passengers
The
maximum
approximate ideal
result is the
and luggage. weight you
should tow, although a a numerically higher axle
compensate
for
ratio
can help
3500-6000 lbs.
heavier weight.
lbs.
and are
When
for
category. Class IV trailers are those over
use with
fifth
you’ve determined the hitch that
you’ll
need, follow the
manufacturer’s installation instructions, exactly, especially
Hitch (Tongue) Weight
it
comes
of stress
Figure the hitch weight to select a proper hitch. Hitch weight is
9-11%
usually
measured
of the trailer
or
various cate-
for larger trailers.
rating of
your
trailer.
a
10% of gross trailer weight. maximum gross weight of 2000 lbs.
maximum tongue
weight of 200
category. Class
trailers
2000-3000
II
lbs.,
an
inferior bolt for
with
hardened
a hardened
bolts.
Never
bolt.
lbs.
Class
I
III
Cooling
Axle
ENGINE
Therefore, a will
have a
trailers fall into this
are those with a gross weight rating
while Class
and good hitches come
substitute
when
hitch will subjected to a lot
Tongue weight
usually figured as
trailer with
of
used
into
rear bumper, the
clamp-on bumper hitches should never be used.
Check the gross weight is
fall
mount on the frame and
bolt-on or weld-on distribution type
mounted
The
gross weight and should be
with the trailer loaded. Hitches
gories: those that
to fastener torques.
6000
wheel trucks, only.
trailers fall into
the
One
of the
most common,
problems associated with
if
trailer
not
THE most common,
towing
is
engine overheating.
you have a standard cooling system, without an expansion tank, you’ll definitely
need
to get
an aftermarket expansion
If
GENERAL INFORMATION AND MAINTENANCE tank
preferably
kit,
one
with at least a 2 quart capacity.
These
are easily installed on the radiator’s overflow hose, and
kits
come
with a pressure
cap designed
Another helpful accessory
expansion tanks.
for
for vehicles using
a
is
creases, the
flex fan.
when
or flatten out, at high speed,
flex,
needed. These fans are requiring less
far lighter in
horsepower
quieter than stock fans.
you do decide
If
if
flex fan
gine
oil
and reducing
life
sary
towing Class
in
recommended Engine
and water pump
overall engine temperatures. Both of
Class
and
II
II
oil
filter,
inlet line.
combined gross weights
the
the radiathe
in-line with
Follow the cooler manufac-
of the vehicle
and
trailer.
Cooler manufacturers recommend that you use an aftermarket cooler
addition
in
to,
and not instead
of,
the pre-
you do want
to
use
your radiator.
in
If
it
in
place of the radiator cooling tank, get a cooler at least two sizes larger than normally necessary.
all
Class
transmission cooler can, sometimes, cause slow or
they are
trailers,
harsh shifting III
a remote
filter
tube, finned heat exchanger, which
is
mounting and a
mounted
the transmission during cold weather,
in
towing.
cooler systems consists of an adapter, screwed on
oil
a multi-tube,
in front of
While not absolutely neces-
life.
and some Class
for heavier
place of the
in
I
usually installed
Select a cooler of at least adequate capacity, based upon
your stock
coolers are helpful for prolonging en-
these factors increase engine
is
turer’s installation instructions.
sent cooling tank oil
of
of the fluid in-
an automatic trans-
install
condenser, and hooked
tor or air conditioning
far
hub.
Aftermarket engine
you
cooler, which consists of
finned heat exchanger,
your vehicle has a fan clutch, a
be needed between the
will
to replace
The
mission cooler.
enemy
the worst
is
of the fluid decreases.
life
essential, therefore, that
is
It
transmission cooler tank
is
weight than stock fans,
them. Also, they are
to drive
fan with a flex fan, note that
spacer
less cooling air
Heat
fluid.
an automatic transmission. As the temperature
a belt-driven
These fans are large diameter units are designed to provide more airflow at low speeds, with blades that have deeply cupped surfaces. The blades then radiator fan
the automatic transmission
1-101
in front
the fluid has a chance to
until
come up
to normal operat-
ing temperature.
Some
retrofitted with a
temperature bypass valve which
coolers can be purchased with or
multi-
of the
low
radiator or air conditioning condenser.
fluid
when
flow through the cooler only
will al-
the fluid has
reached above a certain operating temperature.
TRANSMISSION
A
Handling An automatic transmission is usually recommended for trailer towing. Modern automatics have proven reliable and, of course, easy to operate, in trailer towing. The increased load of
a
trailer,
however, causes an increase
in
the temperature of
Trailer
Towing a trailer with ease and safety requires a certain amount of experience. It’s a good idea to learn the feel of a trailer by practicing turning, stopping and backing in an open area such as an empty parking lot.
TOWING THE VEHICLE I
See Figure 258
Towing trucks and 4Runner’s with the ground requires the
•-WARNING
release the steering lock.
NEUTRAL and
in
Push-starting
is
not recommended.
All
trucks are
equipped with a catalytic converter. Raw gas collecting in the converter may cause damage. Additionally, computer controlled fuel injection system components may be damaged. Jump starting from a known good battery is the only
recommended method
of starting a disabled vehicle.
a Toyota truck needs to be towed, the best
way
is
to
use
a flatbed or rollback tow vehicle which can carry the vehicle with
all
4 wheels
the ground.
off
Trucks and 4Runner’s elevated.
To tow
may
with rear
also be towed with either end
wheels on the ground, release the
parking bake and put the transmission transfer off.
case
(if
4WD) must be
in
H2.
NEUTRAL. The The H4 button must be in
With automatic transmissions, the rear drive shaft must be
disconnected at the
differential
(48 kph) or a total of the driveshaft
will
if
towing
will
exceed 30 mph
50 miles (80 km). Failure
damage
the transmission.
to
disconnect
key
to
On 4WD
be
if
wheels on the
front
the
in
ACC
units, put the
the transfer case selector
the free-wheeling hubs
in
position to
transmission
H2. Disengage
so equipped. To tow with the
front
wheels on the ground, the steering wheel must be held
commonly strong enough
on tow
in
place with special equipment
carried
The
to hold the front
anti-theft lock is not
wheels
trucks.
straight during towing.
Land Cruisers may be towed cases the center
If
ignition
in
differential switch
center differential set
in
the
FREE
similar
manners but
must be
OFF and
in all
the
position.
vehicles are equipped with tow hooks front and rear
All
which
may be used
driver
must be
in
brakes. Towing
for flat
towing with a rope or chain.
the vehicle to steer
it
A
and operate the
manner must only be done for a short The entire drive line, wheels, axles, serviceable condition. The transmission must
in this
distance at low speeds. etc.,
be
in
must be
in
NEUTRAL
On Land
and, on
4WD
models, the transfer case
Cruisers, switch the center differential lock
OFF.
in
H2.
1-102
HINT:
GENERAL INFORMATION AND MAINTENANCE
Do not use any towing methods other than those shown above.
For example, the towing method
shown below
is
dangerous, so do not use
it.
NO During towing with this towing method, there
is
a
danger of the drive
train
heating up and causing breakdown, or of the front wheels flying off the dolly.
J 86821315
Fig.
258 Towing a Full-time
4WD
vehicle
GENERAL INFORMATION AND MAINTENANCE
1-103
JUMP STARTING A DEAD BATTERY >
See Figure 259
Whenever a followed
Jump
vehicle
is
jump
started, precautions
order to prevent the possibility of personal
in
Remember
that batteries contain a small
hydrogen gas which
is
amount
injury.
especially
when
1
of explosive
attaching jumper cables.
possibility of accidental sparks, follow the
sure that the voltages of the 2 batteries are the batteries
and charging systems are
12
of the
volt
variety.
batter-
To minimize
procedure
Make
.
same. Most
a by-product of battery charging.
Sparks should always be avoided when working around ies,
Starting Procedure
must be
jumping vehicle (with the good battery)
Pull the
2.
the
carefully.
a
into
jumper cables can reach the dead battery and
position so the
that vehicle’s engine.
Make
sure that the vehicles do
NOT
touch.
•-WARNING NEVER hook
the batteries up in a series circuit or the
entire electrical
system
Place the transmissions of both vehicles
3.
will
go up
smoke, especially the
in
'Hf necessary
starter!
cedure without significantly increasing the jumping the dead battery.
Be sure
that both batteries are of the
cles covered by this
today •
the •
in
polarity
On
(have
6.
most cases NEGATIVE grounded).
Do
smoke
8.
cold weather,
In
frozen. This in
make
sure the battery electrolyte
can occur more readily
in
Do
position.
Make sure
cell
is
not
do not cover
rag, but
If
and
the terminals on both batteries are clean will
be im-
necessary, clean the battery terminals before
and negative
Connect the
dead
first
jumper cable
battery, then
(-)
terminals on
9.
tive
not allow electrolyte to contact your skin or clothing.
Connect one end
(-)
to
an engine
bolt
of the other
in
the order
to the
is
nega-
and the other cable
positioned
solid,
battery. Try to pick
away from
the bat-
minimize the possibility of the 2 clamps touch-
NUMERICAL ORDER
259 Connect the jumper cables to the batteries and engine
cable
head, alternator bracket or other
a ground on the engine that
IN
jumper cable
on the engine with the dead
tery in order to
of that
booster (good) battery.
terminal on the booster battery
metallic point
MAKE CONNECTIONS
to the positive (+) terminal
connect the other end
to the positive (+) terminal of the
a battery that has been
clamp
Fig.
caps with a
Identify the positive (+)
of the
a state of discharge. •
on both vehicles.
both battery posts.
anywhere near the
batteries.
•
off
proceeding. 7.
or allow sparks
and accessories
Cover the battery
peded.
serviceable batteries, be sure the vent cap holes are
not
lights
free of corrosion or proper electrical connection
that the vehicles are not touching or a short
not obstructed. •
all
the terminals.
could occur. •
difficulty of
sure the ignition switches on both vehicles are turned to
OFF
the
5.
same
Turn
Make
voltage. Vehi-
manual and most vehicles on the road
that both batteries are of the
terminal,
Be sure
same
a 12 volt charging system.
utilize
Be sure
same
on
the entire pro-
Starting Precautions 4.
•
Neutral or
for safety reasons, the hazard lights
may be operated throughout
both vehicles
Jump
in
Park, as applicable, then firmly set their parking brakes.
shown
GENERAL INFORMATION AND MAINTENANCE
1-104
one loosen during the procedure.
ing should
clamp
this
to the negative
(-)
DO NOT
connect
terminal of the bad battery.
Once
12. \
the vehicle
few seconds
to
make
is
started, allow
sure that
it
it
to run at idle for a
operating properly
is
operating.
^CAUTION
Turn on the headlights, heater blower and,
13.
the rear defroster of both vehicles
Be very
careful to keep the
jumper cables away from mov-
ing parts (cooling fan, belts, etc.) on both engines.
verity of voltage spikes
This step
Check to make sure that the cables are routed away from any moving parts, then start the donor vehicle’s engine. Run the engine at moderate speed for several minutes to allow the dead battery a chance to receive some initial charge. With the donor vehicle’s engine
11.
above
idle, try to start
starter cool for at
does not
also
3
start in
wrong or
running slightly
dead
tries,
it
that the battery
is
needs
Carefully disconnect the cables
14.
to the
the reverse order of
in
is
attached to
the engine ground, then the negative cable on the donor bat-
Disconnect the positive cable from the donor battery and disconnect the positive cable from the formerly dead
finally,
is
damage
model vehicles
connection. Start with the negative cable that
tery.
something else
likely that
risk of
equipped with computer control modules.
Crank
battery.
more than 10 seconds at a time and let the least 20 seconds between tries. If the vehi-
the engine for no
cle
still
the vehicle with the
and subsequent
especially important to late
is
equipped,
if
order to reduce the se-
systems when the cables are disconnected.
vehicles’ electrical
10.
in
Be
battery.
when disconnecting
careful
the cables from the
any
positive terminals not to allow the alligator clips to touch
metal on either vehicle or a short and sparks
will
occur.
additional time to charge.
JACKING I See Figures 260, 261, 262, 263 and 264
when
vehicle
it
is
supported only by the tire-changing jack or
other floor jack.
Your vehicle was supplied with a jack repairs. This jack
is
tions not requiring in
an emergency
fine for
changing a
emergency road
for
flat tire
or other opera-
you to go beneath the vehicle.
If
it
is
used
situation, carefully follow the instructions pro-
vided either with the jack or
attempt to use the jack
in
in
your owner’s manual.
Do
A more floor jack.
convenient
way
of jacking is the
use
of
radiator,
when
the jack
is
raised. Additionally,
the floorpan or bodywork; the metal
Whenever you support
it
stacks of
will
a garage or
engine or
damage
though,
structed to
The
plan to work under the vehicle, you must
it
for
vehicle.
Be
careful
too steep to drive your vehicle
you’re only
a few minutes. Never crawl under the
do so by a
member
(unless specifically
repair manual) or
in-
following safety points cannot
underbody panel.
be overemphasized:
Always block the opposite wheel or wheels
to
keep the
vehicle from rolling off the jack. •
going to be under
and support the
the vehicle on any suspension
never jack under
if
to both raise
some ramps may be
for
ramps are also a handy
onto without scraping the front bottom panels. Never support
deform.
even
or supporting the
Small hydraulic, screw, or scissors jacks are satisfactory raising the vehicle. Drive-on trestles or
•
to support the vehicle,
top of the jack or
will
on jackstands or ramps. Never use cinder blocks or
wood
lifting
not
and safe way
Never place the jack under the
wood on
vehicle.
jack.
transmission components. Severe and expensive result
position a block of
stand to protect the finish when
any places other than specified by
the vehicle manufacturer. Always block the diagonally opposite
wheel when using a
^Always
When
raising the front of the vehicle, firmly apply the
parking brake. •
Always use jackstands
to
support the vehicle
when you
are working underneath. Place the stands beneath the scissors jacking brackets. Before climbing underneath, rock the vehicle
a
bit to
make
sure
it
is
firmly supported.
GENERAL INFORMATION AND MAINTENANCE
1-105
JACK POSITION Front
Rear
Under the front differential Under the rear differential
SCREW TYPE JACK POSITION SUPPORT POSITION Safety stand 86821320
Fig.
260 Vehicle
lift
and support locations on the 1989-90 Land Cruiser’s
1-106
GENERAL INFORMATION AND MAINTENANCE
JACK POSITION Front
Under the front
Rear
Under the
differential
rear differential
SCREW TYPE JACK POSITION SUPPORT POSITION Safety stand 86821316
Fig. 261
Vehicle
lift
and support locations on the 1991-96 Land Cruiser’s
GENERAL INFORMATION AND MAINTENANCE
1-107
[2WD]
JACK POSITION
.
.
.
crossmember
Front
Center
Rear
Under the rear
of
differential
SUPPORT POSITION Safety stand
.
86821317
Fig.
i
262 Vehicle
lift
and support locations on the Tacoma’s
1-108
GENERAL INFORMATION AND MAINTENANCE
[2WD]
[4WD] I
JACK POSITION
.
.
.
Front Rear
Center of crossmember
Under the
rear differential
SUPPORT POSITION Safety stand
.
86821318
Fig.
263 Vehicle
lift
and support locations on the TIOO’s
—
GENERAL INFORMATION AND MAINTENANCE
1-109
[2WD]
[4WD]
Fig.
264 Vehicle
lift
and support locations on the 1989-96 Pick-up’s
HOW TO BUY A USED Many people or truck
is
VEHICLE
believe that a two or three year old used car
a better buy than a
new
vehicle. This
may be
as most new vehicles suffer the heaviest depreciation first
old in
two years and, at three years
enough mind,
to present
a
lot
old,
a vehicle
is
the
usually not
of costly repair problems. But
when buying a non-warranted automobile,
no guarantees. Whatever the age might want to purchase,
in
true
of the
this section
keep
and a
little
patience is
safe and
may
not get a warranty that,
used vehicle purchased from a aftermarket warranties this is
your
there are
used vehicle you
should increase your chances of selecting one that
you
3.
to
a point you
many
cases,
with a
may
not
be worth the extra money, so
have
to
debate and consider based on
Never shop faults
at night.
The
Try to get the
make
glare of the lights
on the body caused by accident or
name and phone number
it
easy
rust repair.
of the previous
owner. Contact him/her and ask about the vehicle. of a lot refuses this information, look for a vehicle
dependable.
comes
Of course, some
priorities.
miss 4.
will
in
lot.
If
the
owner
somewhere
else.
A
Tips 1.
want
First
private seller
can
tell
you about the vehicle and mainte-
nance. But remember, there’s no law requiring honesty from decide what model you want, and
how much you
to spend.
Check the used car lots and your local newspaper ads. Privately owned vehicles are usually less expensive, however,
private citizens selling
used vehicles. There
is
a law that
for-
bids tampering with or turning back the odometer mileage. This
includes both the private citizen and the
lot
owner. The law
2.
also requires that the seller or
anyone
transferring ownership
GENERAL INFORMATION AND MAINTENANCE
1-110
must provide the buyer with a signed statement
of the vehicle
on the odometer
indicating the mileage
You may wish
5.
to contact the National
Safety Administration
ever been included
model and
year,
(NHTSA)
to find out
a manufacturer’s
in
was
a
listed for
Highway
the vehicle has
recall.
recall,
make
down
Write
line
the
sure the needed repairs were
Refer to the Used Vehicle Checklist
check
in this
section
the items on the vehicle you are considering.
all
items are more important than others. Only you
and
Some
know how
much money you can afford for repairs, and depending on the price of the vehicle, may consider performing any needed work Beware, however,
yourself.
of trouble in
operation, safety or emission. Problems
areas that in
the
will
indicate
• of
affect
down as follows: Numbers 1-8: Two or more problems in these areas a lack of maintenance. You should beware. Numbers 9-13: Problems here tend to indicate a lack
proper care, however, these can usually be corrected with a
Numbers
14-17: Problems
in
more
walk away from any vehicle with problems
If
you are
vehicle, take
mechanic
a complete check.
program, have specify on the
If
Road
new
section.
in this
agree
— the
to the
is
up
These
roll
Look
Belts
agrees with the overall condition
new
pedal pads, and worn
evidence
for
water leaks or
of
missing hardware, door handles, control
for
lights
and signal operations. Make sure
conditioner, heater, radio, etc.) work.
(air
of the
expected, but be suspicious of
is
Checklist
and Hoses: Open the hood, then check
Low
Battery:
all
electrolyte level, corroded terminals and/or
Look
Radiator:
.
for corrosion or rust in the coolant indi-
of
Air
filter:
A
severely
dirty air filter
would indicate a lack
maintenance.
Check Worn wires
Ignition wires:
uses
Oil level:
If
or leaks.
oil
the
oil
the ignition wires for cracks, burned
Beware
have
will
level of
is
low,
water
in
be replaced. chances are the engine
to
the
oil
(there
is
probably
a cracked block or bad head gasket), excessively thick (which
> See Figure 265
on
15.
out
Mileage: Average mileage
is
about 12,000-15,000 miles
may indicate hard usage many highway miles (which could be less half as many tough around town miles).
and the
per year. More than average mileage
black in
2.
for
Paint:
Check around the
tailpipe,
molding and windows
overspray indicating that the vehicle has been repainted. 3.
Rust:
Check
fenders, doors, rocker panels,
ings, wheelwells, floorboards, for signs of rust.
way
to
Any
rust at
window mold-
under floormats, and all
in
of rust,
is
no
except to replace
the part or panel.
A magnet should
the engine
fluid
a noisy engine), or
may
magnet
to
oil
thin, dirty oil
indicate internal engine
fluid that
need
is
Pull the
running.
The
transmission dipstick
level
should read FULL,
should be clear or bright red. Dark brown or
has
distinct burnt odor, indicates a
transmission
of repair or overhaul.
the exhaust system for leaks; 17.
most accessible in
it
can be expensive
Spark Plugs: Remove one or will
good condition
deposit on the
repair is suspected, try using a filler.
to quiet
16. Exhaust: Check the color of the exhaust smoke. Blue smoke indicates, among other problems, worn rings. Black smoke can indicate burnt valves or carburetor problems. Check
the trunk
be a problem. There
will
permanently stop the spread
'Hf rust for body
used
Automatic Transmission:
when
or could indicate
detrimental than
often
problems).
numbers
this checklist. 1.
is
with a distinct gasoline smell (this
illustrations refer to the
belts
spots.
cating a lack of maintenance.
13.
USED VEHICLE CHECKLIST
weak
wear, cracks or
for
spots, or wear.
to you.
on the
all
Check
cracked case indicate a lack of maintenance.
14.
(The numbers
to
is
easier.
indicate an attempt to cover up hard use. Pull
knobs, etc. Check
your original evaluation and the road test
If
rest
old trick
the vehicle
the entire interior. You’re looking for an
back the carpets and look
1 1
on pass-
Road Test
make
seat covers on sagging seats,
armrests.
10.
you have a state inspection
— refer
One
pressure.
tire air
Reasonable wear
vehicle.
12.
test the vehicle
Check
Interior:
interior condition that
ing state inspection. 8.
conditioner
go.
let
and hoses
of the
of sale that the sale is conditional
air
7. Shock absorbers: Check the shock absorbers by forcing downward sharply on each corner of the vehicle. Good shocks will not allow the vehicle to bounce more than once after you
inspected immediately before purchase, or
it
bill
may
alignment.
an independent diagnostic center or
to
it
for
apparent condition
which
Check the tread wear, open the trunk and check the spare Uneven wear is a clue that the front end may need an
9.
satisfied with the
of
too.
of these areas.
7.
the trunk, severe
windshield wiper operation.
2 or
in
in
any
ripples,
look under the vehicle. There are
pressure up to
tire
accessories
sion can be very expensive. Unless you are looking for a project,
the
flooding.
the engine or transmis-
Check the
Tires:
6.
pump
8.
tune-up or relatively simple parts replacement. •
down and
Leaks: Get
5.
Used Vehicle
Checklist break •
glass, welding
condenser.
that
made. 6.
misalignment, loose hold-down
for in
no normal leaks, other than water from the
the vehi-
If
scratches
indicate crash work.
the vehicle,
can supply).
Check
overall condition. clips, ripples,
misalignment of body panels or
Traffic
be a 1-800 number
(there should
your phone company’s information cle
if
time of transfer.
number before you buy
serial
NHTSA
then contact
at the
do, though
will
all
show plugs
all
of the
to replace.
spark plugs (the
are preferable).
An engine
with a light tan or gray
firing tip.
check
stick to the sheet metal
ROAD TEST CHECKLIST
parts of the body, but will not adhere to areas with large
amounts
of
filler. 1.
4.
vinyl
Body appearance: Check the moldings, bumpers, grille, roof, glass, doors, trunk lid and body panels for general
Engine Performance: The vehicle should be peppy
whether cold or warm, with adequate power and good pickup. It
should respond smoothly through the gears.
GENERAL INFORMATION AND MAINTENANCE
1-111
3
tecs 1096
265 Each of the numbered items should be checked when purchasing a used vehicle
Fig.
2.
Brakes: They should provide quick, firm stops with no
noise, pulling or brake fade. 3.
Steering: Sure control with no binding harshness, or
looseness and no shimmy
in
4.
means
trouble.
should give quick, smooth response with easy clutch pedal should
have free-play before
it
shifting.
The
in first
gear and slowly release the clutch pedal. The
engine should begin to
stall
when
the pedal
is
V2 -
A
of the
way
means worn
5.
Automatic Transmission/Transaxle: The transmission
should
shift rapidly
slipping.
and smoothly, with no noise,
hesitation, or
hitting
bumps
mean worn bushings
Clunks
Frame/Body: Wet the
tires
Tracks should show two straight
line.
A
speeds.
at different
ve-
or ball joints.
and
drive
be wet
for this if
in
a straight
lines, not four.
indicate a frame/body bent by collision can’t
speed or coast con-
bounces excessively has weak shock absorbers or
you and see
up.
Dif-
leaks.
U-joints.
Suspension: Try
hicle that
9.
noise or thumps should be present.
driveshaft problems. Clicking at low
ditions
struts.
disengages the
clutch. Start the engine, set the parking brake, put the trans-
mission
mean 8.
Clutch (Manual Transmission/Transaxle): Clutch action
No
have no normal
Driveshaft/Universal Joints: Vibration and noise could
7.
the wheel should be expected.
Noise or vibration from the steering wheel when turning the vehicle
Differential:
6.
ferentials
damage.
Four If
line.
tire
tracks
the tires
purpose, have a friend drive along behind
the vehicle appears to be traveling
in
a straight
GENERAL INFORMATION AND MAINTENANCE
1-112
MAINTENANCE SCHEDULE A 1989-95 Truck Maintenance operations: A
R I
• Towing a trailer, using a
camper
= = =
Check and adjust if necessary; Replace, change or lubricate; Inspect and correct or replace if necessary
or car top carrier
km) and outside temperatures remain below freezing and/or low speed driving for a long distance such as police, taxi or door-to-door delivery use muddy or salt spread roads.
• Repeat short trips less than 5 miles (8 • Extensive idling
• Operating on dusty, rough,
Maintenance services beyond 60,000 miles (96,000,^) should be performed in each maintenance schedule
Service interval (Odom-
months,
eter reading or
System
whichever comes
first)
Miles X
Km x
1,000
1.000
Months
ENGINE
22R, 22R-E engine
Valve clearance
3VZ-E engine
and
shown
5
7
10
15
20
22 5
2b
30
35
37 5
40
45
50
52
55
60
12
16
24
32
36
40
48
56
60
64
72
80
84
88
96
6
9
12
18
24
27
30
36
42
45
48
54
60
63
66
72
5
5
A
A A
Drive belts' 21 oil
intervals
Rl'l
Valve clearance*
Engine
same
8
3VZ-E engine
Timing belt
at the
1
oil
R
filter*
R
R
R
R
1
R
R
R
R
R
R
Engine coolant 131
R
Exhaust pipes and mountings
FUEL
speed
Idle
speed and speed
idle
1
fast
22R engine
1
A
22R-E, 3VZ-E engine 141
Idle
A
A 1
1
1
1
1
and connections
Fuel lines
1
A
101
1,1
Air filter*
R
1
1
1
1
Spark plugs**
EVAP
Charcoal canister
EXHAUST
1
R R Calif,
1
Fed. and Canada 22R-E,
Oxygen sensor*
Ri«
3VZ-E engine only
4WD 2WD
Brake linings and drums
Brake pads and discs
1
1
1
4WD
1
1
2WD
pipes and hoses
1
Steering linkage"
and dust covers
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
bush grease (4WD only) Propeller shaft grease 101
and nuts on chassis and body
191
1
1
1
1
1
4WD
Front wheel bearing and thrust
For vehicles sold
1
1
1
2WD
Automatic transmission, manual transmission, transfer (4W0), differential and steering gear housing oil ’
*
1
1
1
2WD
Drive shatt boots
Bolts
1
1
1
1
1
1
1
1
1
01
4WD Ball joints
1
1
1
1
1
1
2WD 4WD
CHASSIS
1
1
4W0 line
R
only
BRAKES
Brake
R
1
1
Fuel tank cap gasket
IGNITION
R
1
1
1
1
4WD
1
1
1
1
1
R
1
1
1
1
1
1
1
1
1
R
2WD 4WD 2WD 4WD 4WD 2WD
1
1
1
1
1
R
R
R
R
R
R
R
R R
R
R
R
R
R
R
1
1
1
1
1
1
1
1
1
1
1
R 1
1
1
in California
For vehicles sold outside Calitornia (1)
For the vehicles frequently idled for extensive periods and/or driven for long distances at low speeds such as taxis, police cars and door-to-door delivery vehicles,
it
is
recommended
to replace at
(6)
60,000 miles (96,000 km) or 72 months, After 60,000 miles (96,000 km) or 72 months, After 60,000 miles (96,000 km) or 72 months, Adjustment at 30,000 miles (48,000 km) or 36 Replace at 80,000 miles (129,000 km) only
(7)
Inspect the steering gear housing for
(8)
If
(9)
Applicable
(2)
(3) (4)
(5)
After
the propeller shatt has been
(10) Applicable
oil
immersed
60.000 miles (96,000 km).
inspect every 10,000 miles (16,000
km)
or 12
months.
replace every 30,000 miles (48,000 km) or 36 months. adjust every 30.000 miles (48,000
km)
or
36 months
months only
leakage only in
water,
it
should be re-greased
daily.
when operating mainly on dusty roads If not. follow the schedule B when operating mainly on rough and/or muddy roads If not. follow the schedule B 86821321
GENERAL INFORMATION AND MAINTENANCE
MAINTENANCE SCHEDULE B 1989-95 Truck Conditions other than those listed for
SCHEDULE
A.
Maintenance services beyond 60,000 miles (96,000 km) should be performed at the same intervals shown in each maintenance schedule.
Service interval (Odometer reading or months, which-
System
ever
comes
first)
x 1,000
Miles
Km
Maintenance items
x 1,000
Months
ENGINE
Valve clearance*
22R, 22R-E engine
Valve clearance
3VZ-E engine
Drive belts
Engine
oil
1
’
10
15
20
30
40
45
50
60
16
24
32
48
64
72
80
96
12
18
24
36
48
54
60
72
A
A
A
1 1
and
oil
R
R
filter*
R
1
R
R
Engine coolant 121
R
Exhaust pipes and mountings
FUEL
idle
speed
Idle
speed and
A
22R-E, 3VZ-E engine 131 fast idle
22R engine 141
speed
1
1
A
A
A R
R
Air filter*
Fuel lines and connections
1
1
R
Fuel tank cap gasket
IGNITION
Spark plugs**
EVAP
Charcoal canister
EXHAUST
Oxygen sensor
151
4WD
4WD 2WD 4WD 2WD 4WD 2WD 4WD 2WD
pipes and hoses
Steering linkage
Ball joints
and dust covers
Drive shaft boots
Automatic transmission, manual transmission, transfer (4WD), differential and steering gear housing oil 151 Front wheel bearing and thrust
2WD
Propeller shaft grease 17
4WD 4WD
'
Bolts and nuts on chassis and body 191
For vehicles sold
*
For vehicles sold outside California
60,000 miles (96,000 km) or 72 months, 60,000 miles (96,000 km) or 72 months, After 60,000 miles (96,000 km) or 72 months, Adjustment at 30,000 miles (48,000 km) or 36 Replace at 80,000 miles (129,000 km) only.
(2) After
(6) Inspect the steering
(7)
If
2WD
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
R
R R
R
R
R
R
1
1
1
1
1
1
1
in California
(1) After
(5)
4WD 4WD 2WD 4WD
bush grease (4WD only)
*
1
2WD
CHASSIS
(4)
R(5)
3VZ-E engine only
Brake pads and discs
(3)
1
Fed. and Canada 22R-E,
*
Brake linings and drums
line
R
R only
Calif,
BRAKES
Brake
R
gear housing
for oil
the propeller shaft has been immersed
km) or 12 months. km) or 36 months. adjust every 30,000 miles (48,000 km) or 36 months. months only. inspect every 10,000 miles (16,000 replace every 30,000 miles (48,000
leakage only. in
water,
it
should be re-greased daily 86821322
1-113
GENERAL INFORMATION AND MAINTENANCE
1-114
MAINTENANCE SCHEDULE A 1989-90 Land Cruiser Maintenance operations: A R I
= = =
Check and adjust necessary; Replace, change or lubricate; it
Inspect and correct or replace
if
necessary
Conditions: • • • •
Towing a trailer, using a camper or car top carrier. Repeated short trips of less than 5 miles (8 km) with outside temperatures remain below freezing. Extensive idling and/or low speed driving for long distances such as police, taxi or door-to-door delivery use Operating on dusty, rough, muddy or salt spread roads.
Maintenance services beyond 60,000 miles (96,000 km) should continue in each maintenance schedule.
Service interval
System
whichever comes
first)
Miles
Maintenance items
ENGINE
x 1,000
km x
1
,000
3 75
6
5
7
25
11
12
18
Engine
oil
18 75
22 5
26 25
30
33 75
37 5
41 25
45
48 75
52 5
56 25
60
30
36
42
48
54
60
66
72
78
84
90
96
A
A
R
filter*
R
R
R
R
R
R
R
1
R
R
R
Engine coolant 121
Air filter*
R
R
R
R
the
same
intervals
1
1
1
1
1
1
1
131 1
1
Fuel lines and connections "
1
R
1
1
1
1
1
1
1
Months A: Every 24 1:
Every 6 months
R:
36 months
1
1:
Every 24 months
R
1:
R:
Every 6 months, Every 36 months
1:
Every 36 months
R
R:
Every 72 months
R
R:
Every 36 months
1:
Every 72 months
1
1
1
Fuel tank cap gasket
months
36 months; 72 months
R:
R
R
Exhaust pipes and mountings
FUEL
A
J
oil
at
15
1
and
be performed
24
A
Valve clearance* Drive belts"
to
shown
(Odometer reading or months,
IGNITION
Spark plug**
EVAP
Charcoal canister
Calif,
EXHAUST
Oxygen sensor*
Except California
BRAKES
Brake linings and drums 151
1
1
1
1
1
1
1
1
1:
Every 12 months
Brake pads and discs
1
1
1
1
1
1
1
1
1:
Every 12 months
1
1:
Every 24 months
Brake
CHASSIS
line
R only
R
80,000 miles (128,000 km) only
pipes and hoses
1
Steering linkage Ball joints
1
and dust covers
1
1
1
1
1
1
1
1
1:
Every 12 months
1
1
1
1
1
1
1
1
1:
Every 12 months
Automatic transmission Transfer, differential
box
oil
R
R
R
R
1:
Every 24 months
1
1
1
1
1:
Every 24 months Every 36 months
and steering gear
16
Front wheel bearing and thrust bush grease
Steering knuckle and chassis grease Propeller shaft grease
1
1
'
1
'1
Bolts and nuts on chassis and body 181 *:
For vehicle sold
':
For vehicle sold outside California
(1) After
(4) (5) (6) (7)
R
R
R:
R
R
R
R
R
R
R
R
R:
Every 12 months
R
R
R
R
R
R
R
R
R:
Every 12 months
1
1
1
1
1
1
1
1
1:
Every 12 months
California
60,000 miles (96,000 km) 45,000 miles (72,000 km)
72 months, inspect every 7,500 miles (12,000 km) or 12 months. 36 months, replace every 30.000 miles (48,000 km) or 24 months Applicable when operating mainly on dusty roads. If not, follow schedule B. Includes inspection of fuel tank band and vapor vent system. Also applicable to lining drum for parking brake Inspect the steering gear box for oil leakage only If the propeller shaft has been immersed in water, it should be re-greased within a day.
(2) After (3)
in
1
1
(8) Applicable only
or or
when operating mainly on rough, muddy roads The
applicable parts are listed below
For other usage conditions, refer to
SCHEDULE
B
and rear suspension member cross body. Strut bar bracket cross body U bolts for leaf spring
• Front •
•
• Bolts for
sheet installation 86821323
GENERAL INFORMATION AND MAINTENANCE
1-115
MAINTENANCE SCHEDULE B 1989-90 Land Cruiser Maintenance operations: A R Conditions: Conditions other than those listed for
System
whichever comes
first)
Miles
Maintenance items
ENGINE
x
km x
i
,000
1,000
Engine
oil
1
is
22 5
30
37 5
45
52.5
60
12
24
36
48
60
72
84
96
A
A
A 1
and
R
filter*
oil
R
R
R
1
R
R
Air filter*
Fuel lines and connections 131
IGNITION
Spark plug**
EVAP
Charcoal canister
California only
EXHAUST
Oxygen sensor*
Except California
BRAKES
Brake linings and drums 141
R:
pipes and hoses
Steering linkage Ball joints
1:
months
36 months, 72 months Every 12 months Every 36 months
1:
Every 36 months
R.
Every 36 months
1:
Every 36 months
R
R:
Every 72 months
R
R:
Every 36 months
1
1:
Every 72 months
R
R
1
1
80,000 miles (128,000 km) only
Brake pads discs (Front and rear)
CHASSIS
A: Every 24
R:
1
R
Months
R:
R
1
Fuel tank cap gasket
line
R
R
Exhaust pipes and mountings
Brake
A
’ 1
Engine coolant 121
FUEL
the
7 5
Valve clearance* Drive belts
at
same
months,
or
1
Check and adjust if necessary, Replace, change or lubricate, Inspect and correct or replace if necessary
Maintenance services beyond 60,000 miles (96,000 km) should be performed intervals shown in each maintenance schedule
Service interval
(Odometer reading
SCHEDULE A
= = =
and dust covers
1
1
1
1
1:
Every 24 months
1
1
1
1
1:
Every 24 months
1
1
1
1
1:
Every 24 months
1
1
1
1
1:
Every 24 months
1
1
1
1
1:
Every 24 months
R
R:
Every 24 months
Front wheel bearing and thrust bush grease
R
Steering knuckle and chassis grease 151
R
R
R
R
R:
Every 24 months
Propeller shaft grease 151
R
R
R
R
R:
Every 24 months
1
1
1
1
1:
Every 24 months
1
1
1
1
1:
Every 24 months
1
1
1
1
1:
Every 24 months
Automatic transmission Transfer, differential and steering gear box
oil
161
Bolts and nuts on chassis and body 171 *: For vehicle sold in California *:
For vehicle sold outside California
(1) After
(2) After
(3) Includes inspection of fuel (4)
Also applicable to lining
(5)
If
drum
or 72 or
for
parking brake
the propeller shaft has been immersed
(6) Inspect the steering (7)
months, inspect every 7,500 miles (12,000 km) or 12 months. 36 months, replace every 30,000 miles (48,000 km) or 24 months. tank band vapor vent system
60,000 miles (96,000 km) 45,000 miles (72,000 km)
gear box
for
oil
in
water,
it
should be re-greased within a day.
leakage only
The applicable parts are listed below • Front and rear suspension member cross body • Strut bar bracket cross body
• U bolts for leaf spring. • Bolts for sheet installation 86821324
GENERAL INFORMATION AND MAINTENANCE
1-116
MAINTENANCE SCHEDULE A 1991-92 Land Cruiser Maintenance operations: A R I
= = =
Check and adjust if necessary; Replace, change or lubricate, Inspect and correct or replace if necessary
Conditions:
Towing a trailer, using a camper or car top carrier Repeat short trips less than 5 miles (8 km) and outside temperatures remain below freezing • Extensive idling and/or low speed driving for long distances, such as police, taxi or door-to-door delivery use • Operating on dusty, rough, muddy or salt spread roads •
•
Service interval
(Odometer reading
System
or
whichever comes
months,
Maintenance services beyond 60,000 miles (96,000 km) should continue in each maintenance schedule
first)
Miles
Maintenance items
ENGINE
x
km x
1
1
,000
.000
3 75
6
5
7
12
15
18 75
22 5
26 25
30
33 75
37 5
41 25
45
48 75
52 5
56 25
60'
24
30
36
42
48
54
60
66
72
78
84
90
96
A
A
A
oil
R
filter*
R
R
R
R
R
R
R
1
R
R
R
Engine coolant' 2 1
R
R
R
1
1
1
1
1
1
131
Air filter*
R
the
same
intervals
1
1
1
R
1
1
1
1
1
1
1
1:
months
36 months; 72 months Every 6 months
36 months
1
1:
Every 24 months
R
1:
R:
Every 6 months; Every 36 months
1:
Every 36 months
R
R:
Every 72 months
R
R:
Every 36 months
1
1:
Every 72 months
1
1
Fuel tank cap gasket
A: Every 24
R:
J
Fuel lines and connections"'
Months
R:
R
R
Exhaust pipes and mountings
FUEL
A
1
and
at
18
Drive belts"
oil
be performed
11.25
Valve clearance*
Engine
to
shown
IGNITION
Spaik plugs**
EVAP
Charcoal canister
Calif,
EXHAUST
Oxygen sensor*
Except California
BRAKES
Brake linings and drums' 51
1
1
1
1
1
1
1
1
1:
Every 12 months
Brake pads and discs
1
1
1
1
1
1
1
1
1:
Every 12 months
1
1:
Every 24 months
Brake
CHASSIS
line
R only
80,000 miles (128,000 km) only
pipes and hoses
1
Steering linkage Ball joints
R;
and dust covers
1
1
1
1
1
1
1
1
1:
Every 12 months
1
1
1
1
1
1
1
1
1.
Every 12 months
Automatic transmission
R
R
R
R
1:
Every 24 months
Transfer and differential
R
R
R
R
R:
Every 24 months
1
1
1
1
1:
Every 24 months
R
R:
Every 36 months
Steering gear box
oil
16 '
Front wheel bearing and thrust bush grease
R
R
R
R
R
R
R
R
R:
Every 12 months
Propeller shaft grease"'
R
R
R
R
R
R
R
R
R:
Every 12 months
1
I
1
1
1
1
1
1
1:
Every 12 months
*
For vehicle sold
*:
For vehicle sold outside California
(4)
in
'
California
60.000 miles (96,000 km) 45,000 miles (72,000 km)
months, inspect every 7,500 miles (12,000 km) or 12 months. 36 months, replace every 30,000 miles (48,000 km) or 24 months. Applicable when operating mainly on dusty roads If not, follow schedule B Includes inspection of fuel tank band and vapor vent system
(2) After
(3)
R
Steering knuckle and chassis grease"
Bolts and nuts on chassis and body 18
(1) After
1
1
(5) Also applicable to lining (6) Inspect the steering
drum
gear box
or 72 or
for
parking brake
for oil
leakage only
the propeller shaft has been immersed in water, it should be re-greased within a day. (8) Applicable only when operating mainly on rough, muddy roads The applicable parts are listed below. For other usage conditions, refer to • Bolts for sheet installation (7)
If
SCHEDULE
B.
86821325
GENERAL INFORMATION AND MAINTENANCE
1-117
1
MAINTENANCE SCHEDULE B 1991-92 Land Cruiser Conditions: Conditions other than those listed tor
System
months,
or
whichever comes
first)
Miles
Maintenance items
ENGINE
A.
Maintenance services beyond 60,000 miles (96,000 km) should'be performed in each maintenance schedule.
Service interval
(Odometer reading
SCHEDULE
x 1,000
km x
1,000
15
22 5
30
37 5
45
52 5
60
12
24
36
48
60
72
84
96
A
A
Drive belts "
oil
A
1
oil
R
filter*
R
R
R
R
Engine coolant 121
R
Air filter*
Fuel lines and connections 131
1
R
R
Spark plugs**
EVAP
Charcoal canister
California only
EXHAUST
Oxygen sensor*
Except California
BRAKES
Brake linings and drums 141
R
pipes and hoses
Steering linkage Ball joints
and dust covers
months
36 months, 72 months
R
Every 12 months
R:
Every 36 months
1:
Every 36 months
R:
Every 36 months Every 36 months
R:
Every 72 months
R
R:
Every 36 months
1
1:
Every 72 months
Every 24 months
1
1
1
1:
1
1
1
1:
Every 24 months
1
1
1
1
1:
Every 24 months
1
1
1
1
1:
Every 24 months
1
1
1
1
1:
Every 24 months
R
R:
Every 24 months Every 24 months
R
R
R
R
R:
Propeller shaft grease 151
R
R
R
R
R:
Every 24 months
1
1
1
1
1:
Every 24 months
1
1
1
1
1:
Every 24 months
1
1
1
1
1:
Every 24 months
and steering gear box
Bolts and nuts on chassis and body' *
For vehicle sold
*
For vehicle sold outside California
in
oil
161
7 '
Calitornia
months, inspect every 7,500 miles (12,000 km) or 12 months. 36 months, replace every 30,000 miles (48,000 km) or 24 months' tank band vapor vent system,
60,000 miles (96,000 km) 45,000 miles (72,000 km)
(3) Includes inspection of fuel (4) Also applicable to lining If
1:
Steering knuckle and chassis grease 151
Transfer, differential
(5)
A: Every 24
1
R
Automatic transmission
(2) After
Months
1
Front wheel bearing and thrust bush grease
(1) After
shown
80,000 miles (129,000 km) only
Brake pads discs (Front and rear)
CHASSIS
intervals
1:
4
R:
same
R
1
1
IGNITION
line
R
1
Fuel tank cap gasket
Brake
R
R
Exhaust pipes and mountings
FUEL
A
1
and
the
7 5
Valve clearance*
Engine
at
drum
the propeller shaft has been
(6) Inspect the steering
gear box
or 72 or
for
parking brake
immersed for oil
in
water,
it
should be re-greased within a day.
leakage only. 86821326
GENERAL INFORMATION AND MAINTENANCE
1-118
SCHEDULE A
1993-96
LAND CRUISER
Maintenance operations: A = Check and adjust as necessary;
= Inspect and
I
x
1000
x
1000 km
months, whichever comes first
)
ENGINE Engine
lubricate.
Odometer reading
SERVICE INTERVAL: (Use odometer reading or
R = Replace, change or
correct or replace as necessary;
miles
3.75
7.5
11.25
15
6
12
18
24
18.75 22.5 26.25
30
30
Months
33.75 37.5 41.25
45
48.75 52.5 56.25 60
36
42
48
54
60
66
72
78
84
90
R
R
R
R
R
R
R
R
R
R
96
COMPONENTS AND EMISSION CONTROL SYSTEMS
oil
and
oil
R
filter*
R
R
R
R
Valve clearance Drive belts «See note 1.»
Inspect at
Engine coolant «See note 2.»
Initial
48000 km (30000
change
at first
Exhaust pipes and mountings Air cleaner filter*«See
miles) or
72000 km (45000
1
note 3.»
1
1
1
36 months and miles) or
at
96000 km (60000
1
1
R
1
1
1
R:Every 6 months
A:Every 72 months
72 months.
36 months.
1
1
miles) or
R
A
1
1
1
1
1
1
1
R
LEvery 24 months LEvery 6 months R:Every 36 months
Maintenance operations:
Odometer reading
SERVICE INTERVAL: (Use odometer reeding or
months, whichever comes first.)
x
1000
x
1
miles
000 km
3 75
7 5
6
12
1
1.25
15
18
24
18 75 22 5 26 25
30
36
42
30
48
Fuel lines and connections, fuel tank
Months
33.73 37.5 41.25
54
60
66
45
72
48.75 52.5 56.25 60
78
84
90
1
96 1
LEvery 36 months
R
R:Every 72 months
R
R:Every 36 months
1
LEvery 72 months
vapor vent system hoses and tank band
fuel
Fuel tank cap gasket
Spark plugs* *
R
Charcoal canister
and
(California
New
York only)
Oxygen sensor
Replace
(except California and
New
at initial
128000 km (80000
miles).
York)
CHASSIS AND BODY Brake linings and drums
Brake pads and discs Brake
lines
1
1
1
1
1
1
1
LEvery
1
2 months
1
1
1
1
1
1
1
1
LEvery
1
2 months
1
LEvery 24 months
and hoses
1
1
Steering linkage Ball joints
1
and dust covers
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
LEvery
1
2 months
LEvery
1
2
months
Automatic transmission
R
R
R
R
R:Every 24 months
Transfer and differential
R
R
R
R
R:Every 24 months
1
1
1
1
Steering gear box
LEvery 24 months
Maintenance operations:
SERVICE INTERVAL: (Use odometer reeding or first.)
Wheel bearing and
Months
Odometer reading x
1000
x
1000 km
miles
3.75
7 5
1125
15
6
12
18
24
18.75 22.5 26.25
30
36
42
30
48
33 75 37.5 41.25
45
60
72
54
66
48.75 52.5 56.25 60
78
84
R
drive shaft bushing
90
96 R
R:Every 36 months
grease Steering knuckle grease Propeller shaft grease
Bolts and nuts on chassis and
body
R
R
R
R
R
R
R
R
R:Every
R
R
R
R
R
R
R
R
R:Every
1
1
1
1
1
1
1
1
LEvery
1
1
2
months
1
2
months
2 months
«See note 4» Maintenance services indicated by * or * are required under the terms of the Emission Control Systems Warranty. See Owner's Guide complete warranty information. * For vehicles sold in California and New York only * For vehicles sold outside California and New York
or
Warranty Book-
let for :
:
NOTE: 1.
2. 3. 4.
96000 km (60000 miles) or 72 months, inspect every 12000 km (7500 miles) or 12 months. 72000 km (45000 miles) or 36 months, change every 48000 km (30000 miles) or 24 months. Applicable when you mainly operate your vehicle on dusty roads. If not, apply Schedule B. Applicable when you mainly operate your vehicle on rough and/or muddy roads. If not, apply Schedule After
After
B. 86821327
GENERAL INFORMATION AND MAINTENANCE
SCHEDULE B
1993-96
1-119
LAND CRUISER
Maintenance operations:
A = Check and
adjust as necessary;
= Inspect and correct
I
or replace as necessary;
SERVICE INTERVAL: (Use odometer reading or months,
whichever comes
ENGINE Engine
R = Replace, change or
lubricate.
Months
Odometer reading
000
x
1
x
1000 km
first.)
miles
7.5
15
22.5
30
37.5
45
52.5
60
12
24
36
48
60
72
84
96
R
R
R
R
R
R
R
R:
A
A: Every 72
COMPONENTS AND EMISSION CONTROL SYSTEMS and
oil
oil
R
filter*
Valve clearance Drive belts
«See note 1.»
Inspect at
48000 km (30000
miles) or
36 months and
at
Every
1
2
96000 km (S0000
months months miles) or
72
months. Engine coolant «See note 2.»
Initial
change
at first
72000 km (45000
Exhaust pipes and mountings Air cleaner filter*
and connections, fuel tank vapor vent system hoses and fuel tank band Fuel lines
miles) or
36 months.
1
1
R
R
1
1
Fuel tank cap gasket
Spark plugs* *
R
1:
R: 1:
Every 36 months
Every 36 months Every 36 months
R
R:
Every 72 months
R
R:
Every 36 months
Maintenance operations:
SERVICE INTERVAL: whichever comes
Charcoal canister (California and California
New and
000
miles
x
1
x
1000 km
first.)
Oxygen sensor (except
Months
Odometer reading
(Use odometer reading or months,
7.5
15
22.5
30
37.5
45
52.5
60
12
24
36
48
60
72
84
96
York only)
New
York)
Replace
at initial
128000 km (80000
1
1:
Every 72 months
miles).
CHASSIS AND BODY Brake linings and drums Brake pads and discs
Brake
lines
and hoses
Steering linkage Ball joints
and dust covers
Automatic transmission Transfer and differential Steering gear box
Wheel bearing and
1
1
1
1
1:
Every 24 months
1
1
1
1
1:
Every 24 months
1
1
1
1
1:
Every 24 months
1
1
1
1
1:
Every 24 months
1
1
1
1
1:
Every 24 months
1
1
1
1
1:
Every 24 months
1
1
1
1
1:
Every 24 months
1
1
1
1
1:
Every 24 months
R
drive shaft bushing grease
R
R:
Every 36 months
Every 24 months
Steering knuckle grease
R
R
R
R
R:
Propeller shaft grease
R
R
R
R
R: Every
1
1
1
1
Bolts
and nuts on chassis and body
Maintenance services indicated by * or * are required under the terms for complete warranty information. * For vehicles sold in California and New York only * For vehicles sold outside California and New York
of the Emission Control
1:
24 months
Every 24 months
Systems Warranty. See Owner's Guide
or
Warranty Book-
let
:
:
NOTE: 1.
After
2.
After
96000 km (60000 72000 km (45000
miles) or
miles) or
72 months, inspect every 12000 km (7500 miles) or 12 months. 36 months, change every 48000 km (30000 miles) or 24 months. 86821328
GENERAL INFORMATION AND MAINTENANCE
1-120
SCHEDULE A
TRUCK
1996
Maintenance operations: A = Check and adjust as necessary;
= Inspect and correct
I
months, whichever comes first.)
Months
Odometer reading
SERVICE INTERVAL: (Use odometer reading or
R = Replace, change or lubricate.
or replace as necessary;
x
1
000 km
x
1
000
miles
6
12
3.75
7.5
25
1 1
30
24
18
36
48
42
30
18 75 22 5 26.25
15
60
54
66
72
33.75 37 5 41.25
45
R
R
78
84
90
96
48 75 52.5 56 25 60
ENGINE COMPONENTS AND EMISSION CONTROL SYSTEMS and
Engine
oil
Timing
belt
oil
R
filter*
R
R
R
R
R
R
R
R
R
R
R
R
R:Every 6 months
If
km (60000
miles).
A
Valve clearance Drive belts «See note 1.»
Inspect at
Engine coolant «See note 2.»
Initial
96000 km 160000
change
at first
Exhaust pipes and mountings Air cleaner filter*
R
you operate your vehicle under conditions of extensiVe idling and/or low speed driving for a long distance such as police, taxi or door-to-door delivery use, replace every 96000
(5VZ-FE engine)
miles) or
72000 km (45000
1
«See note 3.»
1
1
1
miles) or
36 months.
1
1
1
1
1
A:Every 72 months
72 months.
1
R
1
1
1
1
1
1
1
1
R
l:Every
24 months
LEvery 6 months R:Every 36 months
Maintenance operations:
SERVICE INTERVAL: (Use odometer reading or first.)
Odometer reading
000 km
x
1
x
1000
miles
6
12
3.75
7.5
18 11
25
24
30
36
42
18.75 22.5 26.25
15
48 30
Fuel lines and connections, fuel tank
54
60
Months 66
33.75 37 5 41.25
72 45
78
84
90
96
48 75 52 5 56 25 60
1
1
l:Every
36 months
vapor vent system hoses and fuel tank
band
Fuel tank cap gasket
Spark plugs* *
R
Charcoal canister «See note 4.»
R
R:Every 72 months
R
R:Every 36 months
1
l:Every
72 months
CHASSIS AND BODY Brake linings and drums fyake pads and discs
1
1
1
1
1
1
1
1
1
Every
1
2 months
1
1
1
1
1
1
1
\
1
Every
1
2
1
1
1
Brake lines and hoses Steering linkage
SRS
1
1
airbag «See note 5.»
Ball joints
1
1
Initial
and dust covers
inspect at 1
first
1
1
1
1
1
1
1
1
1
1
1
1
1
months
Every 24 months
Every
2
1
months
20 months.
1
1
LEvery 12 months
Maintenance operations:
SERVICE INTERVAL: (Use odometer reading or first.)
Months
Odometer reading x
1
000 km
x
1
000
miles
Drive shaft boots (four-wheel drive models)
6
12
3 75
7.5 1
18 1
1
25
24 15 1
30
36
42
48
54
60
66
72
18 75 22 5 26 25
30
33 75 37 5 41 25
45
1
1
1
1
78
84
90
96
48 75 52.5 56 25 60 1
1
Automatic transmission, manual transmission and differential
R
R
R
R
Transfer (four-wheel drive models)
R
R
R
R
1
1
1
1
Steering gear box
Wheel bearing grease
1:
Every
2
1
months
R:Every 24 months R:Every 24 months l:Every
24 months
R
R
R:Every 48 months
R
R
R:Every 36 months
R:Every
(two-wheel drive models)
Wheel bearing and
drive shaft bushing grease (four-wheel drive models) Propeller shaft grease (four-wheel drive models)
and nuts on chassis and body «See note 6.» Bolts
R
R
R
R
R
R
R
R
1
1
1
1
1
1
1
1
l:Every
Maintenance services indicated by * or * are required under the terms of the Emission Control Systems Warranty. See Owner's Guide complete warranty information. * For vehicles sold in California, Massachusetts and New York only * For vehicles sold outside California, Massachusetts and New York
or
1
1
2 months
2
months
Warranty Book-
let for :
:
NOTE:
96000 km 160000 miles) or 72 months, inspect every 12000 km (7500 miles) or 12 months. 72000 km (45000 miles) or 36 months, change every 48000 km (30000 miles) or 24 months. Applicable when you mainly operate your vehicle on dusty roads. If not, apply Schedule B.
1.
After
2.
After
3. 4. 5.
6.
Non-maintenance item except for California, Massachusetts and New York. After 120 months, inspect every 24 months. Applicable when you mainly operate your vehicle on rough and/or muddy roads.
If
not, apply
Schedule
B.
86821330
GENERAL INFORMATION AND MAINTENANCE
SCHEDULE B
1996
TRUCK
Maintenance operations: A = Check and adjust as necessary;
= Inspect and correct or replace as necessary;
I
SERVICE INTERVAL:
ENGINE Engine
R = Replace, change or lubricate.
Months
Odometer reading
(Use odometer reading or months,
whichever comes
1-121
000 km
x
1
x
1000
12
24
36
48
60
72
84
96
7.5
15
22.5
30
37.5
45
52.5
60
R
R
R
R
R
R
first.)
miles
COMPONENTS AND EMISSION CONTROL SYSTEMS
oil
and
R
oil filter*
Valve clearance Drive belts
«See note
1.»
Inspect at
Engine coolant «See note 2.»
Initial
96000 km (60000
change
at first
Air cleaner filter*
Fuel lines and connections, fuel tank vapor vent
Fuel tank
fuel tank
R:
A: Every 72 months
Every
1
72 months.
72000 km (45000
Exhaust pipes and mountings
system hoses and
miles) or
2 months
R
A
miles) or
36 months.
1
1
R
R
1
1
1:
R: 1:
Every 36 months Every 36 months Every 36 months
band
cap gasket
Spark plugs* *
R
Charcoal canister «See note 3.»
R
R:
R
R:
1
1:
Every 72 months Every 36 months
Every 72 months
Maintenance operations:
SERVICE INTERVAL: whichever comes
Months
Odometer reading
(Use odometer reading or months,
000 km
x
1
x
1000
12
24
36
48
60
72
84
96
15
22.5
30
37.5
45
52.5
60
first.)
miles
CHASSIS AND BODY Brake linings and drums
1
1
1
1
1:
Every 24 months
1
1
1
1
1:
Every 24 months
Brake lines and hoses
1
1
1
1
1:
Every 24 months
Steering linkage
1
1
1
1
1:
Every 24 months
Brake pads and discs
SRS
airbag «See note 4.»
Ball joints
Initial
and dust covers
Drive shaft boots (four-wheel drive models)
Automatic transmission, manual transmission and
inspect at
first
120 months.
1
1
1
1
1:
Every 24 months
1
1
1
1
1:
Every 24 months
1
1
1
1
1:
Every 24 months
1
1
1
1
1:
Every 24 months
1
1
1
1
1:
Every 24 months
differential
Transfer (four-wheel drive models) Steering gear box
Wheel bearing grease (two-wheel
drive models)
R
R
R:
Every 48 months
Maintenance operations: Odometer reading
SERVICE INTERVAL: (Use odometer reading or months.
whichever comes
1
000 km
12
24
36
48
60
72
84
96
x
1
000
7.5
15
22.5
30
37.5
45
52.5
60
first.)
Wheel bearing and
Months
x
miles
R
R:
R
R
R:
1
1
R
drive shaft bushing grease
Every 36 months
(four-wheel drive models) Propeller shaft grease (four-wheel drive models)
Bolts
and nuts on chassis and body
R
R
1
1
1:
Every 24 months Every 24 months
Maintenance services indicated by * or * are required under the terms of the Emission Control Systems Warranty. See Owner’s Guide let for complete warranty information. * For vehicles sold in California, Massachusetts and New York only * For vehicles sold outside California, Massachusetts and New York
or
Warranty Book-
:
NOTE:
96000 km (60000 72000 km (45000
miles) or
72 months, inspect every 12000 km (7500 miles) or 12 months. 36 months, change every 48000 km (30000 miles) or 24 months. California and New York.
1
After
2
After
3.
Non-maintenance item except for After 120 months, inspect every 24 months.
4.
miles) or
86821329
1-122
GENERAL INFORMATION AND MAINTENANCE
CAPACITIES Engine
Engine Engine
Displacement
Filter
ID/VIN
Liters (cc)
(qts.)
4-Spd
Model
1989
Pick-up
22R
2.4 (2366)
4.5
-
Pick-up
22R-E
2.4 (2366)
4.5
-
Pick-up
3VZ-E
3.0 (2959)
4.8
-
4Runner
22R
2.4 (2366)
4.5
-
4Runner
22R-E
2.4 (2366)
4.5
-
3.0 (2959)
4.8
-
4.0 (3956)
8.2
-
1991
1992
1993
1994
4Runner
3VZ-E
Land Cruiser
3F-E
Pick-up
22R
2.4 (2366)
4.5
-
Pick-up
22R-E
2.4 (2366)
4.5
-
Pick-up
3VZ-E
3.0 (2959)
4.8
-
4Runner
22R-E
2.4 (2366)
4.5
-
5-Spd
© © © © © © -
© © © 0 ©
4Runner
3VZ-E
3.0 (2959)
4.8
-
Land Cruiser
3F-E
4.0 (3956)
8.2
-
Pick-up
22R-E
2.4 (2366)
4.5
-
Pick-up
3VZ-E
3.0 (2959)
4.8
-
4Runner
22R-E
2.4 (2366)
4.5
-
4Runner
3VZ-E
3.0 (2959)
4.8
-
Land Cruiser
3F-E
4.0 (3956)
8.2
-
Pick-up
22R-E
2.4 (2366)
4.5
-
Pick-up
3VZ-E
3.0 (2959)
4.8
-
4Runner
22R-E
2.4 (2366)
4.5
-
4Runner
3VZ-E
3.0 (2959)
4.8
-
Land Cruiser
3F-E
4.0 (3956)
8.2
-
Pick-up
22R-E
2.4 (2366)
4.5
-
Pick-up
3VZ-E
3.0 (2959)
4.8
-
4Runner
22R-E
2.4 (2366)
4.5
-
4Runner
3VZ-E
3.0 (2959)
4.8
-
3.0 (2959)
4.8
-
6.4
7.8
-
-
T100
3VZ-E
Land Cruiser
1FZ-FE
Pick-up
22R-E
2.4 (2366)
4.5
-
Pick-up
3VZ-E
3.0 (2959)
4.8
-
4Runner
22R-E
2.4 (2366)
4.5
-
4.5 (4477)
Transfer
-
© 0 0 0
© © 0 © -
0 0 0 0 0 0 0 0
4Runner
3VZ-E
3.0 (2959)
4.8
-
T100
3RZ-FE
2.7 (2693)
5.6
-
2.7
T100
3VZ-E
3.0 (2959)
4.8
-
6.4
Land Cruiser
1FZ-FE
4.5 (4477)
7.8
-
-
Axle
Fuel
Cooling
Case
Front
Rear
Tank
System
(pts.)
(pts.)
(pts.)
(gal.)
(qts.)
©
© © © © © ©
© 0 0 © 0 0
© © © © © ©
4.4
6.0
6.8
25.1
® ® ® ®
© © © © ©
0 0 0 0 0
© © © © ©
12.6
4.4
6
6.8
25.1
0 0 0 0
© © © ©
© © © ©
0 0 0 0
0 0 © ©
12.6
© © © 0 © © © 0 0 © 0 © © G © © © © © © 0 © © © @ 0 0 0
(pts.)
Year
1990
Drive
.
Transmission
Oil with
Auto.
0 0 0 0 0 0
©
©
12.6
©
© © © © ©
4.0
6.0
6.8
25.1
0 0 0 0
© © © ©
© © © ©
0 0 0 0
0 © ©
12.6
4.4
6.0
6.8
25.1
0
©
0
2.4
@ © 0
© 0 ©
0 0 0 0 0
© © © © © 0 © © © ©
© ©
0 0
0 © 0 0
6.8
25.1
0 0 0 0
© © © ©
© 0 0 0
-
-
3.8
19.8
9.2
0
12.6
0 0 0 0 -
0
©
0
2.4
©
0
©
12.6
©
0
6.8
25.1
15.0
0 15.0 86821331
GENERAL INFORMATION AND MAINTENANCE
1-123
CAPACITIES Engine Engine
Drive
Transmission
Oil with
Engine
Displacement
Filter
ID/VIN
Liters (cc)
(qts.)
(pts.)
Year
Model
1995
Pick-up
22R-E
2.4 (2366)
4.5
-
Pick-up
3VZ-E
3.0 (2959)
4.8
-
4Runner
22R-E
2.4 (2366)
4.5
-
4Runner
2VZ-E
3.0 (2959)
4.8
-
Tacoma
2RZ-FE
2.4 (2438)
5.8
-
Tacoma
3RZ-FE
2.7 (2693)
5.8
-
Tacoma
5VZ-FE
3.4 (3378)
©
-
T100
3RZ-FE
2.7 (2693)
5.6
T100
5VZ-FE
3.4 (3378)
Land Cruiser
1FZ-FE
Tacoma
2RZ-FE
Tacoma
3RZ-FE
Tacoma
(qts.)
0 0 0 0
© © © © ©
© ©
© ©
©
© © © ©
2.9
15.1
© ©
© ©
18.0 18.0
3.8
19.8
9.2
©
©
0
2.4
3.9
©
-
24.0
©
4.5 (4477)
7.8
-
-
12.6
0
©
6.8
25.1
15.0
2.4 (2438)
5.8
-
15.1
5.8
3.4 (3378)
©
-
© ©
18.0
5VZ-FE
© © ©
2.9
2.7 (2693)
© © ©
2.2
-
© © ©
18.0
© © ©
T100
3RZ-FE
2.7 (2693)
5.6
-
2.7
-
-
-
3.8
19.8
9.2
T100
5VZ-FE
3.4 (3378)
©
©
0
2.4
3.9
©
-
24.0
©
Land Cruiser
1FZ-FE
4.5 (4477)
7.8
-
-
12.6
0
©
6.8
25.1
15.0
Except
4WD
automatic transmission: 8.9
18 Except
transmission:
1 1
19
.1
rear heater: 20.6
2WD 2WD
With
3V2-E AT (VF1A
3VZ-E AT (A340H):
automatic transmission: 9.6
2WD 2WD 4WD 4WD
with
with
2WD-
3.8:
8.0" differential: 3.8
21
2WD:
5.4
4WD:
4.6
oil
17.2; Optional: 19.3
2WD with 4WD with 4WD with
4WD:
5.4
4WD:
5.2
A340F: 4.2
R150. R150F: 5.4
ADD:
A340F: 4.2
25 Without ADD: 2.32
Without rear heater: 8.9
With
Short bed: 13.7
26
Lonqbed: 17.2
Lonqbed4WD:
19.3
manual transmission; 11.0 automatic tranmission: 10.8
manual transmission:
11.1
automatic transmission: 10.9
with
0.8
A340E: 3.4
4.0
10 With rear heater: 9.2
4WD:
1
4.6
24 A43D: 5.0
1.8
Standard: 3.4;
with
4WD'
2WD:
4.6
4WD with
manual transmission: 10.6
A340H: 9.6
4WD:
4WD:
type): 2.4
manual transmission: 10.6
A340E: 3.4
2WD:
with
2.2
4.3
Planetary qear type: 2.4
2WD 2WD 4WD 4WD 2WD
2.2
23 W59.
cooler: 4.3
Counter gear type: 2.4
A340H:
2.2
22 2WD: 4.4
cooler 4.4 oil
2.2
-
1.6
with automatic transmission:
20
4.6
2.2
©
with automatic transmission: 10.5
7.5" differential: 2.8
Without
13
(gai.)
-
5 Standard:
12
(pts.)
-
4WD:
11
(pts.)
-
Without rea r heater: 18.5
9
System
(pts.)
2.7
3 With
8
Auto.
-
Automatic transmission: 10.9
7
Tank
© @ © ©
2 Manual
6
Rear
Axle
0 0 0 0 © © ©
4WD
4
5-Spd
Cooling
Front
© © © © © © ©
1996
1
4-Spd
Fuel
Case
Transfer
ADD: 2.44
2WD 2WD 4WD 4WD
with
manual transmission: 8.5
with automatic transmission: 8.2 with
manual transmission: 8.8
with automatic transmission: 8.7
27 Extra lonq 4.4 All
others: 5.4
28 2WD: 5.5
W56: 5.0
4WD:
W56: 6.4
5.0
29 With ABS: 2.8
G58: 8.2
Without ABS: 3.6
R150F: 6.4
14 With differential lock: 5.6
Without
differential lock: 5.8
15 With standard
tires:
17.2
With optional 31x10.5 16
2WD:
5.7
4WD:
5.5
tires:
18.8
17 G58: 8.2
R150F: 6.4 86821332
GENERAL INFORMATION AND MAINTENANCE
1-124
GASOLINE ENGINE TUNE-UP Ignition
Engine
Engine Year 1989
ID/VIN
Displacement Liters (cc)
Idle
Spark Plugs
Timing
Fuel
Speed
Valve
Gap
(deg.)
Pump
(rpm)
Clearance
MT
(in.)
22R
2.4 (2366)
0.031
-
22R-E
2.4 (2366)
0.031
5B
AT
0
MT
(psi)
AT
In.
Ex.
-
2. 1-4.3
700
750
0.008
0.012
5B
35-38
750
750
0.008
0.012
|
1990
1991
1992
1993
1994
1995
3VZ-E
3.0 (2959)
0.031
10B
10B
38-44
800
800
0.012
0.013
3F-E
4.0 (3956)
0.031
7B
7B
37-46
650
650
0.008
0.014
22R
2.4 (2366)
0.031
“
2.14.3
750
850
0.008
0.012
22R-E
2.4 (2366)
0.031
5B
5B
38-44
750
850
0.008
0.012
3VZ-E
3.0 (2959)
0.031
10B
10B
3844
800
800
0.007-
0.009-
0.011
0.013
3F-E
4.0 (3956)
0.031
“
7B
3746
650
650
0.008
0.014
22R-E
2.4 (2366)
0.031
5B
5B
3844
750
850
0.008
0.012
3VZ-E
3.0 (2959)
0.031
10B
3844
800
800
©
©
3F-E
4.0 (3956)
0.031
-
7B
3746
650
650
0.008
0.014
22R-E
2.4 (2366)
0.031
5B
5B
3844
750
850
0.008
0.012
3VZ-E
3.0 (2959)
0.031
10B
3844
800
800
©
©
3F-E
4.0 (3956)
0.031
7B
3746
650
650
0.008
0.014
22R-E
2.4 (2366)
0.031
5B
5B
3844
750
850
0.008
0.012
3VZ-E
3.0 (2959)
0.041
10B
10B
3844
800
800
©
©
1FZ-FE
4.5 (4477)
0.031
-
3B
3844
600-
0.006-
0.010-
700
0.010
0.014
22R-E
2.4 (2366)
0.031
5B
3RZ-FE
2.7 (2693)
0.031
5B
3VZ-E
3.0 (2959)
0.031
10B
1FZ-FE
4.5 (4477)
0.031
*
1
1
0B
0B
3844
750
850
0.008
0.012
3844
750
*
0.008
0.012
10B
3844
800
800
©
©
3B
3844
-
600-
0.006-
0.010-
700
0.010
0.014
5B
22R-E
2.4 (2366)
0.031
5B
5B
3844
750
850
0.008
0.012
2RZ-FE
2.4 (2438)
0.031
©
©
3844
650-750
650-750
0.006-
0.010-
0.010
0.014 86821210
GENERAL INFORMATION AND MAINTENANCE
1-125
GASOLINE ENGINE TUNE-UP Idle
Ignition
Engine
Spark Plugs
Timing
Fuel
Speed
Valve
Gap
(deg.)
Pump
(rpm)
Clearance
Displacement
Engine
MT
AT
Year
ID/VIN
1995
3RZ-FE
2.7 (2693)
0.031
©
©
38-44
3VZ-E
3.0 (2959)
0.031
10B
10B
5VZ-FE
3.4 (3378)
0.043
©
0
•
FZ-FE
in.
Ex.
750
0.008
0.012
3844
800
800
©
©
3844
650-750
650-750
0.006-
0.011-
3844
3B
AT -
600-700
0.009
0.014
0.006-
0.010-
0.010
0.014
22R-E
2.4 (2366)
0.031
5B
5B
3844
750
850
0.008
0.012
2RZ-FE
2.4 (2438)
0.031
©
©
3844
650-750
650-750
0.006-
0.010-
0.010
0.014
0.008
0.012
3RZ-FE
2.7 (2693)
0.031
©
©
3844
750
3VZ-E
3.0 (2959)
0.031
10B
10B
3844
800
800
©
®
5VZ-FE
3.4 (3378)
0.043
©
0
3844
650-750
650-750
0.006-
0.011-
FZ-FE
1
NOTE: The differ -
MT
(psl)
0.031
1996
B
(in.)
4.5 (4477)
1
1
Liters (cc)
4.5 (4477)
3B
0.031
Vehicle Emission Control Inlormation label often reflects specification chanqes
from those
"
38-44
made
during production.
The
label figures
600-700
must be used
if
0.009
0.014
0.006-
0.010-
0.010
0.014
thev
in this chart.
Before top dead center
T terminal shorted
2
Intake: 0.007-0.011 (cold)
3
Exhaust: 0.009-0.013 (cold)
4
10B
5
5B
at idle, with terminal
at idle, with terminal
TE1 and El connected
TE1 and El connected
of
of
DLC1
DLC1 8682 lppp
GENERAL INFORMATION AND MAINTENANCE
1-126
ENGLISH TO METRIC CONVERSION: MASS (WEIGHT) Current mass measurement is expressed in pounds and ounces (lbs. & 02 s.). The metric unit of mass (or weight) is the kilogram (kg). Even although this table does not show conversion of masses (weights) larger than 15 lbs, it is easy to calculate larger units by following the data immediately below.
To convert ounces (oz.) to grams (g): multiply th number of ozs. by 28 To convert grams (g) to ounces (oz.): multiply the number of grams by .035 To convert pounds (lbs.) to kilograms (kg): multiply the number of lbs. by .45 To convert kilograms (kg) to pounds (lbs ): multiply the number of kilograms by 2.2 lbs
kg
lbs
kg
oz
kg
oz
0.1
0.04
0.9
0.41
0.1
0.003
0.9
kg '
0.024
0.2
0.09
1
0.4
0.2
0.005
1
0.03
0.3
0.14
2
0.9
0.3
0.008
2
0.06
0.4
0.18
3
1.4
0.4
0.011
3
0.08
0.5
0.23
4
1.8
0.5
0.014
4
0.11
0.6
0.27
5
2.3
0.6
0.017
5
0.14
0.7
0.32
10
4.5
0.7
0.020
10
0.28
0.8
0.36
15
6.8
0.8
0.023
15
0.42
ENGLISH TO METRIC CONVERSION: TEMPERATURE To convert Fahrenheit To convert Celsius Fahrenheit °F
(F)
“C
-40 -35 -30 -25 -20 -15 -10
—5 0 1
2 3 4 5 10 15
20 25
30 35 40 45 50 55 60 65 70 75
-40
- 37.2 - 34.4 - 31.7 - 28.9 - 26.1 - 23.3 - 20.6 - 17.8 - 17.2 - 16.7 - 16.1
- 15.6 - 15.0 - 12.2 - 9.4 - 6.7 - 3.9 - 1.1
(
Celsius (°C): take
number
of °F
C) to Fahrenheit (°F): take
number
of
F) to
(
Celsius (C)
"C
-38 -36 -34 -32 -30 -28 -26 -24 -22 -20 -18 -16 -14 -12 -10
-8 -6 -4 -2
°C and multiply by
Fahrenheit •F
- 36.4 - 32.8 - 29.2 - 25.6 -22
- 18.4 - 14.8
- 11.2 - 7.6 -4
and subtract 32; multiply
(F)
result by 5; divide result by
9: divide result
Celsius (C)
•F
•c
80
26.7
18
85
29.4
20
90
32.2
by
5;
add 32
Fahrenheit
•c
(F)
*F
•F
64.4
215
68
220
22
71.6
225
107.2
1
•c
9
to total
Celsius (C) •c
•F
101.7
80
176
104.4
85
185
90
194
202
95
35.0
24
75.2
230
110.0
95
100
37.8
26
78.8
112.8
100
212
105
40.6
28
82.4
235 240
115.6
105
221
110
43.3
30
86
245
118.3
110
230
115
46.1
32
89.6
121.1
115
120
48.9
34
93.2
250 255
123.9
120
239 248
- 0.4
125
51.7
36
96.8
130
54.4
38
100.4
3.2
135
57.2
40
104
6.8
140
60.0
42
107.6
10.4
145
62.8
44
112.2
14
150
65.6
46
114.8
260 265 270 275 280 285
17.6
155
68.3
48
118.4
290
143.3
155
311
126.6
125
257
129.4
130
266
132.2
135
275
135.0
140
284
137.8
145
293
140.6
150
302
21.2
160
71.1
50
122
295
146.1
160
320
24.8
165
73.9
52
125.6
300
148.9
165
329
28.4
170
76.7
54
129.2
305
151.7
170
338
1.7
0
32
175
79.4
56
132.8
310
154.4
175
347
4.4
2
35.6
180
82.2
58
136.4
157.2
180
356
160.0
185
162.8
190
365 374 383
7.2
4
39.2
185
85.0
60
140
10.0
6
42.8
190
87.8
62
143.6
12.8
8
46.4
195
90.6
64
147.2
315 320 325 330
165.6
195
15.6
10
50
200
93.3
66
150.8
335
168.3
200
392
18.3
12
53.6
96.1
68
154.4
171.1
70
158
173.9
205 210
401
98.9
340 345
100.0
75
167
350
176.7
215
21.1
14
57.2
205 210
23.9
16
60.8
212
410 414 tccslcOl
GENERAL INFORMATION AND MAINTENANCE
1-127
ENGLISH TO METRIC CONVERSION: LENGTH To convert inches
(ins.) to millimeters
To convert millimeters (mm)
(mm): multiply number
to inches (ins.): multiply Milli-
Indus
1/64 0.051625 0.03125
3/64 0.046875 0.0625
1/16
5/64 0.078125 3/32
0.09375
7/64 0.109375 0.125
1/8
9/64 0.140625 5/32
0.15625
11/64 0.171875 0.1875
3/16
13/64 0.203125
7/32
0.21875
15/64 0.234375 0.25
1/4
17/64 0.265625
9/32
0.28125
19/64 0.296875 0.3125
5/16
21/64 0.328125 11/32
0.34375
23/64 0.359375 0.375
3/8
25/64 0.390625 13/32
0.40625
27/64 0.421875 0.4375
7/16
15/32 1/2
29/64 0.453125 0.46875
25.4
of millimeters by .04
Inches to millimeters
Decimals inches
mm
0.3969
0.0001
0.00254
0.7937
0.0002
0.00508
1.1906
0.0003
0.00762
1.5875
0.0004
0.01016
1.9844
0.0005
0.01270
2.3812
0.0006
0.01524
2.7781
0.0007
0.01778
3.1750
0.0008
0.02032
meters
1/32
number
of inches by
3.5719
0.0009
0.02286
3.9687
0.001
0.0254
4.3656
0.002
0.0508
4.7625
0.003
0.0762
5.1594
0.004
0.1016
5.5562
0.005
0.1270
5.9531
0.006
0.1524
6.3500
0.007
0.1778
6.7469
0.008
0.2032
7.1437
0.009
0.2286
7.5406
0.01
0.254
7.9375
0.02
0.508
8.3344
0.03
0.762
8.7312
0.04
1.016
9.1281
0.05
1.270
9.5250
0.06
1.524
9.9219
0.07
1.778
10.3187
0.08
2.032
10.7156
0.09
2.286
11.1125
0.1
2.54
11.5094
0.2
5.08
11.9062
0.3
7.62
31/64 0.484375
12.3031
0.4
10.16
0.5
12.7000
0.5
12.70
Inches to millimeters
Milli-
Decimals
Inches
meters
33/64 0.515625 0.53125
17/32
35/64 0.546875 0.5625
9/16
37/64 0.578125 0.59375
19/32
39/64 0.609375 0.625
5/8
41/64 0.640625 0.65625
21/32
43/64 0.671875 0.6875
11/16
45/64 0.703125 0.71875
23/32
47/64 0.734375 0.75
3/4
49/64 0.765625 0.78125
25/32
51/64 0.796875 0.8125
13/16
53/64 0.828125 0.84375
27/32
55/64 0.859375 0.875
7/8
57/64 0.890625 29/32
0.90625
59/64 0.921875 15/16
09375
.
61/64 0.953125 31/32
0.96875
63/64 0.984375
mm
inches
13.0969
0.6
13.4937
0.7
17.78
13.8906
0.8
20.32
14.2875
0.9
22.86
14.6844
1
25.4
15.0812
2
50.8
15.4781
3
76.2
15.8750
4
101.6
15.24
16.2719
5
127.0
16.6687
6
152.4
17.0656
7
177.8
17.4625
8
203.2
17.8594
9
228.6
18.2562
10
254.0
18.6531
11
279.4
19.0500
12
304.8
19.4469
13
330.2
19.8437
14
355.6
20.2406
15
381.0
20.6375
16
406.4
21.0344
17
431.8
21.4312
18
457.2
21.8281
19
482.6
22.2250
20
508.0
22.6219
21
533.4
23.0187
22
558.8
23.4156
23
584.2
23.8125
24
609.6
24.2094
25
635.0
24.6062
26
660.4
25.0031
27
690.6
ENGLISH TO METRIC CONVERSION: TORQUE To convert foot pounds
To convert inch pounds in lbs
N-m
to
Newton meters: multiply the number
of
ft.
lbs.
by
number
of
in.
lbs.
by .11
lbs.) to Newton-meters: multiply the
in lbs
N-m
1
3
N-m
in lbs
N-m
in lbs
N-m
10
1.13
19
2.15
28
3.16
in lbs
0.1
0.01
1
0.2
0.02
2
0.23
11
1.24
20
226
29
3.28
0.3
0.03
3
0.34
12
1.36
21
2.37
30
3.39
0.4
0.04
4
0.45
13
1.47
22
2.49
31
0.5
0.06
5
0 56
14
1.58
23
260
32
3.62
0.6
0.07
6
0.68
15
1.70
24
2.71
33
3.73
0.7
0.08
7
0.78
16
1.81
25
2.82
34
3.84
17
1.92
26
2.94
35
3.95
18
2.03
27
3.05
36
4 0/
O
1
(in.
lbs.)
0.11
"
,
(ft
oo
0.09
8
0.90
cn
0.10
9
1.02
3.50
.
tccslc02
1-128
GENERAL INFORMATION AND MAINTENANCE
ENGLISH TO METRIC CONVERSION: TORQUE Torque is now expressed as either foot-pounds (ft. /lbs.) or inch-pounds (in., lbs ). The metric measurement unit for torque will be used for all SI metric torque references, both the present the Nm is the Newton-meter (Nm). This unit ft lbs. and in. /lbs.
—
—
RTFs
N-m
ft lbs
N-m
ft lbs
N-m
.
ft lbs
N-m
0.1
0.1
33
44.7
74
100.3
115
0.2
0.3
34
46.1
75
101.7
116
157.3
0.3
0.4
35
47.4
76
103.0
117
158.6
155.9
0.4
0.5
36
48.8
77
104.4
118
160.0
0.5
0.7
37
50.7
78
105.8
119
161.3
0.6
0.8
38
51.5
79
107.1
120
162.7
0.7
1.0
39
52.9
80
108.5
121
164.0
0.8
1.1
40
54.2
81
109.8
122
165.4
0.9
1.2
41
55.6
82
111.2
123
166.8
1
1.3
42
56.9
83
112.5
124
168.1
2
2.7
43
58.3
84
113.9
125
169.5
3
4.1
44
59.7
85
115.2
126
170.8
4
5.4
45
61.0
86
116.6
127
172.2
5
6.8
46
62.4
87
118.0
128
173.5
6
8.1
47
63.7
88
119.3
129
174.9
7
9.5
48
65.1
89
120.7
130
176.2
8
10.8
49
66.4
90
122.0
131
177.6
9
12.2
50
67.8
91
123.4
132
179.0
10
13.6
51
69.2
92
124.7
133
180.3
11
14.9
52
70.5
93
126.1
134
181.7
12
16.3
53
71.9
94
127.4
135
183.0
13
17.6
54
73.2
95
128.8
136
184.4
14
18.9
55
74.6
96
130.2
137
185.7
138
187.1
15
20.3
56
75.9
97
131.5
16
21.7
57
77.3
98
132.9
139
188.5
17
23.0
58
78.6
99
134.2
140
189.8
18
24.4
59
80.0
100
135.6
141
191.2
19
25.8
60
81.4
101
136.9
142
192.5
138.3
143
193.9
ms
144
195.2
196.6
—
20
27.1
61
82.7
102
21
28.5
62
84.1
103
22
29.8
63
85.4
104
141.0
145
CO
31.2
64
86.8
105
142.4
146
198.0
24
32.5
65
88.1
106
143.7
147
199.3
25
33.9
66
89.5
107
145.1
148
200.7
26
35.2
67
90.8
108
146.4
149
202.0
27
36.6
68
92.2
109
147.8
150
203.4
OO
38.0
69
93.6
110
149.1
151
204.7
29
39.3
70
94.9
111
150.5
152
206.1
30
40.7
71
963
151.8
153
31
42.0
72
97.6
113
153.2
154
208.8
32
43.4
73
99.0
114
154.6
155
210.2
CNJ
CVj
T~
~T\
tccslc03
GENERAL INFORMATION AND MAINTENANCE
1-129
ENGLISH TO METRIC CONVERSION: FORCE Force is presently measured in pounds (lbs.) This type of measurement is used to measure spring pressure, specifically how many pounds it takes to compress a spring. Our present force unit (the pound) will be replaced in SI metric measurements by the Newton (N). This term will eventually see use in specifications for electric motor brush spring pressures, valve spring pressures, etc.
To convert pounds
(lbs.) to
Newton
(N): multiply the
number
of lbs. by
4.45
lbs
N
0.01
0.04
21
93.4
59
262.4
1
0.02
0.09
22
97.9
60
266.9
2
0.6
0.03
0.13
23
102.3
61
271.3
3
0.8 1.1
lbs
N
lbs
N
oz
N 0.3
0.04
0.18
24
106.8
62
275.8
4
0.05
0.22
25
111.2
63
280.2
5
1.4
0.06
0.27
26
115.6
64
284.6
6
1.7
0.07
0.31
27
120.1
65
289.1
7
2.0
0.08
0.36
28
124.6
66
293.6
8
2.2
0.09
0.40
29
129.0
67
298.0
9
2.5
0.1
0.4
30
133.4
68
302.5
10
2.8
0.2
0.9
31
137.9
69
306.9
11
3.1
0.3
1.3
32
142.3
70
311.4
12
3.3
0.4
1.8
33
146.8
71
315.8
13
3.6
0.5
2.2
34
151.2
72
320.3
14
3.9
0.6
2.7
35
155.7
73
324.7
15
4.2
0.7
3.1
36
160.1
74
329.2
16
4.4
0.8
3.6
37
164.6
75
333.6
17
4.7
0.9
4.0
38
169.0
76
338.1
18
5.0
1
4.4
39
173.5
77
342.5
19
5.3
2
8.9
40
177.9
78
347.0
20
5.6
3
13.4
41
182.4
79
351.4
21
5.8
4
17.8
42
186.8
80
355.9
22
6.1
81
360.3
23
6.4 6.7
5
22.2
43
191.3
6
26.7
44
195.7
82
364.8
24
7
31.1
45
200.2
83
369.2
25
7.0
8
35.6
46
204.6
84
373.6
26
7.2
9
40.0
47
209.1
85
378.1
27
7.5
10
44.5
48
213.5
86
382.6
28
7.8
11
48.9
49
218.0
87
387.0
29
8.1
12
53.4
50
224.4
88
391.4
30
8.3
13
57.8
51
226.9
89
395.9
31
8.6
14
62.3
52
231.3
90
400.3
32
8.9
15
66.7
53
235.8
91
404.8
33
9.2
16
71.2
54
240.2
92
409.2
34
9.4
17
75.6
55
244.6
93
413.7
35
9.7
18
80.1
56
249.1
94
418.1
36
10.0
19
84.5
57
253.6
95
422.6
37
10.3
20
89.0
58
258.0
96
427.0
38
10.6
GENERAL INFORMATION AND MAINTENANCE
1-130
CONVERSION FACTORS LENGTH-DISTANCE Inches Feet
Millimeters
x .305
= =
x 1.609
—
Kilometers (km)
x 25.4
(in.)
(ft.)
Miles
(mm)
x .0394
Meters (m)
x 3.281 x .0621
= = =
Inches
= = = = = = = = = =
m3
= =
Ounces
Feet
Miles
VOLUME Cubic Inches
IMP IMP IMP IMP IMP
(IMP
Pints
Gallons
Gallons
FI.
Ounces
US US US
Pints
x 1.137
qt.)
(IMP
(IMP
Quarts
x .568
pt.)
(IMP
Quarts
x 16.387
(in3)
x 4.546
gal.)
x 1.201
qt.)
(IMP
x 1.201
gal.)
x 29.573
(US
x .473
pt.)
Quarts (US
x .946
qt.)
Gallons (US
x 3.785
gal.)
= Cubic Centimeters = Liters (L) = Liters (L) = Liters (L) = US Quarts (US qt.) = US Gallons (US gal.) = Milliliters = Liters (L) = Liters (L) = Liters (L)
x .061 x 1.76 x .88 x .22
x .833 x .833
x .034 x 2.113 x 1.057
x .264
IMP IMP IMP IMP IMP
pt.
qt.
gal. qt.
gal.
Ounces Pints
Quarts Gallons
MASS-WEIGHT Ounces
(oz.)
Pounds
(lb.)
x 28.35 x .454
= Grams (g) = Kilograms
x .035 x 2.205
(kg)
Pounds
PRESSURE Pounds Per
x 6.895
Sq. In. (psi)
Inches of Mercury (Hg)
x .4912
Inches of Mercury (Hg)
x 3.377
Inches of Water (H 2 0)
x .07355
Inches of Water (H 2 0)
x .03613
Inches of Water
(H 0)
x .248
2
=
= = = = =
Kilopascals (kPa)
x .145 x 2.036
psi
Kilopascals (kPa)
x .2961
Inches of Mercury
x 13.783
psi
x 27.684 x 4.026
Kilopascals (kPa)
= psi = Hg = Hg = H0 = ho - ho 2
2
2
TORQUE Pounds-Force Inches
Pounds-Force Feet
x 1.356
= Newton = Newton
x 1.609
=
x .113
(in-lb)
(ft-lb)
Meters (N m)
x .738
= =
x .621
= MPH
x 8.85
•
Meters (N-m)
in-lb ft-lb
VELOCITY Miles Per
Hour (MPH)
Kilometers Per Hour
(KPH)
POWER Horsepower (Hp)
x .745
FUEL CONSUMPTION Miles Per Gallon
IMP (MPG)
Kilometers Per Liter Miles Per Gallon
Kilometers Per Liter *It
=
(Km/L)
US (MPG) (Km/L)
-
Kilowatts
x 1.34
=
Horsepower
*
x .354
x 2.352 x .425 x 2.352
= Kilometers = IMP MPG = Kilometers = US MPG
common to covert from miles per gallon (mpg) 282 and mpg (US) x 1/100 km — 235. is
Per Liter
(Km/L)
Per Liter
(Km/L)
to liters/100 kilometers
(1/100 km), where
mpg (IMP)
x 1/100
km
TEMPERATURE Degree Fahrenheit
Degree Celsius
(°C)
(°F)
= (°C x 1.8) + 32 = (°F - 32) x .56 tecs 1044
BASIC ELECTRICAL THEORY BATTERY, STARTING AND
CHARGING SYSTEMS 2-4 UNDERSTANDING ELECTRICITY 2-2 CHARGING SYSTEM ALTERNATOR 2-16 ALTERNATOR PRECAUTIONS 2-16 GENERAL INFORMATION 2-16 REGULATOR 2-23 DISTRIBUTORLESS IGNITION SYSTEM CAMSHAFT POSITION SENSOR 2-13 CRANKSHAFT POSITION SENSOR 2-13 DIAGNOSIS AND TESTING 2-12 GENERAL INFORMATION 2-12 IGNITER 2-13 IGNITION COIL PACK 2-13
ELECTRONIC DISTRIBUTOR IGNITION SYSTEM ADJUSTMENTS 2-6 DIAGNOSIS AND TESTING 2-6 DISTRIBUTOR
2-9
GENERAL INFORMATION
2-5
IGNITER 2-9 IGNITION COIL 2-8 FIRING ORDERS 2-15 SENDING UNITS AND
SENSORS ENGINE COOLANT TEMPERATURE SENSOR 2-28 OIL PRESSURE UGHT/GAUGE SENDER 2-28 SPECIFICATIONS CHARTS STARTER SPECIFICATIONS 2-25 STARTING SYSTEM BATTERY 2-25 GENERAL INFORMATION 2-23 STARTER 2-23
ENGINE ELECTRICAL BASIC ELECTRICAL THEORY
CHARGING SYSTEM
2-2
2-16
DISTRIBUTORLESS IGNITION
SYSTEM
2-12
ELECTRONIC DISTRIBUTOR IGNITION
SYSTEM
2-5
ORDERS SENDING UNITS AND SENSORS SPECIFICATIONS CHARTS
2-15
STARTING SYSTEM
2-23
FIRING
2-28 2-25
ENGINE ELECTRICAL
2-2
BASIC ELECTRICAL THEORY Load
Understanding
Electricity Every complete
For any
complete
electrical circuit.
means
that the
make a
circle.
When an
operating,
is
full
and returns
of the circuit. This
to the battery
may be
ground
(DON’T do
electrical
power flows from the
from one pole to another almost
it
is
either another wire or a
how
the
component
not being used by
components
BASIC CIRCUITS
any load
its
of the battery
without the
light bulb,
power supply
entire
instantly.
to
This
a short
is
a short cut to get to ground and the
in
circuit.
This sudden and
damage
to other
the circuit and can develop a tremendous
A
of heat.
develop
sufficient
short
in
an automotive wiring harness can
heat to melt the insulation on
the sur-
all
rounding wires and reduce a multiple wire cable to one sad
and 2
1
in
amount
lump
See Figures
>
electricity is taking
it)
uncontrolled electrical flow can cause great
designed).
is
The
circuit.
through the ground path
metal part of the vehicle (depending upon
but take out word for
this,
the battery would attempt to deliver
battery to the
(load) causing
must include a “load” (something coming from the source). If you were to circuit
electricity
connect a wire between the two terminals
power flow from
components, passes through the component to function,
use the
must be a
to operate, there
This simply
the battery must
component
system
of plastic
and copper. Two common causes
of shorts are
broken insulation (thereby exposing the wire to contact with surrounding metal surfaces or other wires) or a failed switch
Perhaps the easiest way connecting a
light
one
circuit is to think of
two wires was attached
of the
If
post
of the battery
(+),
a
bulb (with two wires attached to
battery. (-)
to visualize
and the other wire
bulb and back to the battery. longer wires on our
Its
light bulb,
it
light
fitted with
become
brighter or
advise the user that
its
dimmer under
burned
Switches and Relays
Some
make
these
components which
circuits carry
also greater.
If
light
electrical current runs
are connected from the battery to one side of the relay
(-)
cable;
if
you
look, you'll
to the battery
through the chas-
see
through the ground
that the battery
connects between the battery and the body
An
additional, smaller wire
1
Here
is
ground cable
turned on,
it
pletes
circuit.
When
The
relay
its
circuit.
the switch
connected from the relay
When
grounds the smaller wire
of the vehicle.
an example of a simple automotive
is
to the control switch for the circuit.
sending power
Fig.
of the relay to the load.
normally open, preventing current from passing through the
circuit.
and returns
to
amperage load and the dash would be twice as large accommodate wiring harnesses as thick as your wrist. To prevent these problems, a relay is used. The large wires in the
is
The
is
were connected from the load
to
out.
automotive components are grounded through their points.
gauge)
of the wire in the circuit (wire
this large wire
and from the opposite side
sis of the vehicle
of
the high
certain conditions, or
circuit
mounting
amount Since
the control switch on the dash, the switch would have to carry
Ground
Some
require a large in their circuit.
a large amount of current (amperage or
amps), the thickness
a switch the
electrical
current to operate also have a relay
Various other
items could be added to our primitive circuit to flash,
and touch each
bulb would
not hard to see that with
off.
out of place
to the negative
could be mounted anywhere
could be turned on and
light
come
other).
a path from the battery to the
on the vehicle. Further, one wire could be so that the
(the pins inside the switch
to the
to the positive post
the circuit would be complete and the
illuminate. Electricity could follow
it)
is
the control switch
to the relay
The main switch inside the relay closes, component without routing the main
to the
closed,
power from the
positive battery
terminal flows through the fuse, then the switch and to the load (light bulb), the light illuminates and then, the circuit
completed through the return conductor and the vehicle ground. If the a voltmeter or test light at the battery, fuse, switch or bulb socket
is
and com-
light did not
work, the tests could be
made
is
with
ENGINE ELECTRICAL
2-3
TROUBLESHOOTING > See Figures Electrical
•
3,
4 and 5
problems generally
The component
that
is
fall
into
one
not functioning
of three areas: is
not receiving
current.
•
The component
using
it
incorrectly
is
power but
receiving
(component
is
not using
it
or
is
failure).
• The component is improperly grounded. The circuit can be can be checked with a test light and a jumper wire. The test light is a device that looks like a pointed screwdriver with a wire on one end and a bulb in its handle. A
jumper wire
is
simply a piece of wire with alligator clips or
special terminals on each end.
power through the inside
may use
which
Some common
of the vehicle.
a component
is
not working,
circuits
and
relays are the horn, headlights, starter
If
rear
window defogger systems. Protective Devices It
possible for larger surges of current to pass through the
is
system
electrical to
damage
your vehicle.
of
reach the load
in
the
To prevent
it.
circuit,
this,
If
it
this
surge
could burn
fuses, circuit breakers and/or fus-
system. These items are nothing more than a
(the
the system.
in
out or severely
are connected into the supply wires of the electrical
ible links
spot
were
of current it
tccs2006
weak
built-in
much easier to go to a known location why a circuit is inoperative than to dissect
Its
fusebox) to see
Fig. 3
A
12 volt test light
of a circuit for
is
useful
when checking
parts
power
15 feet of wiring under the dashboard, looking for what
happened.
When
an
electrical current of
excessive power passes
through the fuse, the fuse blows (the conductor melts) and preventing the passage of current and pro-
breaks the
circuit,
tecting the
components.
A
circuit
the circuit short
is
breaker in
is
basically a self repairing fuse.
same
the
removed
fashion as a fuse, but
when
It
open
will
either the
or the surge subsides, the circuit breaker
and does not need replacement. A fuse link (fusible link or main link) is a wire that acts as a fuse. One of these is normally connected between the starter resets
relay
itself
and the main wiring harness under the hood. Since the draw on the vehicle, an
starter is usually the highest electrical
internal short during starting could direct
the
wrong places. Consider the damage
this
current into a system
and
you’ll
very early
whose
understand the need in
the electrical path,
wiring
about 130 amps
is
rated at 15
for protection. its
the
first
is
properly connected.
Since
amps
this link
place to look
nothing on the vehicle works, but the battery
charged and
into
potential of introducing
seems
to
tccs2007
is
if
be
Fig. 4
Here,
sure there
is
someone power
is
checking a circuit by making component’s fuse
to the
ENGINE ELECTRICAL
2-4 1.
you must follow a systematic plan three causes
Turn
^•Some
is
ON
the
determine which
to
jumper
the switch that controls the item not working.
when
items only work
the ignition switch
to
life,
the switch has failed.
is
•-WARNING supply wire from the component.
2.
Disconnect the power
3.
Attach the ground wire of a test
good metal ground. 4. Touch the end probe the wire, the
light in
ter will indicate the
power
lished that current
Turn the
the test
amount is
light
wire;
if
there
is
current
come on (or the voltage). You have now
light will
of
getting to the
in
Checking the ground
battery
the problem
to the
reconnect the
and the battery
itself.
across the fuse
clips.
simply replace the fuse.
The
the switches,
all
The next place
easiest
the fuse
If
is
way
and the component. This
sign of an internal short
power wire fuse holds,
in
is
to
check
A
is
fuse;
ground
particularly in
modern
cir-
(solid state) will
vehicles.
The
systems are
change
their func-
one occurs.
if
that for
any
ALL
electrical circuit to work,
connections must be clean and
^For more
in
grounds and
highly sensitive to improper
the
the
tight.
information on Understanding and
Troubleshooting Electrical Systems, please refer to Section 6 of this manual.
a
are certain that
a portion of the circuit (such as a stretch of wire or a
DOES NOT
almost always yield an answer.
computers and on-board electronic
Remember if
jumper wire from it operates on 12 volts. Many electronic components are designed to operate with less voltage and connecting them to 12 volts could destroy them. Jumper wires are best used to bypass switch) that
itself will
are becoming a larger problem
tion drastically
the component. Disconnect the
component by running
UNLESS you
systematic search through the fuse, connectors, switches
and the component cuits,
a short between
component again and replace the the component is the problem.
test a
starts working, you’ve
is to
**WARNING DO NOT
component
Loose and/or corroded connectors,
generally (not always) a
at the
the battery
the
if
or the ground connector, you
a piece of clean, solid metal on
to
to look is
blown, and upon re-
placement, immediately blows again, there the fuse
mounting bolts
the jumper wire can be connected
If
component
of the
the vehicle. Again,
between the
is
the fusebox; check carefully either by eye or by using the test light
case
itself.
found the problem.
and the component. This includes
fuses, relays
component
can ground the other end
was no power, then
can mean tracing wires
circuit
estabfor the
OFF and
any
for
to the body, cleaning connections or tightening
wire to the component.
there
Never substitute the jumper for the component. The cirneeds the electrical load of the component. If you bypass it, you will cause a short circuit.
cuit
voltme-
component.
dash switch
ignition or
or a voltmeter to a
of the test light (or the positive
lead of the voltmeter) to the
If
is
power wire coming
to the
end
turned ON.
5.
done by connecting one end of the into the switch and the other the wire leaving the switch. If the component comes to
the jumper wire. This
of the
villain.
contain a resistor and
is
and Charging Systems
Battery, Starting
BASIC OPERATING PRINCIPLES
sus-
pected to be bad. Battery If
all
the fuses are
good and the component
power, find the switch for the
circuit.
is
not receiving
Bypass the switch with
The
battery
work together
most modern
is
the
first
link in
vehicles, the battery
cal device consisting of six
series so the unit
is
of
connected
(cells)
The two types
in
producing approximately 12v of of a series of
and negative plates held a short distance apart
solution of sulfuric acid
In
a lead/acid electrochemi-
is
Each subsection consists
electrical pressure.
positive
automobile engine.
2v subsections
capable
mechanisms which
the chain of
to provide cranking of the
in
a
and water.
of plates are of dissimilar metals. This sets-up
a chemical reaction, and
it
is
current flow from the battery
this reaction
when
its
which produces
positive
and negative
terminals are connected to an electrical accessory such as a
lamp or motor. The continued transfer tually
of electrons
make
convert the sulfuric acid to water, and
plates identical
in
removed from the
chemical composition. As battery,
its
would eventhe two
electrical
energy
is
voltage output tends to drop.
Thus, measuring battery voltage and battery electrolyte composition
are two
ways
of
checking the
ability of
the unit to supply
power. During engine cranking, electrical energy
condition
removed from the which
will
is
removed
in good and the operating conditions are normal, the power
from the battery. However,
battery
if
will
the charging circuit
is
be replaced by the alternator
force electrons back through the battery, reversing
ENGINE ELECTRICAL the normal flow, and restoring the battery to
chemi-
original
its
cal state.
the pinion to spin faster than the starter shaft so that the
When
starter will not operate at excessive speed.
switch
System
Starting
and starting motor are linked by very heavy cables designed to minimize resistance to the flow of current. Generally, the major power supply cable that leaves battery
mesh
Some
employ a separate
starters
The
not eliminate the need for a solenoid
The
starter
One
size. of
power
a specially designed,
is
motor capable
through a
its
tremendous
tiny pinion
rotating speed.
it
that only intermittent operation
is
power
allowance
drives the engine
starter’s armature),
starter solenoid
to
is
produce so much
required of
it.
Thus,
gages the
the battery.
The
moves
a plunger which mechanically en-
and closes the heavy switch connecting
starter
it
to
starting switch circuit usually consists of the
starting switch contained within the ignition switch, a neutral
safety switch or clutch pedal switch, to
connect these
The
in
clutch. This clutch
When
and the
wiring necessary
series with the starter solenoid or relay.
pinion, a small gear, is
is
mounted
is
moved
a one way drive
to
and
spring.
If
match properly, the pinion ately.
START
to the
position, the
engage the flywheel immedi-
the gear teeth butt one another, the spring
If
compressed and starter turns far
will
force the gears to
enough
to allow
noid plunger reaches the end of tacts that
them its
connect the battery and
will
be
mesh as soon as
to
do
travel,
starter,
battery serves as an electrical
chemical form) the energy
(in
also provides a
means
tery from being
overcharged and
of regulating output to protect the bat-
The storage
it
so.
As the
battery in
excessive voltage
to avoid
to
a chemical device incorporating paral-
is
a tank containing a sulfuric acid/water solu-
Adjacent plates are
tion.
slightly dissimilar,
the
closes the conis
and the chemical
reaction of the two dissimilar plates produces electrical energy
when
the battery
motor.
connected
is
The chemical
generator
is
reaction
a load such as the starter
to is
reversible,
so that when the
(electrical
pressure) greater
producing a voltage
than that produced by the battery, electricity
and the battery
ternators,
is
returned to
forced into the
is
charged
its fully
tor,
because they are more
the
usually rotates while
field
passes only through the
state.
alternating current generators or alefficient,
can be rotated
higher speeds, and have fewer brush problems.
against continuous
sole-
then the engine
lead plates
lel
Newer automobiles use
the teeth on the pinion and flywheel will
for
produced by the engine driven generator. The system
originally
battery,
solenoid plunger slides the pinion toward the flywheel ring gear via a collar
The
electrical accessories.
all
splined to the starter armature shaft.
the ignition switch
power
electrical
the accessories.
small current supplied by the start circuit of the ignition switch.
This magnetic action
The automobile charging system provides
operation of the vehicle’s ignition system, starting system and
a magnetic device which employs the
is
reduce the amount of current the starting switch
carry.
surge or storage tank, storing
ings can be built into a very small space.
The
mechanically engage the starter drive gears. The relay to
its
necessary, and the wind-
for air circulation is
starter
Charging System for
gear at a greatly
ring
reduced speed. Another factor allowing
little
of
It
gear (attached to the
which drives the very large flywheel
power
must
thing that allows the motor to produce a great deal is
to
used
is
mounted on the
direct current electric
producing a great amount
of
used
does
relay replaces the solenoid electrical switch, but
off.
system needs are supplied by a smaller cable. During
power flows from the battery to the starter and is grounded through the vehicle’s frame/body or engine and the battery’s negative ground strap.
mounted away from
relay,
the starter, to switch the motor and solenoid current on and
the battery goes directly to the starter, while other electrical
operation,
de-
is
interrupting
the current flow to the starter.
electrical
starter
the ignition
released from the starter position, the solenoid
is
energized, and a spring pulls the gear out of
The
2-5
at
an alterna-
the current produced
all
The brushes bear
stator winding.
slip rings.
In
This causes the current produced
to periodically reverse the direction of
Diodes
flow.
its
(electri-
one way valves) block the flow of current from traveling the wrong direction. A series of diodes is wired together to cal
in
permit the alternating flow of the stator to be rectified back to
DC
use by the vehicle’s
cranked.
12 volts
As soon as the engine starts, the flywheel ring gear begins turning fast enough to drive the pinion at an extremely high rate of speed. At this point, the one-way clutch begins allowing
The voltage regulating function is performed by a regulator. The regulator is often built in to the alternator; this system is
for
termed an integrated or
electrical
system.
internal regulator.
ELECTRONIC DISTRiBUTORJGNITION SYSTEM tronic ignition
General Information
voltage which ing
In
order to extract the best performance and
your engine
it
is
essential that
it
economy from
be properly tuned
at regular
Although computerized engine controls and more durable components have reduced ignition maintenance, a regular tune-up will keep your Toyota's engine running smoothly
intervals.
and
will
prevent the annoying minor breakdowns and poor per-
formance associated with an untuned engine. Electronic ignition systems offer many advantages over the conventional breaker points ignition system. By eliminating the points,
maintenance requirements are greatly reduced. An elec-
system
is
capable of producing much higher
turn aids in starting,
in
and provides
The system Toyota uses consists an
signal generator, signal generator of the igniter.
It
reduces spark plug
foul-
better emission control.
is is
ignition coil
used
of
a distributor with a
and an electronic
to activate the electronic
located
in
the distributor
igniter.
and consists
three main components; the signal rotor, the pick-up the permanent magnet.
The
signal rotor (not to
The
components of
coil
and
be confused
with the distributor rotor) revolves with the distributor shaft,
while the pick-up ary.
As the
coil
and the permanent magnet are
signal rotor spins, the teeth on
leading from the pick-up
coil.
When
this
it
station-
pass a projection
happens, voltage
is
ENGINE ELECTRICAL
2-6
allowed to flow through the system,
There
need
to replace burnt or
worn
the spark plugs.
firing
no physical contact and no
is
SPARK TEST
hence no
electrical arcing,
parts.
The spark
Service consists of inspection of the distributor cap, rotor
them as necessary. In addition, the air gap between the signal rotor and the projection on the pick-up coil should be checked periodically. The resistances of the coil and pick-up circuits should be measured and the
ignition wires, replacing
test
is
used
see
to
if
the ignition system
a s a preliminary test
test
a simple
Its
if
the engine cranks but won’t
but can give a nasty shock
test,
if
deliv-
Use
this
start.
not performed
correctly.
periodically.
1
Disconnect the end
.
of the coil wire at the distributor.
Use a well-insulated tool (such as hold the exposed end of the wire about 2.
Adjustments
is
ering electricity through the coil wire to the distributor.
ignition wire pliers) to
(13mm) from
'k inch
the metal of the engine block.
AIR
'CAUTION
GAP
^The
air
gap
is
NOT
If the gap is not within must be replaced.
adjustable.
specifications, the distributor
Remove
1.
the distributor cap. Inspect the cap for cracks,
carbon tracks or a worn center contact. Replace sary, transferring the wires
new
the
a time from the old cap to
at
one.
and remove
Do
pitted.
it.
not
Replace file
it
the contact
if
up
pickup
coil is directly
until
a socket wrench on
the projection on the
and
(paper, brass, or plastic) feeler
use that feeler gauge.
insert
it
0.008-0.016
in.
into the pick-up air gap.
(0.20-0.40mm)
These vehicles
Cruisers.
than 0.001
in.
except
its
pass through the easiest path to
Make sure the metal
not you.
clear of
in.
(0.30mm)
The gauge
for
1989-90 Land
gap be greater
require only that the
(0.2mm).
START
position, but only for
1
or 2 seconds.
moving parts under the hood, and keep clothing
hair well out of the
way.
the cable end
If
is
the correct
distance from solid metal, a distinct, blue-white spark should
jump
metal as the engine cranks.
to the
The engine may be cranked
4.
cause the
will
in
the 1-2 seconds bursts.
fuel injectors to deliver fuel into
the cylinders, flooding the engine or at least fouling the spark plugs.
should just touch either side of the gap. The permissible range is
will
assistant crank the engine by turning the igni-
Longer cranking
Select a non-ferrous feeler blade of 0.02
and
Have an
tion switch to the
Keep
if
5.
charge
ground point nearest the cable end is safe; don’t choose components that might contain fluids or electronic components.
3.
may use
gauge set. This means that they are non-magnetic; you have any doubt, check the feeler with a magnet. If the magnet
thickness,
electrical
ground, make certain
worn, burned or
is
opposite the signal rotor tooth.
Use only a non-ferrous
sticks, don't
The
the contacts.
Turn the engine over (you
the front pulley bolt to do this)
4.
neces-
if
Pull the ignition rotor (not the signal rotor) straight
2.
3.
one
it
Do not attempt to hold the wire with your bare hand. Use much insulation as possible between the wire and the tool holding it. Do not stand on wet concrete while testing. Do not lean on the bodywork of the car while testing. as
5.
If
proceed
no spark to
is
present, turn the ignition switch
check the resistance
voltage supply to the
coil
OFF and
of the of the coil wire, the
(12 volts with the ignition ON), the
coil
resistance, the resistance of the pickup coil
gap
within the distributor.
and the
air
Diagnosis and Testing IGNITION COIL
PRECAUTIONS 1.
Do
•
not allow the ignition switch to be
ten minutes
When
•
if
the engine
a tachometer
Some
system;
it
is
for
more than
2.
is
connected
to the
system, always
nega-
to the ignition coil
that
NEVER
• it
in
damage
remove the
high-
coil.
Carefully unplug the smaller electrical connector from the
The 1989-90 Land Cruisers and all 4 cylinder trucks and 4Runners do not have this small connector; battery wires run to external terminals on the coil. These terminals do not need to
be undone. 3.
allow the ignition
could result
carefully
this
you consult with the
manufacturer.
as
OFF,
coil.
tachometers are not compatible with
recommended
ignition switch
not start.
will
connect the tachometer positive lead tive terminal.
ON
With the
tension cable (coil-to-distributor wire) from the
coil
terminals to touch ground
to the igniter
and/or the ignition
Use an ohmmeter
to test
primary side resistance. Con-
nect the probes to the 2 terminal pins of the small electrical
connector or the two external terminals on each side of the coil.
coil itself.
• •
Do not disconnect the battery when Make sure that the igniter is always
the body
4.
the engine
is
Perform the check before running the engine.
All
the
running.
properly grounded to
following values are
on cold engines.
Resistance should be:
— 22R engine: 0.4-0.5 ohms — 22R-E engine: 0.52-0.64 ohms 1993-95 — 22R-E engine: 0.36-0.55 ohms 1994-96 — 2RZ-FE and 3RZ-FE engines: 0.36-0.55
•
1989-91
•
1989-92
• •
ohms
ENGINE ELECTRICAL — 3VZ-E engine: 0.4-0. 5 ohms — 3VZ-E engine: 3-0.6 ohms 989-90 — 3F-E engine: 0.52-0.64 ohms 1991 — 3F-E engine: 0.41-0.50 ohms 1992-96 — 1FZ-FE engine: 3-0.6 ohms 1989-91
•
1 992-95
• •
0.
1
• •
Check the secondary
Make
ter.
certain the meter
is
set to a
much
ignition
OFF,
carefully detach the connector in
Using an ohmmeter, check the resistance of the signal
5.
ohmme-
coil).
With the engine cold, the reading
should be 185-275 ohms; hot reading
higher scale than
Connect one probe of the meter to the and the other to the high-tension terminal.
the previous test.
the rotor.
generator (pick-up
resistance with the
circuit
Remove With the
the harness coming from the side of the distributor.
0.
5.
3.
4.
2-7
6.
If
the resistance
is
is
240-325 ohms.
not within specifications, replace the
housing assembly.
distributor
positive coil terminal 6.
Correct resistances for a cold
3VZ-E and 1FZ-FE
coil are:
— 22R engines: 8.5-1 1.5k ohms 1989-92 — 22R-E engines: 11. 4-1 5.6k ohms 1993-95 — 22R-E engine: 9.0-1 5.4k ohms 1989-91 — 3VZ-E engine: 10.2-1 3.8k ohms 1992-95 — 3VZ-E engine: 9-1 5k ohms 1994-96 — 2RZ-FE and 3RZ-FE engines: 9.0-1 5.4k
•
1989-91
• • • • •
I
1
1989-90
•
—
If
Remove
distributor connector.
the distributor cap without removing the spark-
3.
Remove
4.
Using an ohmmeter, check the resistance of the pick-up
coil.
5.
—
the rotor.
Refer to the chart for specifications.
engine: 11. 5-1 5. 5k
either resistance
7 and 8
plug wires.
ohms 1991 3F-E engine: 10.2-1 3.8k ohms 1992-96 1FZ-FE engine: 9-1 5k ohms
• 7.
— 3F-E
6,
Detach the
.
2.
ohms •
See Figures
If
the resistance
distributor
is
not within specifications, replace the
housing assembly.
not within specifications, the coil
is
must be replaced. 8.
For the 1989
negative
coil
should be
infinite
replace the
22R
engine, measure resistance from the
terminal to the body of the igniter. Resistance
(no continuity).
any continuity
If
is
found,
coil.
PICK-UP COIL(S)
1989-91 Models 1
.
2.
Detach the
Remove
distributor connector.
the distributor cap without removing the spark-
plug wires. 3.
Remove
the rotor.
4.
With the
ignition
the harness 5.
OFF,
carefully detach the connector
coming from the side
in
of the distributor.
For 2-pin connectors, measure the resistance between
the two terminals. Resistance for
1989-90 vehicles
all
is
140-180 ohms. For 1991 vehicles, resistance should be
Fig. 6
Attach the ohmmeter to the terminals as
shown
205-255 ohms. 6.
The
3-pin connectors are used on the
Land Cruisers.
Hold the connector so that the empty section of the 4-pin
housing
in
is
the lower
called G-. Test
each
resistance of 140-180 7.
square part
the connector
ohms on 1989-91
in
the lower right
is
vehicles.
of the
G-. Correct resistance for
1991, If
housing
it’s
is
at the bottom.
in this position, the terminal
Use the ohmmeter
called G-.
8.
terminal
Four-pin connectors require you to hold the connector so
that the
for
The
left.
of the other terminals to G-, looking for
Viewing
on the lower
Pickup
right is
check each other terminal to 1989-90 vehicles is 140-180 ohms; to
is
-
125
1
G2
205-255 ohms.
any resistance
(-10
G
NE
G© - G© - G©
Hot
Cold
coil
resistance
~
50" C)
(50
~
100"C)
125
- 200 0 - 200 0
160 - 235
155
- 250 0
190 - 290
1
60 - 235
0 0 0
out of specification, the distributor 8682 2 gpq *
housing assembly must be replaced.
1992-95 Models 22R-E, 2RZ-FE and 3RZ-FE 1
.
2.
Detach the
Remove
plug wires.
distributor connector.
the distributor cap without removing the spark-
Fig.
7 Pick-up coil resistance on the 3VZ-FE engine
ENGINE ELECTRICAL
2-8
Distributor
Air
0.2
gap
Pickup
at cold (G
resistance
coil
1
(G2
(NE at hot (G
1
(G2
(NE
-
0.4
mm
— G©) - G©)
185 - 275 0 185 - 275 0
- G©) - G©)
- 275 0 240 - 325 0 240 - 325 Q
- G©) - G©)
(0.008
-
0.016
in.)
185
240 - 325
0 86822gpr
Fig.
8 Pick-up coil resistance on the 1FZ-FE engine
-
Ignition Coil
REMOVAL & INSTALLATION External >
Mounted
See Figures
9, 10, 11,
12 and 13
1.
Disconnect the negative battery cable.
2.
Remove Remove
3. 4.
the cover on the
coil,
if
equipped.
the coil wire lead.
Tag and disconnect all electrical leads remove the igniter.
to the coil.
If
applicable, 5.
Remove
the two mounting bolts and
lift
off
the ignition
coil.
To
install:
the
coil in position
and
tighten the
6.
Install
7.
Connect
8.
Connect the negative battery cable.
all
wires and
install
mounting
86822005
bolts.
the igniter.
Fig.
10 Detach the coil wire from the unit
86822004
Fig. 9
Remove
the cover on the coil
86822006
Fig. 11
Unplug the connector and remove the
igniter
ENGINE ELECTRICAL and
the two nuts.
8.
Connect the
9.
Install
the dust proof packing and dust cover.
10.
Install
the rotor and distributor cap.
1 1
Connect the negative battery cable.
.
ignition coil wires
install
2-9
Igniter
REMOVAL & INSTALLATION I
See Figures
mounted
Igniters are
and 18
15, 16, 17
one
in
two places on your Toyota
of
On the remotely mounted coils, the igniter coil. On the integral coil vehicles (where the
secured to
truck.
is
the
coil is in
distributor) the igniter
secured
is
the
to the fenderwell.
86822007 1
12 Loosen and remove the mounting bolts securing the coil Fig.
Disconnect the negative battery cable.
.
2.
Separate the wiring harness connections.
3.
Unbolt the
10. 4.
If
igniter.
mounted
to the coil,
loosen the nut holding the wire
lead. 5.
Tag and disconnect the wire
6.
Lift
To
the igniter
lead.
mount.
off its
install:
7.
Mount the
8.
Attach the wire lead to the
9.
Connect the harness.
igniter to the bracket. coil
if
used.
Connect the negative battery cable.
Distributor
;
>
' '
•
REMOVAL t See Figures 19, 20, 21, 22, 23 and 24 86822008 1
Once
leads and bolts are removed,
Fig.
13
coil
from the fenderwell
all
lift
the
>
.
2. 3.
^Set For
Disconnect the negative battery cable.
Remove Remove
coil
dust cover and dust proof
5.
Unfasten the two nuts and disconnect the three
Remove
from the
ignition
the ignition
coil retaining
screws and the
coil
install:
6.
Before
the ignition
installing,
coil.
Install
remove any
old packing material from
Apply sealer 08826-00080 or equivalent
to the
the ignition
do
housing.
will
be easier to the
removed from the cap, mark
their
installation.
1
to
TDC
of the
compression stroke. at 0.
On
Remove
the dust cover
and mark the
position of the
mark the
position of
the body relative to the block. 3.
Disconnect and tag any wires and the vacuum
4.
Remove
the pinch-bolt and
the engine.
The
rotor
lift
lines.
the distributor straight out,
and body are marked so
that
removed. Do not turn or disturb the engine (unless absolutely necessary, such as for engine rebuilding), after the distributor
the distributor with the four
the distributor and the position of the engine
spark the wires for the ignition coil, be sure not contact with the signal rotor or distribu-
**When connecting tor
It
connected
has been removed. The relationship between the position coil to
screws.
the wires
off.
they can be returned to the position from which they were
mounting surface.
7.
is left
engines except 22R-E, set the timing mark
away from
distributor.
To
coil
the wiring
rotor relative to the distributor body; then
terminals.
coil
in
cylinder No.
all
2.
packing. 4.
if
22R-E, set the timing mark at 5 degrees.
the distributor cap and rotor. the ignition
the distributor cap straight
the wires must be
If
positions to aid
Mounted
See Figure 14 1
lift
to install the distributor
cap. Internal
Unfasten the retaining clips or remove the retaining
.
screws and
5.
is
to
be sent
Remove
one. Apply a
to the
if
of
the
proper place at the proper time.
the distributor O-ring, discard
light
is critical
coat of engine
oil
and
install
on the O-ring.
a
new
2-10
ENGINE ELECTRICAL
Oust Proof Packing
Non-reusable part
Fig.
14 Exploded view of the internal
mounted
ignition coil distributor
86822003 86822011
Fig.
15 The igniter can be found
remote ignition
mounted on the
coil
Fig.
17
If
mounted
to the coil, detach the wire
86822010
Fig. 16
screws
Unplug the connector and remove the retaining
86822013
Fig.
then
18 Check that lift
all
the connections are separated,
the unit from the vehicle
ENGINE ELECTRICAL
86822020
Fig.
19
Remove
the cap with the wires attached
2-11
86822024
Fig.
22 Detach the electrical connections
86822025 86822022
Fig. Fig.
20 Mark the position of the rotor
.
.
.
23 After the pinch-bolt
is
removed,
pull the
distributor out
86822026
Fig. Fig. 21
.
.
.
and the
distributor
base
24 Discard the O-ring.
during installation
A new one should be used
ENGINE ELECTRICAL
2-12
No.
INSTALLATION
the 22R-E, align the mark at 5°.
Timing Not Disturbed
be Align the
.
matchmarks on the
distributor with the rotor;
position the distributor to align with the block. Insert the distributor
damage
in
mark made on the
marks also
timing
pression
the marks
all
•On
be
will
exhaust stroke, but no com-
align during the
felt.
engines which have the spark plugs buried into the
ft.
(19 Nm).
lbs.
2. Install
compression can
definite
pressing against your finger. Doing this important; the
felt
manifold, use a compression gauge.
Tighten the pinch-bolt to 14
1.
3.
A
bolt)
On
the block, taking care not to
the drive gear at the bottom or to knock
out of alignment. 2.
finger over the spark plug
Turn the engine (with a wrench on the crank pulley the timing marks align at 0°, except on the 22R-E.
until
1
and placing your
cylinder
1
hole.
Check
the distributor cap and wires.
Install
the rotor. Position the rotor so
it
is
at the
No.
1
the ignition cylinder firing position.
timing.
Check
4.
3.
Slowly insert the distributor
4.
Tighten the pinch-bolt to 14
5.
Install
the idle speed.
Timing Disturbed
into the cylinder block. ft.
(19 Nm).
lbs.
Check
the distributor cap and wires.
the ignition
timing. If
the engine has been cranked, dismantled, or the timing
otherwise
lost,
Check the
6.
speed.
idle
proceed as follows:
Determine Top Dead Center (TDC)
of the
No.
1
cylin-
compression stroke by removing the spark plug from the
der’s
DISTRIBUTORLESS IGNITION SYSTEM The
charge
electrical
pass through the easiest path to
will
General Information
ground, make certain
The V6 5VZ-FE engines are equipped
ground point nearest the cable end is safe; don’t choose components that might contain fluids or electronic components.
with
what
is
called
the Toyota Direct Ignition (TDI). This system improves the tim-
accuracy and enhances the overall
ing
reliability of
the ignition
system. The TDI uses a two-cylinder simultaneous (waste
Check
5.
spark) ignition system which fires two cylinders at the
time with one
end
of the
secondary
causes one
same
engine
coil
is
attached to each
winding. This circuit arrangement
of the plugs in
each cylinder
forward direction, and the other to
fire in
cylinder on the compression stroke
see
if
a bright blue spark occurs when the
••To prevent any gasoline from being injected during this crank the engine no more than 1-2 seconds at one
time.
pair to fire in a
a reverse direction. is
If
defined as the
“event” cylinder, while the cylinder
in
the exhaust stroke
The
coils are positioned
bad, connect
is
over one b.
of the plugs. This
arrangement has eliminated
following:
the connection to the ignition coil and igniter,
is it
called the “waste" cylinder.
does not occur, perform the
the spark
Check
a.
bank
to
being cranked.
test,
6.
The
is
coil.
a waste spark system, one spark plug
In
Make sure the metal
not you.
its
it
securely.
If
this is
OK
Inspect the resistance of the wires,
it
if
then proceed.
should be 25k
half of the
normal required plug wires.
ohms. Replace the wires
if
not to specifications.
the wires
If
are good proceed. c.
Diagnosis and Testing
Check
Turn the
the ignition
blies.
.
Disconnect a spark plug wire from a plug.
Remove
coil.
If
it
not,
and
igniter
the resistance of the ignition coils,
is
at
check the wiring
assem-
OK, proceed.
specifications, replace the coil.
the
If
ignition switch to the coil
this is
Check
d.
1
If
power supply to the coil and the igniter. ON. Check that there is battery voltage
coil positive terminal.
between the
SYSTEM TEST
2.
the
ignition
If
if
not within
this is not correct replace
good, continue.
the spark plug.
3.
Reattach the spark plug to the wire.
4.
Ground the spark
e.
Check
the resistance of the camshaft position sensor
(refer to Section 4).
If
this is not correct, replace the sensor.
plug. If
i:*CAUTION
proceed.
this is correct, f.
Check the
resistance of the crankshaft position sensor
(refer to Section 4).
Do not attempt to hold the wire with your bare hand. Use as much insulation as possible between the wire and the tool holding it. Do not stand on wet concrete while testing. Do not lean on the bodywork of the car while testing.
If
this is correct, g.
If
the spark
tween the ECM, replace the
If
this is not correct,
replace the sensor.
proceed. is
still
not present, check the wiring be-
distributer
igniter.
and
igniter.
If
the wiring
is
OK,
ENGINE ELECTRICAL
2-13
9.
Ignition Coil
Reconnect the
Pack
coil
harnesses.
10.
Install
the wires to the coils.
11.
Install
the
cleaner cap and the
air
MAF
sensor.
TESTING
REMOVAL & INSTALLATION >
See Figure 25
'“This test hot.
A
may be performed
while the engine
I is
cold engine has a coolant temperature of less than
122°F (50°C).
Remove
1.
See Figures 26 and 27
cold or 1
the
air
cleaner cap and the
Mass
Air
Flow
(MAF) sensor assembly. 2.
Disconnect the wires from the
3.
Disconnect the
4.
Inspect the primary
coil
Hot
5. 6.
If
— 0.85-1.23
the
coil
Cold Hot
Mass
Air
Flow
resistance
Disconnect and label the wires from the
3.
Unplug the connectors from the
positive
and negative
To 4.
from the
left
Remove
cylinder head. Arrange the
Install
the coils on the cylinder heads
same
the
resistance. Using a
in
the reverse
pri-
order of removal.
not as noted, replace the coil
coils
install:
bolts to is
and
coils.
ignition coils.
coils in the correct order for installation.
Using a ohmmeter,
ohms
Inspect the secondary
•
the air cleaner cap and the
2.
coils.
coil resistance.
measure the resistance between the and the spark plug wire. •
Remove
the bolts
harnesses.
measure the resistance between the mary terminals. • Cold -0.67-1.05 ohms •
.
(MAF) sensor assembly.
place where
69 inch
it
lbs. (8
was removed. Tighten
6.
Install
7.
Start the engine
the
MAF
is
replaced
in
the mounting
Nm).
Attach the plug wires to the
positive primary terminal
— 9.3-1 6.0k ohms
certain the correct coil
5. coil.
ohmmeter,
Make
coils.
sensor and the
and check
for
air
cleaner cap.
proper operation.
Igniter
-11. 7-1 8.8k ohms
the coil resistance
7.
If
8.
Reinstall the coils.
is
not as noted, replace the
coil.
REMOVAL & INSTALLATION The
igniter
mounted on the fenderwell
is
of your
Toyota
truck. 1
Ohmmeter
.
2.
Disconnect the negative battery cable.
Unplug the wiring harness connections.
3.
Remove
4.
Lift
To 5.
the bolts retaining the
the igniter
off its
igniter.
mount.
install:
Mount the
igniter to the bracket.
Tighten the bolts
snug. 6.
Connect the harness.
7.
Connect the negative battery cable.
Crankshaft Position Sensor See Section 4
for information
and procedures.
Camshaft Position Sensor Fig.
25 Check the primary resistance as shown
See Section 4
for information
and procedures.
until
2-14
ENGINE ELECTRICAL
Ignition Coil
Fig.
26 Exploded view of the ignition
coil
mountings
ENGINE ELECTRICAL ORDERS
FIRING
See Figures
>
The
firing
cylinder.
28, 29, 30, 31,
order
is
the order
The spark must
bustion cycle or
32 and 33 in
which spark
is
sent to each
arrive at the correct time in the
damage may
result.
For
this
com-
reason, connect-
ing the correct plug to the correct distributor terminal
is critical.
To avoid confusion, always replace the spark plug wires one at
a time.
^ FRONT I—
L
© ® © © © ©
Fig.
30 3F-E Engine
Firing order
— 1-5-3-6-2-4
Distributor rotation: clockwise
/d©6)\ (l)
Fig.
•)(§)
28 3VZ-E Engine
Firing order
— 1-2-3-4-5-6
Distributor rotation: counterclockwise
H©@®@©©
86822067
Fig. 31
(© v
Fig.
©)
© ©,
29 1FZ-FE Engine
Firing order
— 1-5-3-6-2-4
Distributor rotation: counterclockwise
22R and 22R-E Engines
Firing order
—
1
-3-4-2
Distributor rotation: clockwise
2-15
ENGINE ELECTRICAL
2-16
© © ©
©i ®i
i
3
©|
FROfs/T
KD©©©
OF CAP o
86822070
86822069
32 5VZ-FE Engine
Fig.
Firing order
33 2RZ-FE and 3RZ-FE Engines
Fig.
— 1-2-3-4-5-6
Firing orders
—
1
-3-4-2
Distributor rotation: clockwise
Distributorless ignition
CHARGING SYSTEM it
General Information
The automobile charging system provides operation of the vehicle’s ignition and ries.
The
storing
all
electrical
power
for
chemical form) the energy originally produced by the
The system
engine-driven alternator.
also provides a
means
of
To prevent damage
The
excessive voltage to the accessories.
to avoid
vehicle’s alternator
is
by the engine crankshaft.
It
driven mechanically, through belts,
consists of two coils of fine wire,
and one movable (the rotor). The known as the armature, and consists of fine wire wrapped around an iron core which is mounted on a shaft. The electricity which flows through the two coils of wire
one stationary rotor
may
(provided
initially
intense magnetic
be the battery field
in
some cases)
around both the
rotor
creates an
and
stator,
•
tions are
spond •
made
to
is
ensure that
to the battery
ground
to all
be done before any connecconnections corre-
of the
polarity of the truck.
positive terminal of the battery which
•
Make
Booster batteries must be connected properly.
the positive cable of the booster battery is
is
connected
sure
to the
getting the boost.
Disconnect the battery cables before using a fast charger;
the charger has a tendency to force current through the diodes
and in
power the accessories and charge the
when working
Never reverse the battery connections. Always check the
battery polarity visually. This
the interaction between the two fields creates voltage, allowing the alternator to
regulator, the fol-
with the electrical system.
(the stator),
also be
and
to the alternator
lowing precautionary measures must be taken
regulating alternator output to protect the battery from being
overcharged and
components.
Alternator Precautions
the electrical accesso-
battery serves as an electrical surge or storage tank,
(in
to limit the output of the alternator to usable levels. Ex-
stroy electrical
See Figure 34
>
is
cess output can damage the battery and overvoltage can de-
the opposite direction. This causes •
Never use a
fast
damage.
charger as a booster
for starting the
battery. truck.
Almost
more
all
vehicles today use alternators because they are
efficient,
can be rotated
fewer brush problems. all
In
an
at higher
speeds, and have
•
alternator, the field rotates while
•
the current produced passes only through the stator wind-
ings.
The brushes bear against continuous
slip rings
•
rather field
than a commutator. This causes the current produced to periodically reverse the direction of
power supply
to your house.
its
flow, very similar to the
Diodes
(electrical
one-way
switches) block the flow of current from traveling direction.
A
series of diodes
is
alternating flow of the stator to
in
the
is
Do Do
not ground the alternator output terminal. not operate the alternator on an
open
circuit with
the
energized.
•
Do
•
Disconnect the battery cables and remove the alternator
not attempt to polarize the alternator.
before using an electric arc welder on the truck.
wrong
wired together to permit the
be converted
Never disconnect the voltage regulator while the engine
running.
•
gine
Protect the alternator from excessive moisture. is
to
be steam cleaned, cover or remove the
If
the en-
alternator.
to a pulsating, but
unidirectional flow at the alternator output. This inverter circuit
switches the
dard
DC
AC
The
alternator’s field
is
wired
in
>
series with the voltage regulator.
The voltage ply described,
regulator it
Alternator
current unusable by the vehicle to the stan-
or direct current.
is
contained within the alternator. Sim-
consists of solid-state
components whose job
See Figure 35 All
current trucks use a nominal 12 volt alternator. (Exact
output should be slightly higher, generally 13.5-14.4 volts).
Am-
f
ENGINE ELECTRICAL
Fig.
34 Charging system circuit
Fig.
35
Fig.
A common
perage ratings accessories.
may
All
alternator found
on Toyota trucks
vary according to the year, model and
have a
36 Attach the ammeter and voltmeter as shown to
test the charging
4.
2-17
system
Ground the negative
(-)
lead of the voltmeter.
10.
transistorized, non-adjustable regulator,
5.
With the engine running from
the reading on the
integrated with the alternator.
ammeter and
perage should be 10
A
idle to
voltmeter.
or less; standard voltage cold
13.9-15.1 volts, and 13.5-14.3 volts hot.
TESTING
2000 rpm, check The standard am-
If
the reading
is is
greater than standard voltage, replace the regulator. If
>
See Figures
36, 37, 38, 39,
40 and 41
»»lf a battery/alternator tester is available, ter to
the charging circuit
the reading
regulator
connect the tes-
recommended by the manufac-
6.
and
is
less than the standard voltage,
check the
alternator:
With terminal (F) grounded,
start the
engine and check
the voltmeter reading of terminal (B). 7.
If
ture’s instructions.
the voltmeter reading
is
more than the standard
is
less than standard voltage,
volt-
age, replace the regulator. If
a tester
ter to 1
.
is
not available, connect a voltmeter and a
amme-
the voltmeter reading
Disconnect the wire from terminal (B) of the alternator to the negative (-) lead of the ammeter.
beam
Connect the
positive (+) lead of the
ammeter
Connect the
positive (+) lead of the voltmeter to terminal
(B) of the alternator.
9.
to terminal
(B) of the alternator. 3.
If
the alternator
and attach 2.
8.
the charging circuit by doing the following:
faulty.
With the engine running at 2000 rpm turn on the high headlights and place the heater switch on high.
Check more.
may be
the reading on the ammeter.
It
should be 30
A
or
2-18
ENGINE ELECTRICAL
Fig.
11.
40 The ammeter reading should be above 30 A
If
the
ammeter reading
is
less than the standard
amper-
age, replace the alternator.
^If the battery
charged, the indication
is fully
will
some-
times be slightly less than the standard amperage.
REMOVAL & INSTALLATION "On
some models, the alternator is mounted very low on On these models, it may be necessary to re-
the engine.
move
the gravel shield and work from beneath the truck
order to gain access to the alternator. Replacing the nator while the engine
engine can result
in
is
cold
is
recommended. A hot
personal injury.
22R and 22R-E Engines I See Figures 42 and 43 1
8
\
7
-?
7
4
1Jmmlun/L t
J
6
,
I
C 86822gpv
Fig.
39 Note whether the reading
standard voltage
is
above or below the
.
Disconnect the negative battery terminal.
in
alter-
ENGINE ELECTRICAL
2-19
2.
If
the vehicle
is
equipped with power steering, drain the
coolant from the system.
8.
Hold the alternator; remove the pivot
To
WARNING
9.
Housepets and small animals are attracted to the odor and taste of engine coolant (antifreeze). It is a highly poisonous mixture of chemicals; special care must be taken to protect open containers and spillage. Disconnect the wiring
remove the
the rubber boot,
then the
install:
Mount the
10.
pivot 11.
12. at the
back
of the alternator.
Lift
nut from the external terminal
and
on
alternator
its
bracket; install the pivot
and
adjusting bolts. Install
the drive belt and adjust
and adjusting Install
fan shroud 3.
bolt
alternator.
the water
and
correctly. Tighten the
it
bolts.
install
hose
inlet
if
it
was removed.
the
Install
the engine splash shield.
Connect the wire
to the terminal; install the nut
and
secure the rubber boot. Attach the wire harness connector to the alternator.
the wire. 4.
If
equipped with power steering, remove the engine
splash shield or undercover, then the water
13.
inlet pipe.
14. 5.
If
Close the radiator drain cock and
the system with
refill
coolant.
Connect the negative battery cable.
the truck has air conditioning, remove the No. 2
(lower) fan shroud. 6.
Loosen the
7.
Push the
pivot bolt
3VZ-E and 3F-E Engines and remove the adjusting
alternator towards the enqine
bolt.
I See Figures 42 and 43
and remove the
belt.
1
.
2.
Disconnect the negative battery cable. Disconnect the wiring at the back of the alternator.
the rubber boot,
Lift
remove the nut from the external terminal and
the wire. 3.
Loosen the alternator
pivot bolt
and loosen the upper
locknut. 4.
Push the
and remove the
alternator towards the engine
belt.
5.
Remove
the adjusting bar and 6.
To 7.
pivot 8.
Remove
its
pump
3F-E, remove
support, then
remove
bolts.
the alternator.
install:
Place the alternator
and adjusting
On
3F-E,
Install
position
in
and loosely
install
the
bolts.
Set the
bolts.
install
the adjusting bar and
nuts and bolts just snug. 9.
On
the pivot and adjusting bolts.
the nuts and bolts holding the air
the drive
Install
the
adjust
belt;
it
air
its
pump
2
support.
proper tension,
to the
tight-
ening the adjusting and pivot bolts. Tighten the 3F-E adjuster bar bolts. 10.
Connect the wire
to the terminal
and
install
the nut.
Fit
the rubber boot over the terminal. Attach the plastic wire har-
ness connector. 11.
Connect the negative battery cable.
2RZ-FE and 3RZ-FE Engines I
See Figures 44 and 45 1
.
2.
Disconnect the negative battery cable. Disconnect the wiring at the back of the alternator.
the rubber boot,
remove the
Lift
nut from the external terminal
and
the wire. 3.
Loosen the alternator
lockbolt, pivot bolt, nut
and
adjust-
ing bolt. 4.
Push the
alternator towards the engine
and remove the
belt.
5. 6.
7.
To your vehicle has power steering, remove the water inlet pipe for ease of access Fig.
43
If
8.
pivot
Remove Remove Remove
the wiring harness with the the alternator lockbolt, pivot
clip.
bolt, nut.
the alternator.
install:
Place the alternator
and adjusting
bolts.
into position
and loosely
install
the
2-20
ENGINE ELECTRICAL
9.
Install
the drive belt; adjust
Tighten the lockbolt to 21
43
ft.
lbs.
ft.
lbs.
it
to the
(29
proper tension.
Nm) and
the pivot bolt to
(59 Nm).
10.
Connect the wire harness with
11.
Connect the wire
tighten to 7
ft.
lbs.
clip.
to the terminal. Install the nut
(10 Nm).
Fit
and
the rubber boot over the
terminal. Attach the wire harness connector. 12.
Connect the negative battery cable.
5VZ-FE Engine >
See Figures 46 and 47 1
.
2.
Disconnect the negative battery cable. at the back of the alternator. Lift remove the nut from the external terminal and
Disconnect the wiring
the rubber boot, the wire. 3.
Loosen the
alternator locknut, pivot bolt, nut
and
adjust-
ing bolt. 4.
Fig.
45 Locations of the adjusting, pivot and lockbolts
Push the
alternator towards the engine
and remove the
belt.
5. 6.
Remove Remove
the alternator lockbolt, pivot the alternator.
bolt, nut.
ENGINE ELECTRICAL
2-21
10.
To 7.
pivot 8.
Pivot Bolt
install:
Place the alternator
and adjusting Install
the drive
belt;
Tighten the locknut 25 lbs. (51 9.
into position
and loosely
install
the
bolts.
ft.
adjust
lbs.
(33
it
to the
proper tension.
Nm) and
the pivot bolt 38
ft.
Nm).
Connect the wire
to the terminal
tighten. Fit the rubber boot
and
install
the nut
and
over the terminal. Attach the wire
harness connector.
Connect the negative battery cable.
1FZ-FE Engine I
Fig.
47 Locations of the adjusting and pivot bolts and
the locknut
See Figures
48,
49 and 50
1.
Disconnect the negative battery terminal.
2.
Remove
3.
Disconnect the power steering reservoir tank.
4.
Loosen the
5.
Remove
6.
Disconnect the wiring at the back of the alternator.
the battery
lock, pivot
tray.
and adjusting
bolts.
the 2 drive belts.
the rubber boot, the wire.
and
Lift
remove the nut from the external terminal and
2-22
ENGINE ELECTRICAL
PS
Reservoir Tank
Generator Wire
1
S>
Generator Connector
w Battery -
-
-
-
Drive Belt Adjusting Bar Battery Tray-
Drive Belt
-
Fig.
48 Exploded view of the 1FZ-FE alternator, battery, belt
etc. locations
j -
—
Fig.
50 The wiring clamp
is
mounted
into the alternator
-
as shown 1
—
ENGINE ELECTRICAL 8.
Remove Remove
9.
Hold the alternator; remove the pivot
7.
the wire clamp from the alternator.
14.
Install
the lockbolt, nut and drive belt adjusting bar.
15.
Tighten the pivot bolt to 43
then the
bolt
To
install:
10.
Mount the
Do
the drive belts.
lockbolt to 15
alternator.
alternator ion the bracket with the pivot bolt.
ft.
ft.
lbs.
Connect the power steering reservoir
17.
Install
Start
8.
Nm) and
(59
the
Nm).
lbs. (21
16.
1
2-23
tank.
and battery. the vehicle and check the alternator operation. the battery tray
not tighten the bolt yet.
11.
the drive belt adjusting bar with the bolt and nut.
Install
Tighten the bolt to 15 12.
Temporarily
lbs. (21
ft.
install
Regulator
Nm).
the lockbolt. Connect the alternator
regulators are contained inside the case of the alternator
All
and rubber cap. Connect the wire clamp
wiring, nut
13.
and are not replaceable as a separate to the alternator. fails,
unit.
If
the regulator
the entire alternator must be replaced.
STARTING SYSTEM The
General Information
power
I See Figure 51
motor
starting
for
its
size.
One
a great deal of power
The
battery
is
the
first
link in
the chain of items which work
together to provide power of the automobile engine.
modern
trucks, the battery
is
vice consisting of six two-volt subsections connected
so the unit
capable
is
of
most
In
in
gear
series
producing approximately 12 volts of
electrical pressure. cell,
and water. The two types
a solution of
in
it
this reac-
is
which produces current flow from the battery when
and negative terminals are connected
positive
to
an
its
would eventually convert
trolyte to water,
As
composition. its
electrical
sulfuric acid in the elec-
and make the two plates electrical
energy
chemical
identical in
removed from the
is
battery,
voltage output tends to drop. Thus, measuring battery
age and battery
electrolyte composition are
two ways
of
volt-
check-
ing the ability of the unit to supply power. During the starting
engine, electrical energy
of the
is
removed from the
battery
if
will
the charging circuit
is
in
be replaced by the alternator which
will
force elec-
trons back through the battery, reversing the normal flow, restoring the battery to
^The
its
original
chemical
and
line, “I
know
ring
Thus,
allowance
little
starter solenoid
it
that only intermittent operation
to is
for air circulation is re-
built into
a very small space.
a magnetic device which employs the
is
action
The magnetic moves a plunger which mechanically engages the
starter
and
electrically closes the
The
to the battery.
heavy switch which connects
starting circuit consists of the starting
signal controlled by the ignition switch, a transmission neutral
safety switch or clutch pedal switch, to
and the wiring necessary
connect these with the starter solenoid or
circuit
has multiple switches,
all
must be
in
relay.
the
ON
Since the position for
the system to operate.
As soon as the engine starts, the flywheel ring gear begins enough to drive the pinion at an extremely high rate of speed. At this point, the one-way clutch begins allowing
turning fast
starter will not operate at dition is similar to riding
excessive speed. (This overrun con-
a bicycle downhill; the rear wheel
turning faster than the chain sprocket.)
switch
it
is
Some
produce it. what is stored within it. Thus, a low battery may not be able to supply enough power to crank the starter but will still operate the lights, horn and other lower amperage This should eliminate the famous
The
it.
is
and the windings can be
gear out
does not The battery can only deliver power equal to
circuits.
which drives the very large flywheel
of
mesh and
The
in
de-
interrupts the current flow to the starter.
relay replaces the solenoid electrical switch, but
need
for
reduce the amount
does
a solenoid mounted on the starter to
mechanically engage the starter drive gears. The relay to
is
the solenoid assembly pulls the
employ a separate relay, mounted away from switch the motor and solenoid current on and
not eliminate the
it’s
is
the ignition
starters
the starter, to off.
When
released from the starter position, the solenoid
energized, and a spring
state.
battery only stores electrical energy,
It
the pinion to spin faster than the starter shaft so that the
battery.
good condition and the operating conditions are normal, the power removed from the However,
required of
it
appliance such as a lamp or a motor. The continued transfer of electrons
rotating speed.
small current supplied by the ignition switch.
of plates are of dissimi-
metals. This causes a chemical reaction and
lar
tion
tremendous
its
produce so much power
consists of a series of positive and
negative plates held a short distance apart sulfuric acid
is
a greatly reduced speed. Another factor allowing
at
quired,
Each subsection, or
of
thing that allows the motor to produce
drives the engine through a tiny pinion gear (attached to the starter's armature),
a lead/acid electrochemical de-
a specially designed, direct current
is
motor capable of producing a very great amount
electric
of current the starting switch
is
must
used carry.
not the battery because the radio works...”
and starting motor are linked by very heavy cables designed to minimize resistance to the flow of current. Generally, the major power supply cable that leaves
The
battery
Starter
electrical
the battery
goes
directly to the starter, while other electrical
TESTING
needs are supplied by a smaller cable. During the starter operation,
power flows from the battery
grounded through the ground strap.
truck's
to the starter
and
is
frame and the battery’s negative
(These
tests
must be performed within a 3
to avoid burning out the coil.
to 5
seconds
ENGINE ELECTRICAL
2-24
Fig. 51
Starting
system
diagram
circuit
Pull-in
I See Figure 52 1.
Disconnect the
2.
Connect the battery
field coil
lead wire from terminal C.
to the
magnetic switch shown
in
the
diagram. 3.
Check
gear moves
that the clutch pinion
in
the outward
motion.
Hold-in
> See Figure 53 With the battery connected as
in
the picture and with the
clutch pinion gear out, disconnect the negative
terminal C.
Check
that the pinion
gear stays
in
(-)
lead from
the outward
position.
Inspect Clutch Pinion Gear Return I See Figure 54
Fig.
53 Connect the battery as shown here to test the
hold-in windings
Disconnect the negative lead from the magnetic switch body.
Check
Fig.
that the pinion
gear returns to the inward position.
52 Connect the battery to the magnetic switch as
shown here
Fig.
54 Disconnect the negative lead from the starter as
shown here
ENGINE ELECTRICAL
2-25
8.
No-Load I
Connect the negative battery cable.
See Figure 55 1
.
Connect the battery ammeter
to the starter
as shown
RELAY REPLACEMENT in
the illustration. 2.
Check the
rotation of the starter,
it
must be smooth and
steady with the pinion gear moving outwards. Compare the ammeter reading to the starter specifications chart.
> See Figure 57
The
starter relays
on most
of
your Toyota trucks are located
either in the relay block in the engine driver’s side junction block.
REMOVAL & INSTALLATION
ments should be marked,
number >
See Figure 56
pull
^Replacing the starter while the engine is cold is recommended. A hot engine can result in personal injury. 1.
Disconnect the negative battery cable.
2.
Remove
the nut and disconnect the battery cable from
it
with a suffix of
out,
and
a
install
The cover
compartment or on the for the relay
“starter” or the relay will
28300-XXXXX. Simply new one needed.
compart-
have a part
locate the relay,
if
Battery
REMOVAL & INSTALLATION
the magnetic switch on the starter motor. 3.
Disconnect the remaining
electrical
connections
at the
^Refer
starter. 4. bell
Remove
the nuts and/or bolts securing the starter to the
housing, then
5.
the starter toward the front of the vehi-
remove.
cle to
To
pull
for details
on battery maintenance.
Disconnect the negative battery cable from the terminal,
then disconnect the positive cable. Special pliers and pullers
wires and
fittings
many
on and around the positive terminal.
Insert the starter into the bell housing being sure that
jammed
engaged
with the flywheel teeth, not
Tighten the attaching hardware to 29 all
ft.
lbs.
(39
Nm)
electrical connections.
Connect the
f"*To avoid sparks, always disconnect the negative cable first
against the flywheel.
and replace 7.
.
1
are available to remove the clamps. Be careful of the
install:
the starter drive teeth are
6.
1
to Section
positive battery cable (starter wire) to the
and reconnect
it
last.
2.
Unscrew and remove the
3.
Remove
battery hold
down clamp.
the battery, being careful not to
spill
any
of the
acid.
starter.
'Spilled acid can be neutralized with a baking soda and If you somehow get acid into your eyes, flush it out with lots of clean water and get to a doctor as quickly as possible. water solution.
4.
when
Clean the battery posts thoroughly before installing
a
new
one.
A
light
battery terminal spray protectant 5.
will
jelly
or
help fight corrosion.
Clean the cable clamps using the special tools or a wire
brush, both inside 6.
reinstalling or
coating of petroleum
Install
and
out.
the battery, and the hold
down clamp. Connect Do not hammer them
the positive and then the negative cable. into place.
The
terminals should be coated with grease to
prevent corrosion. 86822094
**CAUTION Make absolutely sure
that the battery is connected propyou turn on the ignition switch. Reversed pocan burn out an alternator in a matter of seconds.
erly before Fig.
55 Make the connections to the battery, ammeter
and
starter as
shown here
larity
2-26
Fig.
ENGINE ELECTRICAL
56 Exploded view of a
common
starter
mounting found on Toyota trucks
ENGINE ELECTRICAL STARTER SPECIFICATIONS ~~
1989
Engine
Pickup
22R
90
11.5
22R-E
90
11.5
3VZ-E
90
11.5
22R
90
11.5
90
11.5
3VZ-E
90
11.5
3000
3F-E
90
11.5
22R
90
11.5
22R-E
90
11.5
3VZ-E
90
11.5
22R-E
90
11.5
3VZ-E
90
11.5
© © © © ©
Land Cruiser
3F-E
90
11.5
3000
Pickup
22R-E
90
11.5
3VZ-E
90
11.5
22R-E
90
11.5
3VZ-E
90
11.5
© © © ©
3F-E
90
11.5
3000
Land Cruiser
22R-E
90
11.5
3VZ-E
90
11.5
© © © ©
Land Cruiser
3F-E
90
11.5
3000
Pickup
22R-E
90
11.5
3VZ-E
90
11.5
22R-E
90
11.5
3VZ-E
90
11.5
© © © ©
3VZ-E
90
11.5
3500
90
11.5
3000
22R-E
90
11.5
3VZ-E
90
11.5
22R-E
90
11.5
3VZ-E
90
11.5
© © © ©
3RZ-FE
90
11.5
3500
3VZ-E
90
11.5
©
90
11.5
3000
22R-E
90
11.5
3VZ-E
90
11.5
Pickup
4Runner
1993
4Runner
T100 Land Cruiser 1994
Pickup
4Runner
T100
Land Cruiser 1995
RPM
22R-E
Pickup
4Runner
1992
Max. Volts
Land Cruiser
4Runner
1991
Amps
Max.
© © © © ©
4Runner
1990
No-Load Test
Model
Pickup
4Runner
Tacoma
T100
Land Cruiser
22R-E
90
11.5
3VZ-E
90
11.5
1
FZ-FE
FZ-FE
1
22R-E
90
11.5
3VZ-E
90
11.5
© © © ©
2RZ-FE
90
11.5
3000
3RZ-FE
90
11.5
3000
5VZ-FE
90
11.5
3000
3RZ-FE
90
11.5
3500
5VZ-FE
90
11.5
3500
FZ-FE
90
11.5
3000
1
86822117
2-27
ENGINE ELECTRICAL
2-28
STARTER SPECIFICATIONS No-Load Test Max. Volts
RPM
90
11.5
“IT
90
11.5
2RZ-FE
90
11.5
3RZ-FE
90
11.5
Year
Model
Engine
7996
4Runner
3RZ-FE 5VZ-FE
Tacoma
T100
Land Cruiser CD
Amps
Max.
5VZ-FE
90
11.5
© © © ©
3RZ-FE
90
11.5
3500
5VZ-FE
90
11.5
3500
1FZ-FE
90
11.5
3000
kw-3000 rpm
1.0
1.4, 1.6
2.0
kw-3500 rpm
kw-2500 rpm 86822118
SENDING UNITS AND SENSORS REMOVAL
Engine Coolant Temperature Sensor
OPERATION
& INSTALLATION
— 1
Drain the coolant from the vehicle.
.
Disconnect the engine wiring protector from the
2.
brackets.
>
See Figure 58
The engine coolant temperature sensor
is
usually located on
the thermostat housing. This sensor controls the readings of the coolant temperature
gauge
in
your vehicle
when
the igni-
3.
Disconnect the sensor wire.
4.
Using a
To
There engine.
is If
ON.
Apply a
By hand,
a needle that shows the temperature area of the the needle points
in
the red zone or higher (this
is
tance for
overheating), you should pull to the side of the road and turn
your engine
OFF
immediately and allow
it
to cool.
socket,
remove the sensor and
install:
5.
tion switch is
19mm deep
gasket.
Loctite® or equivalent to the switch.
thin coat of
carefully thread the switch into the engine. at
is felt
all,
any damage. Continue
tighten to 14
ft.
If
resis-
remove the switch and inspect the threads
lbs.
to install the switch.
Once
installed
(20 Nm).
6.
Connect the sensor
7.
Install
8.
Refill
wiring.
the engine wire protector to the brackets.
the coolant. Start the engine and check for leaks.
Pressure Light/Gauge Sender
Oil
OPERATION
> See Figure 59
The
light
oil
pressure sender/switch controls the gauge or
operation
gauge
will
in
you vehicle while the engine
fluctuate during engine operation.
is
If
the pressure
should stay below the normal range, you should side of the road and turn your engine
your
oil
level of the vehicle
on
minutes. Oil pressure low.
may
if
and recheck
not build up
pull to the
Check
immediately.
level ground,
the proper level. Start the engine Fig. 58 A common engine coolant temperature gauge found on Toyota trucks
OFF
idiot
ON. The
when
it
is
after
low,
fill
to
a few
the level
is
too
ENGINE ELECTRICAL
Fig.
59
A common
oil
2-29
pressure gauge found on Toyota
trucks
Fig.
60
A
special socket
is
used to remove the switch
REMOVAL & INSTALLATION >
See Figures 60 and
61
equipped, remove the lower engine splash shield.
1.
If
2.
Using special
tool
09816-33010 or an equivalent
oil
pres-
sure switch socket, remove the switch.
To 3.
install:
Apply a
By hand, tance for
is
thin coat of
Loctite® or equivalent to the switch.
carefully thread the switch into the engine. felt
at
all,
any damage. Continue
tighten to 11
ft.
lbs.
removed,
If
resis-
remove the switch and inspect the threads to install the switch.
Once
installed
(15 Nm).
4.
If
5.
Start the engine
install
the engine splash shield.
and inspect
for leaks.
Fig. 61
Apply a thin coat of adhesive such as Loctite®
or an equivalent to the switch prior to installation
2-30
ENGINE ELECTRICAL Troubleshooting Basic Starting System Problems Cause
Problem Starter motor rotates engine slowly
Solution
Battery charge low or battery
•
•
Charge
•
Clean and
or replace battery
defective
Defective
•
and
Low
•
circuit
starter
between
battery
motor
load current
tighten, or replace
cables Bench-test starter motor. Inspect
•
worn brushes and weak brush springs. Bench-test starter motor. Check engine for fnction, drag or coolant for
1
High load current
•
•
in
cylinders.
Check
ring gear-to-
pmion gear clearance. Starter
motor
will
not rotate engine
•
Battery charge low or battery
•
Charge or replace
•
Check solenoid ground. Repair
battery
defective •
Faulty solenoid
or
replace as necessary. •
Damaged
drive pinion gear or gear Starter motor engagement weak Starter motor rotates slowly with
•
Replace damaged gear(s)
ring
•
•
•
•
Bench-test starter motor Inspect drive yoke pull-down and point gap,
high load current
check
for
worn end
bushings, check ring gear clear-
ance
Starter
motor drive
(solenoid
known
will
to
not
engage
•
Engine seized
•
Defective contact point assembly
will
not
Repair engine
•
Repair or replace contact point
•
Repair connection
assembly
be good) •
Starter motor drive
•
Inadequate contact point assembly ground
•
Defective hold-in
•
Starter motor loose
coil
on flywheel
at
ground screw
•
Replace
•
Tighten mounting bolts
field
winding assembly
housing
disengage •
•
•
Worn drive end busing Damaged ring gear teeth
•
•
Drive yoke return spring broken or
•
Replace bushing Replace ring gear or driveplate Replace spnng
missing Starter motor drive
prematurely
Low
load current
disengages
•
Weak
•
Hold-in coil defective
•
•
Worn brushes
•
•
Weak
•
drive
assembly
brush springs
thrust
spnng
•
Replace dnve mechanism Replace field winding assembly Replace brushes Replace springs tcc82c01
ENGINE MECHANICAL
TROUBLESHOOTING THE
BLOCK HEATERS 3-165 CAMSHAFT AND BEARINGS 3-144 CAMSHAFT SPROCKETS OR PULLEYS 3-142 COMPRESSION TESTING 3-4 CRANKSHAFT AND MAIN BEARINGS 3-166 CYLINDER HEAD 3-74
SERPENTINE DRIVE BELT
3-199
VACUUM GAUGE INDICATIONS 3-192
VALVE SPECIFICATIONS
3-6
ENGINE 3-15 ENGINE COOLING FAN 3-69 ENGINE OIL COOLER 3-63 ENGINE OVERHAUL TIPS 3-2 EXHAUST MANIFOLD 3-51
FLYWHEEL AND RING GEAR FREEZE PLUGS 3-164 GENERAL INFORMATION 3-2 INTAKE MANIFOLD 3-43 OIL PAN 3-108 OIL
PUMP
3-171
3-112
PISTONS AND CONNECTING
RODS
3-151
ENGINE
RADIATOR 3-56 REAR MAIN OIL SEAL
3-165
ROCKER ARM (VALVE) COVER ROCKER ARM/SHAFTS 3-39 THERMOSTAT 3-42
3-35
TIMING BELT 3-130 TIMING BELT COVER AND
SEAL
3-122
AND ENGINE
TIMING CHAIN 3-135 TIMING CHAIN COVER AND
SEAL 3-122 TIMING GEAR
SEAL
COVER AND
3-126
ENGINE MECHANICAL
TIMING GEARS 3-128
VALVE GUIDES 3-107 VALVE LIFTERS 3-107 VALVE SEALS 3-106 VALVE SEATS 3-107 VALVE SPRINGS 3-106 VALVES AND SPRINGS
WATER PUMP
OVERHAUL EXHAUST SYSTEM SPECIFICATIONS CHARTS
3-103
3-69
EXHAUST SYSTEM GENERAL INFORMATION 3-171 SAFETY PRECAUTIONS 3-172 SPECIFICATIONS CHARTS CAMSHAFT SPECIFICATIONS 3-8 CRANKSHAFT SPECIFICATIONS 3-10 ENGINE REBUILDING
3-181
GENERAL ENGINE SPECIFICATIONS 3-5 PISTON AND RING SPECIFICATIONS 3-12 TORQUE SPECIFICATIONS 3-14 TORQUE SPECIFICATIONS 3-188 TROUBLESHOOTING ENGINE
MECHANICAL PROBLEMS 3-193 TROUBLESHOOTING ENGINE PERFORMANCE 3-196
3-2
3-171 3-5
ENGINE AND ENGINE OVERHAUL
3-2
?
ENGINE MECHANICAL
V-6 engines cam). Toyota trucks with either the 4 cylinder or Cruiser 3F-E Land The engines. overhead cam (OHC)
General Information
use
engine
The
piston engine
a metal block containing a series
is
round chambers or cylinders. These chambers
arranged as an block
is
or
in line
of
may be
the engine.
a V; hence, the description of an engine
in
The
usually an iron or aiuminum-alloy casting.
in
provides a
points for the crankshaft
and
referred to as the
a long, steel shaft mounted at the bottom
is
engine and free
of the
to turn in
mounts. The mounting
its
and the bearings
points (generally four to seven)
shaft which this
on
made
is
motion
is
to turn
then passed into the transmission/transaxle and
to the drive
wheels.
Attached to the crankshaft are the connecting rods which run
explodes within the
and the shaft
rod to the crankshaft finishes
its
power
stroke,
its
turns.
As one
By the top
of the stroke, the
and the intake valve has begun charge
air/fuel
to
be sucked
now-open exhaust
to open, allowing the fresh
by the downward
power
power motions in between
the charge explodes and another
you count the piston
If
four-stroke or four-cycle engines.
While one cylinder
is
performing this cycle,
also contributing; but
in
different timing. Obviously,
cylinders cannot
steady.
on
fire at
As any one
the others are all
is
on
its
power
will
a problem by
allow you to begin accurate
stroke, another
is
fairly
standard.
In
and
specifications for your individual engine, this section also
is
turning; a large round flywheel attached to the
crankshaft provides a stable
mass
to
end
standard rebuilding practice are shown and should be used along with specific details concerning your particular engine.
Competent and accurate machine shop services
maximum
performance,
instances
it
more
is
and engine
reliability
life.
will
profitable for the do-it-yourself
ensure
most
In
mechanic
smooth out the
and
shop
deliver these to a
the other hand,
much
You
of the do-it-yourself
will
have
involvement you desire
to in
machine work. work (crankshaft,
and other components)
block, bearings, piston rods,
scope
for actual
of the rebuilding
is
well
mechanic's tools and
decide for yourself the depth of
an engine repair or rebuild.
TOOLS
rotation.
covers for the cylinders. They contain machined chambers
The
which the
fuel
charge
is
into
forced as the piston reaches the top
These combustion chambers contain at least one intake and one exhaust valve which are opened and closed through the action of the camshaft. The spark plugs are screwed into the cylinder head so that the tips of the plugs travel.
Since the timing of the vaive action (opening and closing) critical to
the combustion process, the camshaft
belt or chain.
(called
The valves are operated
either
is
is
driven by a
by pushrods
overhead valves the valves are above the cam) or by
the direct action of the
cam
pushing on the valves (overhead
tools required for an engine overhaul or parts
replacement
will
depend on the depth
With a few exceptions, they
mechanic’s
tool
depth work
will
•
a
kit
(see Section
require
dial indicator
will
some
(reading
or in
of
your involvement.
be the tools found 1
all
of this
micrometers and telescope gauges scraper
• valve spring compressor •
ring
•
piston ring expander
a in-
thousandths) mounted on a
• jaw and screw-type pullers •
in
manual). More
of the following:
universal base •
protrude into the chamber.
to
remove, clean and inspect the component, buy the necessary
of the
At the top of the engine, the cylinder head(s) provide tight
a
acceptable rebuilding procedures. Examples of
to
exhaust stroke, another on intake and another on
its
its
involved
is
addition to specific parts replacement procedures
abilities.
compression. These constant power pulses keep the crank
of
lubrication, cooling, starting, etc.
electronics, etc. Being able to identify
within the
the
once or the power flow would not be
cylinder
an automotive
diagnosis of the symptoms and causes.
On all
in
to
supporting systems such as fuel
exhaust handling,
vacuum,
parts
see why automotive engines are called
strokes, you'll
many
in
Operation of these systems involve principles of mechanics,
guide
closed cylinder. At the top (approximately) of this stroke the
stroke takes place.
Due
a motor
Most engine overhaul procedures are
The intake valve closes, the piston once again comes back up and compresses the charge in the fires,
a
to turn
then harnessed to perform a
is
piston
stroke of the piston.
spark plug
of the shaft
that the sole
is
Engine Overhaul Tips
exhaust valve has closed
into the cylinder
mind
gas, diesel, electric, solar
forced
next upward journey forces the
burnt gasses out of the cylinder through the valve.
is
transferred through the connecting
is
engine cooling.
in
mixture
sealed cylinder, the piston
tightly
downward. This motion
air/fuel
of the
task such as pumping water, moving the vehicle, etc.
what system
up to the pistons within the cylinders. As the
25-40%
the constantly changing operating conditions found
delivery,
through the function of the engine;
of
Additionally, the
and head.
the block
provides
any motor
of
The motion
engine requires
the
is
in
oil
vehicle, accomplishing this shaft-turning
for the
The crankshaft
crankshaft are called main bearings.
purpose shaft.
crankcase.
The crankshaft
oil
seems very complicated, keep
this
bottom
at the
the parts of the engine by the
all
lubricates the entire engine by travelling
through passages
all
sump
a pan or
driven by either the crank or the
pump which may be
If
in
force fed to
is
circulation of the
between, through which coolant circulates. The lower block
its
oil
stored
is
oil
It
camshaft. The
casting
forms outer walls around the cylinders with hollow areas
number of rigid mounting bearings. The lower block is
a pushrod or overhead valve engine.
is
Lubricating
4 or 6 or a V-6. The upper part of the engine
inline
.
groove cleaner
and compressor
ENGINE AND ENGINE OVERHAUL •
ridge
reamer
•
Plastigage®
•
engine stand
The use
or glaze breaker
Two these tools
of
is
illustrated in this section.
Many can be
rented for a one-time use from a local parts jobber or tool supply house specializing in automotive work. Occasionally, the use of special tools is called for. See the information on Special Tools and the Safety Notice in the
front
book before
of this
— making
welding, plugging and
oversize fasteners unnecessary.
types of thread repair inserts are usually supplied: a
standard type for most inch coarse, inch
most
of
a prewound insert
installing
hone
• cylinder
substituting another tool.
and metric
fine thread sizes
and a spark
kits will
contain a selection of
prewound threaded
installation tool.
Spark plug inserts usually
section.
pilot
master in this
section for
limits of
most
major components. Other procedures such as Magnaflux® and Zyglo® can be used to locate material flaws and stress
Magnaflux®
cracks.
ferrous materials.
is
a magnetic process applicable only to
The Zyglo® process coats the
material with
most
inserts,
a tap
kit
differ
be-
threads and a
Most manufacturers also supply
blister-packed thread repair inserts separately
and assessing the wear
fit
(corresponding to the outside diameter threads of the insert)
combined reamer/tap
Procedures and specifications are given
metric course
lug type to
catalog to determine exact applications. Typical thread repair
and an
INSPECTION TECHNIQUES
fine,
spark plug port sizes. Consult the individual manufacturer’s
cause they require a tap equipped with
inspecting, cleaning
3-3
in
addition to a
containing a variety of taps and inserts plus installa-
tion tools.
Before attempting to repair a threaded hole, remove any
snapped, broken or damaged bolts or studs. Penetrating
can be used
removed
to free frozen threads.
The offending
oil
item can be
with locking pliers or using a screw/stud extractor.
After the hole
is
clear, the
thread can be repaired, as
shown
a fluorescent dye penetrant and can be used on any material. Checking for suspected surface cracks can be more readily
made
The dye is sprayed onto the and the area sprayed with a
using spot check dye.
suspected area, wiped developer. Cracks
OVERHAUL
off
show up
will
brightly.
BOLT OR
TIPS
SCREW
Aluminum has become extremely popular for use in engines, to its low weight. Observe the following precautions when handling aluminum parts: • Never hot tank aluminum parts (the caustic hot tank
due
solution
•
all
aluminum
THREADS
lightly with
installation, to
Never overtighten
engine
oil
or anti-seize
prevent seizure.
bolts or spark plugs especially
in
Fig.
aluminum threads. Stripped threads
any
of several
Keenserts®,
When
in
any component can be repaired using
commercial repair
kits
initial
start-up.
must be prelubed
Any product
bolt hole threads
can be replaced with
recommended as a prelube
When semi-permanent is
will
be exposed
to provide
specifically formulated
purpose can be used, but engine
bolts or nuts
Damaged
(Heli-Coil®, Microdot®,
assembling the engine, any parts that
lubrication at
1
thread repair inserts
etc.).
to frictional contact, the parts
for this
DAMAGED
parts (identification tag, etc.) from
to the tanking.
Always coat threads
compounds before •
INSERT
eat the aluminum.
will
Remove
engine parts prior •
THREADED
oil
is
not
most cases.
in
(locked, but removable) installation of
desired, threads should be cleaned
and coated
with Loctite® or other similar, commercial non-hardening sealant.
REPAIRING DAMAGED THREADS >
See Figures
1, 2, 3,
4 and 5
Several methods of repairing
damaged threads
are available.
Heli-Coil® (shown here), Keenserts® and Microdot® are
among
the most widely used.
principle
—
drilling
All
involve basically the
same
out stripped threads, tapping the hole and
Fig. 2
Standard thread repair insert
plug thread insert
(left),
and spark
3-4
ENGINE AND ENGINE OVERHAUL in
and the series of accompanying illustrations
in
the
kit
manu-
facturer’s instructions.
Compression Testing I
See Figure 6
noticeable lack of engine power, excessive oil consumpand/or poor fuel mileage measured over an extended pepiston riod are all indicators of internal engine wear. Worn gaskets, head leaking bores, cylinder rings, scored or worn
A
tion
sticking or burnt Valves
A check
Culprits here.
and worn valve seats are all possible each cylinder’s compression will help
of
you locate the problems.
As mentioned
the Tools
in
and Equipment part of Section 1, is more accurate that the
a screw-in type compression gauge
type you simply hold against the spark plug hole, although takes slightly longer to use. It’s worth it to obtain a more
it
accurate reading. Follow the procedures below. 1
.
Warm
up the engine
to
normal operating temperature.
2.
Remove
3.
Disconnect the high tension lead
all
the spark plugs. (coil
wire) from the
ignition coil. 4.
open the throttle either by operating the carburetor by hand or by having an assistant floor the
Fully
throttle linkage
accelerator pedal. 5.
hole
Screw the compression gauge the
until
fitting
is
into the
No.1 spark plug
snug.
•-•'WARNING Be
careful not to crossthread the plug hole.
On aluminum
cylinder heads use extra care, as the threads in these
heads are easily ruined.
TCCS3042
6.
Ask an
assistant to depress the accelerator pedal fully
on both carbureted and Fig. 4
Using the
kit,
tap the hole
in
order to receive the
thread insert. Keep the tap well oiled and back frequently to avoid clogging the threads
it
out
fuel injected vehicles.
Then, while you
read the compression gauge, ask the assistant to crank the
engine two or three times
in
short bursts using the ignition
switch. 7.
Read
of cranks,
the compression gauge at the end of each series and record the highest of these readings. Repeat
TCCS3801
Fig. 6
A
screw-in type compression gauge
is
more
accurate and easier to use without an assistant
ENGINE AND ENGINE OVERHAUL this
procedure
each
for
new motors
of the engine’s cylinders.
As a general
105
will
Many engines
the cylinders.
run very well with
all
bit
8.
after
harder to
bers, doesn't warrant
start, but, based on these numan engine tear-down yet. Compare the
highest reading of
the cylinders.
all
Any
variation of
more than
be
fair to
say that cylinder number three
is
not working
adding the
oil,
it
through the spark plug hole and
test.
comes up
the compression
If
appears that the cylinder’s piston rings
some of the may not be
or bore are
damaged
leakage.)
the pressure remains low, the valves
If
adjacent cylinders
or worn. (The
is
low,
and coolant
in
problem. There
engine
oil
is
and
may
sealed
if
If
compression
the addition of
in
oil
any two doesn’t help
leakage past the head gasket.
the combustion
dipstick
oil
needed), or the head gasket
is
that cylinder.
the compression, there
would
it
unusually low, pour a tablespoon of clean
is
into the cylinder
may be blown near
through 4 were: 135 psi (930 kPa), 125 psi
1
(861 kPa), 90 psi (620 kPa) and 125 psi (861 kPa),
a cylinder oil
burning,
oil
fuel mileage.
seating properly (a valve job
10% should be considered a sign of potential trouble. For example, on a 4 cylinder engine, if your comoression readings for cylinders
poor
repeat the compression
oil
little
If
almost certainly the cause of your
is
idle or
engine
The lower number simply shows a general
psi (724 kPa).
and may be a
rough
cylinders at
deterioration internally. This motor probably burns a
and
ciently
have compression on the order of 150-170 psi (1034-1172 kPa). This number will decrease with age and wear. The number of pounds of pressure that your test shows is not as important as the evenness between all rule,
3-5
chamber can
result
from
Oil this
also be evidence of water droplets on the
when a head gasket has
blown.
effi-
GENERAL ENGINE SPECIFICATIONS Engine
Engine Displacement
Year
1D/VIN
Liters (cc)
1989
22 R
2.4 (2366)
System Type 2 BBL
22R-E 3VZ-E
2.4 (2366)
EFI
11 6(5)4800
3.0 (2959)
EFI
1
50@4800
3F-E
4.0 (3956)
EFI
1
54(5)4000
22R 22R-E 3VZ-E
2.4 (2366)
1990
1995
1996
129(5)2800
3.62x3.50
9.3:1
36-71(5)4000
140@2800
2
BBL
@
(ft.
@ rpm
lbs.)
Bore x Stroke (In.)
Ratio
@ rpm
3.62x3.350
9.3:1
36-71(6)4000
80(5)3400
3.44x3.23
9.0:1
36-71 @4000
3.70x3.74
8.1:1
36-71 @4000
3.62x3.50
9.3:1
36-71 @3000
6@4800
220@3000 129@2800 140@2800
3.62x3.50
9.3:1
36-71 @3000
96(5)4800
1
EFI
1 1
3.0 (2959)
EFI
1
50(5)4800
180(5)3400
3.44x3.23
9.0:1
36-71 @4000
3F-E
4.0 (3956)
EFI
154@4000
3.70x3.74
8.1:1
36-71 @4000
22R-E
2.4 (2366)
EFI
1 1
3.62x3.50
9.3:1
36-71 @3000
3VZ-E
3.0 (2959)
EFI
150(5)4800
220@3000 140@2800 180@3400
3.44x3.23
9.0:1
36-71 @4000
3F-E
4.0 (3956)
EFI
154@4000
220(6)3000
3.70x3.74
8.1:1
36-71 @4000
22R-E
2.4 (2366)
EFI
116(6)4800
140(5)2800
3.62x3.50
9.3:1
36-71 @3000
3VZ-E
3.0 (2959)
EFI
150(6)4800
180(5)3400
3.44x3.23
9.0:1
36-71 @4000
6(5)4800
3F-E
4.0 (3956)
EFI
154(5)4000
220(5)3000
3.70x3.74
8.1:1
36-71 @4000
2.4 (2366)
EFI
116(5)4800
140(6)2800
3.62x3.50
9.3:1
36-71 @3000
3.0 (2959)
EFI
36-71 @4000
EFI
1
180@3400 95@4400
9.0:1
3.0 (2952)
150@4800 85@5200
3.44x3.23
3VZ-FE 1FZ-FE 22R-E 3RZ-FE
1
3.44x3.23
9.6:1
4.3
4.5 (4477)
EFI
212(5)4600
275(6)3200
3.94x3.74
9.0:1
36-71 @3000
2.4 (2366)
EFI
1 1
6@4800
140(5)2800
3.62x3.50
9.3:1
36-71 @3000
2.7 (2693)
EFI
150(5)4800
77(5)4000
3.74x3.74
9.5:1
36-71 @3000
3VZ-E
3.0 (2959)
EFI
180(5)3400
3.44x3.23
9.0:1
36-71 @4000
3VZ-FE 1 FZ-FE 22R-E 2RZ-FE 3RZ-FE 3VZ-E 5VZ-FE 1 FZ-FE 2RZ-FE
3.0 (2952)
EFI
95@4400
3.44x3.23
9.6:1
4.5 (4477)
EFI
150@4800 185@5200 212@4600
275(5)3200
3.94x3.64
9.0:1
2.4 (2366)
EFI
1 1
6(5)4800
1
40@2800
3.62x3.50
9.3:1
2.4 (2438)
EFI
142(6)5000
1
60(5)4000
3.74x3.38
9.5:1
2.7 (2693)
EFI
9.5:1
EFI
3.44x3.23
9.0:1
3.4 (3378)
EFI
190(5)4800
3.68x3.23
9.6:1
4.3
4.5 (4477)
EFI
212(6)4600
3.94x3.64
9.0:1
36-71 @3000
2.4 (2438)
EFI
142(6)5000
177@4000 180@3400 220@3400 275@3200 60@4000
3.74x3.74
3.0 (2959)
150@4800 150@4800
3.74x3.38
9.5:1
36-71 @3000
3RZ-FE 5VZ-FE
2.7 (2693)
EFI
150(6)4800
1
77(6)4000
3.74x3.74
9.5:1
36-71 @3000
3.4 (3378)
EFI
1
90@4800
220(5)3400
3.68x3.23
9.6:1
4.3
FZ-FE
4.5 (4477)
EFI
212(5)4600
275(6)3200
3.94x3.64
9.0:1
36-71 @3000
1
1
96(5)4800
Net
Torque
22R-E 3VZ-E
1993
1994
Oil
Pressure
Net
Horsepower rpm
2.4 (2366)
1991
1992
Compression
Fuel
1
1
1
O
O
4.3
@3000 36-71 @3000 36-71 @3000 36-71 @3000 36-71 @3000 36-71
©
O
At idle
BBL EFI
•
Barrel carburetor
-
Electronic fuel injection
86823002
3-6
ENGINE AND ENGINE OVERHAUL
VALVE SPECIFICATIONS Spring
Engine Year 1989
ID/VIN
22R
Engine
Seat
Face
Springiest
Installed
Clearance
Angle
Angle
Pressure
Height
(irn)
Liters (cc)
2.4 (2366)
(deg.)
45
(deg.)
44.5
(lbs.
@
66.1
in.)
2.4 (2366)
45
3.0 (2959)
45
1.594
0.0010-
(toj
Exhaust 0.0012-
Exhaust
Intake
0.3136-
0.3138-
0.0024
0.0026
0.3144
0.3142
0.0012-
0.3138-
0.3136-
44.5
66.1
1.594
0 00100.0024
0.0026
0.3144
0.3142
44.5
54-57
1.575
0.0010-
0.0012-
0.3138-
0.3136-
0.0024
0.0026
0.3144
0.3142
0.0016-
0.3140
0.3137
0.3136-
G
1990
Intake
(in.)
G 3VZ-E
Stem Diameter
Displacement
0 22R-E
Stem-to-Guide
.
3F-E
4.0 (3956)
45
44.5
71.6
1.693
0.0012-
0.0024
0.0028
22R
2.4 (2366)
45
44.5
66.1
1.594
0.0010-
0.0012-
0.3138-
0.0024
0.0026
0.3144
0.3142
0.0010-
0.0012-
0.3138-
0.3136-
0.0024
0.0026
0.3144
0.3142
0.0010-
0.0012-
0.3138-
0.3136-
0.0024
0.0026
0.3144
0.3142
0.0012-
0.0016-
0.3140
0.3137
0.0024
0.0028
0.0010-
0.0012-
0.3138-
0.3136-
0.0024
0.0026
0.3144
0.3142
1.575
0.0010-
0.0012-
0.3138-
0.3136-
0.0024
0.0026
0.3144
0.3142
0.0016-
0.3140
0.3137
0.3136-
G 22R-E
2.4 (2366)
45
44.5
66.1
1.594
'
G 3VZ-E
3.0 (2959)
45
44.5
54-57
1.575
G 3F-E
1991
22R-E
4.0 (3956)
2.4 (2366)
45
45
44.5
44.5
71.6
66.1
1.593
1.594
G 3VZ-E
3.0 (2959)
45
44.5
54-57
G
1992
3F-E
4.0 (3956)
45
44.5
22R-E
2.4 (2366)
45
44.5
71.6
1.693
0.0012-
0.0024
0.0028
66.1
1.594
0.0010-
0.0012-
0.3138-
0.0024
0.0026
0.3144
0.3142
0.0012-
0.3138-
0.3136-
G 3VZ-E
3.0 (2959)
45
3F-E
4.0 (3956)
45
44.5
54-57
1.575
0.0010-
0.0024
0.0026
0.3144
0.3142
44.5
71.6
1.693
0.0012-
0.0016-
0.3140
0.3137
0.0024
0.0028
0.0010-
0.0012-
0.3138-
0.3136-
0.0024
0.0026
0.3144
0.3142
0.0012-
0.3138-
0.3136-
G
1993
22R-E
2.4 (2366)
45
44.5
66.1
1.594
G 3VZ-E
3.0 (2959)
45
1FZ-FE
4.5 (4477)
45
44.5
54-57
1.575
0.0010-
0.0024
0.0026
0.3144
0.3142
44.5
53.4
1.437
0.0010-
0.0012-
0.2744-
0.2742-
0.0024
0.0026
0.2750
0.2748
0.0012-
0.3138-
0.3136-
Q
1994
22R-E
2.4 (2366)
45
3RZ-FE
2.7 (2693)
45
3VZ-E
3.0 (2959)
45
3VZ-FE
3.0 (2952)
1FZ-FE
4.5 (4477)
44.5
66.1
1.594
0.0010-
0.0024
0.0026
0.3144
0.3142
44.5
57-63
1.406
0.0010-
0.0012-
0.2350-
0.2348-
0.0024
0.0026
0.2356
0.2354
44.5
54-57
1.575
0.0010-
0.0012-
0.3138-
0.3136-
0.0024
0.0026
0.3144
0.3142
45
44.5
3842
1.311
0.0010-
0.0012-
0.2350-
0.2348-
0.0024
0.0026
0.2356
0.2354
45
44.5
53.4
1.437
0.0010-
0.0012-
0.2744-
0.2742-
0.0024
0.0026
0.2750
0.2748
Q G G
86823003
ENGINE AND ENGINE OVERHAUL
3-7
VALVE SPECIFICATIONS
1995
Engine
Seat
Face
Engine
Displacement
Angle
Angle
ID/VIN
Liters (cc)
(deg.)
(deg.)
22R-E
2.4 (2366)
2RZ-FE
2.4 (2438)
45
44.5
Spring
Stem-to-Guide
Stem
Spring Test
Installed
Clearance
Diameter
Pressure
Height
(lbs.
66.1
@
in.)
@1.594
(in.)
44.5
40-46@
O 3RZ-FE
2.7 (2693)
45
3VZ-E
3.0 (2959)
45
5VZ-FE
3.4 (3378)
45
57-63(3)
44.5
54-57@
44.5
41.9-46.3®
0
0.0026
0.3144
0.3142
1.406
0.0012-
0.2350-
0.2348-
0.0024
0.0026
0.2356
0.2354
1.406
0.0010-
0.0012-
0.2350-
0.2348-
0.0024
0.0026
0.2356
0.2354
1.575
0.0010-
0.0012-
0.3138-
0.3136-
0.0024
0.0026
0.3144
0.3142
1.311
0.0010-
0.0012-
0.2350-
0.2348-
0.0024
0.0026
0.2356
0.2354
1.437
0.0010-
0.0012-
0.2744-
0.2742-
0.0024
0.0026
0.2750
0.2748
1.406
0.0010-
0.0012-
0.2350-
0.2348-
0.0024
0.0026
0.2356
0.2354
1.406
0.0010-
0.0012-
0.2350-
0.2348-
0.0024
0.0026
0.2356
0.2354
1.311
0.0010-
0.0012-
0.2350-
0.2348-
0.0024
0.0026
0.2356
0.2354
1.311
1996
4.5 (4477)
45
44.5
2RZ-FE
2.4 (2438)
45
44.5
40-46@
3RZ-FE
2.7 (2693)
45
44.5
57-63@
5VZ-FE
3.4 (3378)
45
44.5
41.9-46.3®
53.
4® 1.437
1.406
•o
©
1.406
1.311
1FZ-FE
1
4.5 (4477)
45
44.5
53.4@1 437
Exhaust 0.3136-
0.0024
1.575
1FZ-FE
0.3138-
0.0010-
1.406
O
0.0012-
Intake
0.0010-
1.406 44.5
Exhaust
1.594
O 45
(In.)
(in.)
Intake
1.437
0.0010-
0.0012-
0.2744-
0.2742-
0.0024
0.0026
0.2750
0.2748
Blend seat with 30 and 60 deqree cutters to center the 45 degree Dortion on valve face 86823004
3-8
ENGINE AND ENGINE OVERHAUL
CAMSHAFT SPECIFICATIONS All
measurements given
in inches.
Engine Engine Year 1989
ID/VIN
22R
22R-E
3VZ-E
3F-E
1990
22 R
22R-E
3VZ-E
3F-E
1991
1994
2.4 (2366)
3.0 (2959)
4.0 (3956)
2.4 (2366)
2.4 (2366)
3.0 (2959)
4.0 (3956)
2
3
4
1.2984-
1.2984-
1.2984-
1.2984-
1.2992
1.2992
1.2992
1.2992
1.2984-
1.2984-
1.2984-
1.2984-
1.2992
1.2992
1.2992
1.2992
1.0610-
1.0610-
1.0610-
1.0610-
1.0616
1.0616
1.0616
1.0616
1.8880-
1.8289-
1.7699-
1.7108-
1.8888
.1.8297
1.7707
1.7116
1.2984-
1.2984-
1.2984-
1.2984-
1.2992
1.2992
1.2992
1.2992
1.2984-
1.2984-
1.2984-
1.2984-
1.2992
1.2992
1.2992
1.2992
1.0610-
1.0610-
1.0610-
1.0610-
1.0616
1.0616
1.0616
1.0616
1.8880-
1.8289-
1.7699-
1.7108
1.8888
1.8297
1.7707
1.7116
1.2984-
1.2984-
1.2984-
2.4 (2393)
1.2984-
1.2992
1.2992
1.2992
1.2992
3VZ-E
3.0 (2959)
1.0610-
1.0610-
1.0610-
1.0610-
1.0616
1.0616
1.0616
1.0616
4.0 (3956)
1.8880-
1.8289-
1.7699-
1.7108-
1.8888
1.8297
1.7707
1.7116
1.2984-
1.2984-
1.2984-
22R-E
2.4 (2366)
1.2984-
1.2992
1.2992
1.2992
1.2992
3VZ-E
3.0 (2959)
1.0610-
1.0610-
1.0610-
1.0610-
1.0616
1.0616
1.0616
1.0616
4.0 (3956)
1.8880-
1.8289-
1.7699-
1.7108-
1.8888
1.8297
1.7707
1.7116
1.2984-
1.2984-
1.2984-
3F-E
1993
2.4 (2366)
1
22R-E
3F-E
1992
Liters (cc)
Ele vation
Journal Diameter
Displacement
22R-E
2.4 (2366)
1.2984-
1.2992
1.2992
1.2992
1.2992
3VZ-E
3.0 (2959)
1.0610-
1.0610-
1.0610-
1.0610-
1.0616
1.0616
1.0616
1.0616
3VZ-FE
3.0 (2952)
1.0610-
1.0610-
1.0610-
1.0610-
1.0616
1.0616
1.0616
1.0616
1.0614-
1.0614-
1.0614-
1FZ-FE
4.5 (4477)
1.0614-
1.0620
1.0620
1.0620
1.0620
22R-E
2.4 (2366)
1.2984-
1.2984-
1.2984-
1.2984-
1.2992
1.2992
1.2992
1.2992
3RZ-FE
2.7 (2693)
1.0614-
1.0614-
1.0614-
1.0614-
1.0620
1.0620
1.0620
1.0620
5
In.
Ex.
Bearing
Camshaft
Clearance
End-Play 0.0031-
1.6783-
1.6807-
0.0004-
1.6819
1.6842
0.0024
0.0071
1.6783-
1.6807-
0.0004-
0.0031-
1.6819
1.6842
0.0024
0.0071
NA
1.6598-
1.6520-
0.0014-
0.0013-
1.6638
1.6559
0.0028
0.0031
NA
1.5102-
1.5059-
0 0010-
0.0079-
1.5142
1.5098
0.0030
0.0103
1.6783-
1.6807-
0.0004-
0.0031-
1.6819
1.6842
0.0024
0.0071
NA
1.6783-
1.6807-
0.0004-
0.0031-
1.6819
1.6842
0.0024
0.0071
NA
1.6598-
1.6520-
0.0014-
0.0013-
1.6638
1.6559
0.0028
NA NA
NA
NA
.
-
0.0031
1.5102-
1.5059-
0 0010
1.5142
1.5098
0.0030
0.0103
NA
1.6783-
1.6807-
0.0004-
0.0031-
1.6819
1.6842
0.0024
0.0071
NA
1.5102-
1.5059-
0.0010-
0.0079-
1.5142
1.5098
0.0030
NA
.
-
0.0079-
0.0103
1.5102-
1.5059-
0 0010
1.5142
1.5098
0.0030
0.0103
NA
1.6783-
1.6807-
0.0004-
0.0031-
1.6819
1.6842
0.0024
0.0071
NA
1.6598-
1.6520-
0.0014-
0.0013-
1.6638
1.6559
0.0028
NA
1.5102-
1.5059-
0 0010
1.5142
1.5098
0.0030
0.0103
NA
1.6783-
1.6807-
0.0004-
0.0031-
1.6819
1.6842
0.0024
0.0071
NA
1.6598-
1.6520-
0.0014-
0.0013-
1.6638
1.6559
0.0028
0.0031
NA
1.6598-
1.6520-
0.0014-
0.0013-
1.6638
1.6559
0.0028
0.0031
NA
1.9925-
1.9925-
0 0010-
0.0012-
1.9965
1.9965
0.0024
0.0031
NA
1.6783-
1.6807-
0.0004-
0.0031-
1.6819
1.6842
0.0024
0.0071
NA
1.7839-
1.7740-
0 0010-
0.0016-
1.7878
1.7779
0.0031
0.0047
.
-
.
.
.
0.0079-
0.0031 0.0079-
86823005
ENGINE AND ENGINE OVERHAUL
3-9
CAMSHAFT SPECIFICATIONS All
measurements given
in inches.
Engine
Year
Displacement
ID/VIN
Liters (cc)
3VZ-E
1994
3.0 (2959)
Bearing
Camshaft
Clearance
End-Play
0.6520-
0.0014-
0.0013-
1.6638
1.6559
0.0028
0.0031
NA
1.6598-
0.6520-
0.0014-
0.0013-
1.6638
1.6559
0.0028
0.0031
NA
1.9925-
1.9925-
0.0010-
0.0012-
1.9965
1.9965
0.0024
0.0031
NA
1.6783-
1.6807-
0.0004-
0.0031-
1.6819
1.6842
0.0024
0.0071
1.0614-
1.7839-
1.7740-
0.0010-
0.0016-
Elevation
Journal Diameter 1
2
3
4
5
In.
Ex.
1.0610-
1.0610-
1.0610-
1.0610-
NA
1.6598-
1.0616
1.0616
1.0616
1.0616
1.0610-
1.0610-
1.0610-
3VZ-FE
3.0 (2952)
1.0610-
1.0616
1.0616
1.0616
1.0616
1FZ-FE
4.5 (4477)
1.0614-
1.0614-
1.0614-
1.0614-
1.0620
1.0620
1.0620
1.0620
22R-E
2.4 (2366)
1.2984-
1.2984-
1.2984-
1.2984-
1.2992
1.2992
1.2992
1.2992
2RZ-FE
2.4 (2438)
1.0614-
1.0614-
1.0614-
1.0614-
1.0620
1.0620
1.0620
1.0620
1.0620
1.7878
1.7779
0.0024
0.0037
3RZ-FE
2.7 (2693)
1.0614-
1.0614-
1.0614-
1.0614-
1.0614-
1.7839-
1.7740-
0.0010-
0.0016-
1.0620
1.0620
1.0620
1.0620
1.0620
1.7878
1.7779
0.0031
0.0047
5VZ-FE
3.4 (3378)
1.0610-
1.0610-
1.0610-
1.0610-
NA
1.6657-
0.6520-
0.0014-
0.0013-
1.0616
1.0616
1.0616
1.0616
1.6697
1.6559
0.0028
0.0031
1FZ-FE
4.5 (4477)
1.0614-
1.0614-
1.0614-
1.0614-
NA
1.9925-
1.9925-
0.0010-
0.0012-
1.0620
1.0620
1.0620
1.0620
1.9965
1.9965
0.0024
0.0031
2RZ-FE
2.4 (2438)
1.0614-
1.0614-
1.0614-
1.0614-
1.0614-
1.7839-
1.7740-
0.0010-
0.0016-
1.0620
1.0620
1.0620
1.0620
1.0620
1.7878
1.7779
0.0024
0.0037
1.0614-
1.0614-
1.0614-
1.0614-
1.0614-
1.7839-
1.7740-
0.0010-
0.0016-
1.0620
1.0620
1.0620
1.0620
1.0620
1.7878
1.7779
0.0031
0.0047
1.0610-
1.0610-
1.0610-
NA
1.6657-
0.6520-
0.0014-
0.0013-
1.6697
1.6559
0.0028
0.0031
NA
1.9925-
1.9925-
0.0010-
0.0012-
1.9965
1.9965
0.0024
0.0031
1995
1996
Engine
3RZ-FE
2.7 (2693)
5VZ-FE
3.4 (3378)
1.0610-
1.0616
1.0616
1.0616
1.0616
FZ-FE
4.5 (4477)
1.0614-
1.0614-
1.0614-
1.0614-
1.0620
1.0620
1.0620
1.0620
1
NA
*
Not Available 86823006
3-10
ENGINE AND ENGINE OVERHAUL
CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS All
measurements are given
Engine Year
ID/VIN
1989
22R
22R-E
3VZ-E
3F-E
1990
22 R
1992
1993
1994
Liters (cc)
2.4 (2366)
2.4 (2366)
3.0 (2959)
4.0 (3956)
2.4 (2366)
Connecting Rod
Main Brg.
Main Brg.
Oil
Shaft
Thrust
Crank Rod
Oil
Side
on No.
Clearance
Clearance
Clearance
3
2.0861-
0.0010-
0.0008-
2.0866
0.0022
0.0087
0.0010-
0.0008-
Clearance
End-play
2.3616-
0.0010-
0.0008-
2.3622
0.0022
0.0087
Journal Dia.
2.3616-
0.0010-
0.0008-
2.3622
0.0022
0.0087
2.5195-
0.0009-
0.0008-
2.5197
0.0017
©
3
2.0861-
2.0866
0.0022
0.0087
3
2.1648-
0.0009-
0.0059-
0.0098
2.1654
0.0021
0.0130
0.0008-
0.0024-
3
2.1252-
0.0008-
0.0043-
0.0017
0.0063
2.3616-
0.0010-
0.0008-
2.3622
0.0022
0.0087
0.0010-
0.0008-
2.1260
0.0024
0.0091
3
2.0861-
0.0010-
0.0008-
2.0866
0.0022
0.0087
3
2.0861-
0.0010-
0.0008-
2.0866
0.0022
0.0087
3
2.1648-
0.0009-
0.0059-
22R-E
2.4 (2366)
2.3616-
2.3622
0.0022
0.0087
3VZ-E
3.0 (2959)
2.5195-
0.0009-
0.0008-
2.5197
0.0017
0.0098
2.1654
0.0021
0.0130
0.0008-
0.0024-
3
2.1252-
0.0008-
0.0043-
0.0017
0.0063
2.1260
0.0024
0.0091
0.0010-
0.0008-
3
2.0861-
0.0010-
0.0008-
2.0866
0.0022
0.0087
3
2.1648-
0.0009-
0.0059-
2.1654
0.0021
0.0130
3
2.1252-
0.0008-
0.0043-
2.1260
0.0024
0.0091
3
2.0861-
0.0010-
0.0008-
2.0866
0.0022
0.0087
3
2.1648-
0.0009-
0.0059-
2.1654
0.0021
0.0130
3
2.1252-
0.0008-
0.0043-
2.1260
0.0024
0.0091
3
2.0861-
0.0010-
0.0008-
2.0866
0.0022
0.0087
3
2.1648-
0.0009-
0.0059-
3F-E
1991
Displacement
in inches.
Crankshaft
Engine
4.0 (3956)
©
22R-E
2.4 (2366)
2,3616-
2.3622
0.0022
0.0087
3VZ-E
3.0 (2959)
2.5195-
0.0009-
0.0008-
2.5197
0.0017
0.0098
4.0 (3956)
ft)
0.0008-
0.0024-
0.0017
0.0063
22R-E
2.4 (2366)
2.3616-
0.0010-
0.0008-
2.3622
0.0022
0.0087
3VZ-E
3.0 (2959)
2.5195-
0.0009-
0.0008-
2.5197
0.0017
0.0098
3F-E
4.0 (3956)
©
0.0008-
0.0024-
0.0017
0.0063
22R-E
2.4 (2366)
2.3616-
0.0010-
0.0008-
2.3622
0.0022
0.0087
3VZ-E
3.0 (2959)
2. .5195-
0.0009-
0.0008-
2.5197
0.0017
0.0098
1FZ-FE
4.5 (4477)
2.7158-
0.0016-
0.0008-
2.7165
0.0032
0.0087
2.3616-
0.0010-
0.0008-
3F-E
22R-E
2.4 (2366)
2.3622
0.0022
0.0087
0.0009-
0.0008-
3RZ-FE
2.7 (2693)
2.3617-
2.3622
0.0019
0.0087
3VZ-E
3.0 (2959)
2.5195-
0.0009-
0.0008-
2.5197
0.0017
0.0098
1FZ-FE
4.5 (4477)
2.7158-
0.0016-
0.0008-
2.7165
0.0032
0.0087
2.1654
0.0021
0.0130
3
©
0.0013-
0.0063-
0.0020
0.0103
3
2.0861-
0.0010-
0.0008-
2.0866
0.0022
0.0087
3
2.0861-
0.0012-
0.0063-
2.0866
0.0023
0.0123
3
2.1648-
0.0009-
0.0059-
3
2.1654
0.0021
0.0130
©
0.0013-
0.0063-
0.0020
0.0103 86823010
ENGINE AND ENGINE OVERHAUL
3-11
CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS measurements are given in
All Engine
1995
Engine
Displacement
Main Brg.
ID/VIN
Liters (cc)
Journal Dia.
22R-E
2.4 (2366)
2RZ-FE
2.4 (2438)
inches. Connecting Rod
Crankshaft Shaft
Thrust
Crank Rod
Oil
Side
Clearance
End-play
on No.
Clearance
Clearance
Clearance
2.3616-
0.0010-
0.0008-
3
2.0861-
0.0010-
0.0008-
2.3622
0.0022
0.0087
2.0866
0.0022
0.0087
®
®
0.0008-
©
0.0012-
0.0063-
Main Brg.
Oil
3
0.0087
3VZ-E
3.0 (2959)
3RZ-FE
2.7 (2693)
2.5195-
0.0009-
2.5197
0.0017
0.0098
®
®
0.0008-
0.0008-
3
2.1648-
0.0021
0.0130
©
0.0012-
0.0063-
0.0022
0.0123
3
2.1648-
0.0009-
0.0059-
0.0021
0.0130 0.0063-
5VZ-FE
3.4 (3378)
2.5195-
0.0009-
0.0008-
2.5197
0.0017
0.0087
2.1654
1FZ-FE
4.5 (4477)
2.7158-
0.0016-
0.0008-
3
©
0.0013-
2.7165
0.0032
0.0087
0.0020
0.0103
3
©
0.0012-
0.0063-
0.0022
0.0123
3
2.1648-
0.0009-
0.0059-
2RZ-FE
2.4 (2438)
®
®
0.0008-
3VZ-E
3.0 (2959)
2.5195-
0.0009-
0.0008-
2.5197
0.0017
0.0098
3RZ-FE
2.7 (2693)
®
©
0.0008-
2.1654
0.0021
0.0130
3
©
0.0012-
0.0063-
0.0022
0.0123
3
2.1648-
0.0009-
0.0059-
0.0087
5VZ-FE
3.4 (3378)
1FZ-FE
4.5 (4477)
2.5195-
0.0009-
0.0008-
2.5197
0.0017
0.0087
2.7158-
0.0016-
0.0008-
2.7165
0.0032
0.0087
No. 1:2.6367-2.6376
3
2.1654
0.0021
0.0130
©
0.0013-
0.0063-
0.0020
0.0103
3
No. 2 2.6957-2.6967
2
No.
3:
2.7548-2.7557
No.
4:
2.8139-2.8148
There are
live sizes ol
the
number
No.
3:
2.2615-2.3620
Others: 2.3617-2.3622
4
No. All
standard connecting rod beannqs marKeo
2, 3. 4.
Replace with one havmq the same number (number imprinted on outside If
0.0059-
2.1654
0.0087
1
0.0123
0.0009-
3
0.0087
1996
0.0022
of bearinq
5 and 6 accordingly. of
cannot be determined, select correct bearing by adding toqether the numbers
imprinted on connecting rod and crankshaft, then selecting the bearing with the
EXAMPLE: Connecting
5
beannq end).
rod 3 + Crankshaft 1=4.
Use bearing
same number as
3:
0.0012-0.0022
others: 0.0009-0.0019
Mark
4:
Mark
5:
2.2050-2.2052
Mark
6:
2.2052-2.2054
2.2047-2.2050
the total.
4.
86823011
3-12
ENGINE AND ENGINE OVERHAUL PISTON AND RING SPECIFICATIONS All measurements are given in inches. Ring
Engine Engine Year
ID/VIN
1989
22R
22R-E
3VZ-E
3F-E
1990
Compression Compression 0.0098-
0.0236-
Oil
Control 0.0079-
Bottom
Compression Compression 0.0012-
0.0012-
0.0016
0.0185
0.0323
0.0224
0.0028
0.0028
2.4 (2366)
0.0008-
0.0098-
0.0236-
0.0079-
0.0012-
0.0012-
0.0016
0.0185
0.0323
0.0224
0.0028
0.0028
3.0 (2959)
0.0031-
0.0090-
0.0150-
0.0060-
0.0012-
0.0012-
0.0039
0.0130
0.0190
0.0160
0.0028
0.0028
0.0011-
0.0079-
0.0197-
0.0079-
0.0012-
0.0020-
0.0028
0.0035
0.0012-
0.0012-
4.0 (3956)
Oil
Control
SNUG SNUG SNUG SNUG
0.0019
0.0165
0.0283
0.0008-
0.0098-
0.0236-
0.0079-
0.0016
0.0185
0.0323
0.0224
0.0028
0.0028
22R-E
2.4 (2366)
0.0008-
0.0098-
0.0236-
0.0079-
0.0012-
0.0012-
0.0016
0.0185
0.0323
0.0224
0.0028
0.0028
0.0031-
0.0091-
0.0150-
0.0059-
0.0012-
0.0012-
0.0012-
0.0039
0.0327
0.0366
0.0354
0.0028
0.0028
0.0028
0.0011-
0.0079-
0.0197-
0.0079-
0.0012-
0.0020-
SNUG
0.0028
0.0035
0.0012-
0.0012-
3.0 (2959)
4.0 (3956)
SNUG
SNUG
0.0019
0.0165
0.0283
0.0323
22R-E
2.4 (2366)
0.0008-
0.0098-
0.0236-
0.0079-
0.0016
0.0185
0.0323
0.0224
0.0028
0.0028
3VZ-E
3.0 (2959)
0.0031-
0.0091-
0.0150-
0.0059-
0.0012-
0.0012-
0.0039
0.0327
0.0366
0.0354
0.0028
0.0028
0.0011-
0.0079-
0.0197-
0.0079-
0.0012-
0.0020-
0.0019
0.0165
0.0283
0.0323
0.0028
0.0035
0.0008-
0.0098-
0.0236-
0.0079-
0.0012-
0.0012-
0.0028
0.0028
0.0012-
0.0012-
0.0012-
22R-E
4.0 (3956)
2.4 (2366)
SNUG SNUG SNUG
SNUG
0.0016
0.0185
0.0323
0.0224
3VZ-E
3.0 (2959)
0.0031-
0.0091-
0.0150-
0.0059-
0.0039
0.0327
0.0366
0.0354
0.0028
0.0028
0.0028
3F-E
4.0 (3956)
0.0011-
0.0079-
0.0197-
0.0079-
0.0012-
0.0020-
SNUG
0.0019
0.0165
0.0283
0.0323
0.0028
0.0035
0.0008-
0.0098-
0.0236-
0.0079-
0.0012-
0.0012-
0.0016
0.0185
0.0323
0.0224
0.0028
0.0028
0.0091-
0.0150-
0.0059-
0.0012-
0.0012-
22R-E
2.4 (2366)
SNUG SNUG
3VZ-E
3.0 (2959)
0.0031-
0.0039
0.0327
0.0366
0.0354
0.0028
0.0028
3VZ-FE
3.0 (2952)
0.0051-
0.0110-
0.0150-
0.0059-
0.0004-
0.0012-
0.0059
0.0197
0.0236
0.0234
0.0031
0.0028
0.0016-
0.0118-
0.0177-
0.0059-
0.0016-
0.0012-
0.0024
0.0205
0.0264
0.0205
0.0031
0.0028
0.0008-
0.0098-
0.0236-
0.0079-
0.0012-
0.0012-
0.0016
0.0185
0.0323
0.0224
0.0028
0.0028
0.0019-
0.0118-
0.0157-
0.0157-
0.0008-
0.0012-
0.0024
0.0157
0.0194
0.0194
0.0028
0.0028
0.0024
0.0091-
0.0150-
0.0059-
0.0012-
0.0012-
0.0012-
1FZ-FE
1994
0.0008-
Bottom
2.4 (2366)
3F-E
1993
Clearance
Top
22R
3F-E
1992
Liters (cc) 2.4 (2366)
Piston
Top
0.0323
3VZ-E
1991
Displacement
Ring Side Clearance
Gap
22R-E
3RZ-FE
4.5 (4477)
2.4 (2366)
2.7 (2693)
SNUG SNUG SNUG 0.0019-
3VZ-E
3.0 (2959)
0.0031-
0.0039
0.0327
0.0366
0.0354
0.0028
0.0028
0.0028
3VZ-FE
3.0 (2952)
0.0051-
0.0110-
0.0150-
0.0059-
0.0004-
0.0012-
SNUG
0.0059
0.0197
0.0236
0.0234
0.0031
0.0028
0.0016-
0.0118-
0.0177-
0.0059-
0.0016-
0.0012-
0.0024
0.0205
0.0264
0.0205
0.0031
0.0028
1FZ-FE
4.5 (4477)
SNUG 86823007
ENGINE AND ENGINE OVERHAUL
3-13
PISTON AND RING SPECIFICATIONS All measurements are given in inches. Ring Gap
Engine
Ring Side Clearance
Engine
Displacement
Piston
Top
Bottom
Oil
Year
ID/VIN
Liters (cc)
Clearance
Compression
Compression
Control
1995
22R-E
2RZ-FE
3RZ-FE
5VZ-FE
1FZ-FE
1996
2RZ-FE
2.4 (2366)
2.4 (2438)
2.7 (2693)
3.4 (3378)
4.5 (4477)
2.4 (2438)
Top
Bottom
Compression Compression
Oil
Control
SNUG
0.0008-
0.0098-
0.0236-
0.0079-
0.0012-
0.0012-
0.0016
0.0185
0.0323
0.0224
0.0028
0.0028
0.0022-
0.0118-
0.0157-
0.0051-
0.0008-
0.0012-
0.0031
0.0157
0.0197
0.0150
0.0028
0.0028
0.0019-
0.0118-
0.0157-
0.0051-
0.0008-
0.0012-
0.0019-
0.0024
0.0157
0.0194
0.0150
0.0028
0.0028
0.0024
0.0053-
0.0118-
0.0157-
0.0059-
0.0016-
0.0012-
0.0012-
0.0060
0.0197
0.0236
0.0217
0.0031
0.0028
0.0028
0.0016-
0.0118-
0.0177-
0.0059-
0.0016-
0.0012-
SNUG
0.0024
0.0205
0.0264
0.0205
0.0031
0.0028
0.0022-
0.0118-
0.0157-
0.0051-
0.0008-
0.0012-
0.0031
0.0157
0.0197
0.0150
0.0028
0.0028
0.0118-
0.0157-
0.0051-
0.0008-
0.0012-
SNUG
SNUG
3RZ-FE
2.7 (2693)
0.0019-
0.0024
0.0157
0.0194
0.0150
0.0028
0.0028
0.0024
5VZ-FE
3.4 (3378)
0.0053-
0.0118-
0.0157-
0.0059-
0.0016-
0.0012-
0.0012-
0.0060
0.0197
0.0236
0.0217
0.0031
0.0028
0.0028
1FZ-FE
4.5 (4477)
0.0016-
0.0118-
0.0177-
0.0059-
0.0016-
0.0012-
SNUG
0.0024
0.0205
0.0264
0.0205
0.0031
0.0028
0.0019-
86823008
ENGINE AND ENGINE OVERHAUL
3-14
TORQUE SPECIFICATIONS All readings in
Engine
ft.
lbs.
Engine
Cylinder
Main
Rod
Crankshaft
Displacement
Head
Bearing
Bearing
Damper Bolts
Year
ID/VIN
1989
22 R
2.4 (2366)
53-63
69-83
40-47
120-130
22R-E
2.4 (2366)
53-63
69-83
40-47
3VZ-E
3.0 (2959)
©
3F-E
4.0 (3956)
87-93
© ©
22 R
2.4 (2366)
53-63
69-83
1990
Liters (cc)
1992
1993
76
13-19
26-36
11-15
76
11-15
25-33
11-15
76
60-68
©
©
11-15
116
120-130
73-86
13-19
26-36
11-15
76
120-130
73-86
13-19
26-36
11-15
76
11-15
76 116
120-130
73-86
©
176-186
63-67
40-46
247-259
40-47
3VZ-E
3.0 (2959)
©
©
176-186
63-67
11-15
3F-E
4.0 (3956)
87-93
© ©
25-33
40-46
247-259
60-68
©
©
11-15
22R-E
2.4 (2366)
53-63
69-83
40-47
120-130
73-86
13-19
26-36
11-15
76
3VZ-E
3.0 (2959)
©
©
176-186
63-67
11-15
252-33
11-15
,76
3F-E
4.0 (3956)
87-93
© ©
40-46
247-259
60-68
©
22R-E
2.4 (2366)
53-63
69-83
40-47
120-130
73-86
13-19
3VZ-E
3.0 (2959)
©
©
63-67
3F-E
4.0 (3956)
87-93
0 ©
176-186
40-46
247-259
22R-E
2.4 (2366)
53-63
69-83
40-47
© © ©
©
11-15
116
26-36
11-15
76
11-15
25-33
11-15
76
60-68
©
©
11-15
116
120-130
73-86
13-19
26-36
11-15
76
© ©
176-186
63-67
11-15
25-33
11-15
76
181
61
13
29
13
76
©
304
-
15
29
15
108 76
•
3.0 (2959)
3VZ-FE
3.0 (2952)
1FZ-FE
4.5 (4477)
© © © 53-63
69-83
40-47
120-130
73-86
13-19
26-36
11-15
© © 0 ©
© © © ©
192
©
22
36
14
76
176-186
63-67
11-15
25-33
11-15
76
22R-E
2.4 (2366)
3RZ-FE
2.7 (2693)
3VZ-E
3.0 (2959)
3V7.-FE
3.0 (2952)
1FZ-FE
4.5 (4477)
© © © ©
22R-E
2.4 (2366)
53-63
69-83
2RZ-FE
2.4 (2438)
3RZ-FE
2.7 (2693)
5VZ-FE
3.4 (3378)
FZ-FE
4.5 (4477)
2RZ-FE
2.4 (2438)
3RZ-FE
2.7 (2693)
5VZ-FE
3.4 (3378)
FZ-FE
4.5 (4477)
© © © © © © © ©
© © © © © © © ©
Step
V
18
Step
2:
90 degree
Step
Step
ft.
ft.
7
lbs
turn
lbs.
90 deqree
2:
3 Step 1:27
5
Nut
11-15
40-47
2 Step 1-45
4
Plugs
26-36
13-19
69-83
1
1
Exhaust
Intake
73-86
53-63
1
1996
Bolts
Lug
3VZ-E
1994
1995
Bolts
Bolts
Spark
2.4 (2366)
22R-E
1991
Bolts
Manifold
Flywheel
ft.
lbs.
ft.
lbs.
8
turn
181
61
13
29
13
76
304
-
15
29
15
108
40-47
120-130
73-86
13-19
26-36
11-15
76
©
193
65
22
36
14
76
0 © © © © © ©
©
©
22
36
14
76
176-186
63-67
11-15
25-33
11-15
76
304
-
15
29
15
108
193
65
22
36
14
76
36
14
76
Step 1:27
ft.
©
©
22
176-186
63-67
11-15
25-33
11-15
76
304
-
15
29
15
108
lbs.
Step
2:
90 deqree
turn
Step
3:
90 deqree
turn
Step
1
54
Step
2:
:
ft.
lbs.
90 deqree
turn
2:
33
Step
3:
90 deqree
turn
Step
2:
90 deqree
turn
Step
4:
90 deqree
turn
Step
3:
90 deqree
turn
17mm 19mm 14mm 17mm
9
bolts:
85
ft.
lbs.
bolts:
99
ft.
lbs.
bolts:
37
ft.
lbs.
ft.
lbs.
bolts: 51
Nuts: 41
ft.
10
11
12
1:
25
Step
2:
90 deqree
Step
3:
90 deqree turn
It.
lbs.
Recessed head
turn
bolt:
13
Step 1:35 2'
Step
lbs.
6 Step
Step 1:29
13
ft.
lbs.
lbs.
90 deqree
Step 1:33
ft.
2:
90 deqree
Step
1:
19
Step
2:
90 deqree
Step 1:29 2:
ft.
ft.
turn
lbs.
Step
Step ft.
ft.
turn
lbs.
turn
lbs.
90 deqree
turn
lbs.
86823009
ENGINE AND ENGINE OVERHAUL 11.
Engine
Tag and disconnect the
Vacuum
•
3-15
following wires:
switching valve (VS V) wire at the evaporative
emissions (EVAP) canister
tioning
^CAUTION Please refer to Section
1
before discharging the compres-
sor or disconnecting air conditioning lines.
Damage
to the
conditioning system or personal injury could result.
air
Consult your local laws concerning refrigerant discharge
and recycling.
In
many areas
may be
it
anyone
illegal for
but a certified technician to service the A/C system. Al-
ways use an approved recovery
station
12.
when discharging
the air conditioning system.
the process of removing the engine, you
In
a number of steps which
component
or system,
“remove the
call for
the removal of a separate
most instances, a detailed removal
procedure can be found elsewhere impossible to
is virtually
It
come across
will
“disconnect the exhaust system” or
i.e.
radiator.” In
list
in this
each
and hose
additions to any repair procedure.
and wire
or
hose before
it
is
many
different
are the best possible
Be absolutely sure
to tag
disconnected, so that you can be
assured of proper reconnection during
installation.
Disconnect the negative battery cable.
2.
Remove
the engine undercover or splash shield.
matchmarks around the hinges, then remove the hood. Drain the engine
oil.
and the cylinder
Drain the engine coolant from the
block.
•
Fuel cut solenoid wire
•
Water temperature sender gauge wire
•
Electronic air control
•
Starter wire
•
Oil
pressure switch wire
•
Brake booster hose
•
Main
•
Fuel return line at the fuel return pipe
•
Charcoal canister hose
fuel line at the fuel inlet pipe
•
HAC
•
Vacuum
from the bracket (except
are attracted by ethylene glycol antifreeze,
and are quite an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant may be reused unless it is contaminated or sev-
and Vacuum Switching Valve (VSV)
Calif,
Use a piece
15.
On models
and remove the
way
is left in
air
Drain the automatic transmission
fluid
on models so
Disconnect the
Remove
stiff
its
wire to support
it.
Disconnect
17.
with air conditioning, loosen the drive belt
air
conditioning compressor. Position
stiff
still
attached.
On
it
out of
Use several
wire to support the compressor.
Disconnect the engine ground straps
at the rear
and
the engine.
trucks with a
manual transmission, remove the
shift
lever from inside the truck. 18.
On models
with automatic transmission,
remove the
shift
lever retainer.
20.
Remove the On vehicles
manual
shift
rear driveshaft.
with automatic transmissions, disconnect the
linkage at the neutral start switch.
On 4WD mod-
els with automatic transmission, disconnect the transfer shift
.
the
Remove
the cross-shaft from the body.
Disconnect the speedometer cable. Be sure not
felt
to lose
dust protector and washers.
26.
On 4WD models, remove the transfer case undercover. On 4WD models, remove the stabilizer bar. On 4WD models, remove the front driveshaft. Remove the No. 1 frame crossmember.
27.
Disconnect the oxygen sensor wiring. Disconnect the ex-
23. 24. 25.
28.
Remove On models
the exhaust pipe from the catalytic converter. with
manual transmission, remove the clutch
release (slave) cylinder and air
cleaner hoses and then remove the
29.
Remove
the No.
1
brake tube heat insulator
cleaner. 7.
with
haust pipe at the manifold; remove the clamp from the clutch
years old.
equipped. 6.
of
with the refrigerant lines
housing. 5.
Calif.)
switch, Electronic Bleed Air Control Valve
the ground strap from the bracket.
22.
draining coolant, keep in mind that cats and dogs
any that
(Calif.)
Disconnect the following parts:
the hoses.
21
::*CAUTION
likely to drink
(EACV) valve wire
linkage at the cross-shaft.
10.
eral
Cold mixture heater wire
switch wire
wire (ex. Calif.)
Remove the drive belt. Remove the power steering pump from its bracket (if equipped). Move the pump to one side without disconnecting
19.
Disconnect the windshield washer hose. Scribe
When
•
right side of
»»Apply a lubricant onto any nuts or bolts that will be removed. Allow the lubricant to sit for a short while. This will aid in removal of tight and frozen nuts and bolts.
radiator
HAC
13.
16.
4.
Vacuum
•
pieces of
22R Engine
3.
•
(EBCV)
the
1.
condi-
air
14.
model and engine combinations have been manufactured.
common sense
switching (VS V) valve wire at the
compressor
bracket
manual.
individual wire
which must be disconnected, simply because so Careful observation and
Vacuum
•
REMOVAL & INSTALLATION
the fan coupling with the fan.
8.
Disconnect the two heater hoses at the engine.
9.
Remove
the radiator with the shroud attached.
Disconnect the accelerator cable
at the carburetor.
30. bolts.
On 2WD
31.
(4WD
four support
On 4WD
bolts, raise the
bracket from the transmission.
and the
only).
models, remove the four rear engine mount
Raise the transmission
remove the
its
front floor heat insulator
slightly with
a
member mounting
floor jack
and then
bolts.
models, remove the four rear engine mount transmission slightly with a floor jack and then
ENGINE AND ENGINE OVERHAUL
3-16
remove the four bolts from the side member and remove the No. 2 frame crossmember. 32. Attach an engine hoist chain to the lifting brackets on
Remove
the engine. slowly
the
lift
mount nuts and
the starter.
If
and
automatic transmission, remove
cooler lines from the transmission.
oil
bolts
the engine/transmission out of the truck.
Remove
33.
the engine
57.
Remove
the two
34.
Remove
35.
If
58.
the transmission.
tive
retaining bolts are tight.
support the engine
an engine stand
If
To
install:
37.
Install
lift
or hoist.
the clutch and pressure plate onto the engine.
the transmission onto the engine.
38.
Install
39.
Slowly lower the engine assembly into the engine
compartment.
On 4WD
models, use a
floor jack to raise the transmis-
sion onto the crossmember. Always use a piece of
wood
be-
59.
Align the holes
60.
the engine mounts and the frame,
in
the bolts and then
On 2WD
remove the engine
hoist chain.
models, raise the transmission
slightly
61.
and
engine mount with the support member. Tighten ft.
lbs.
Lower the transmission
(13 Nm).
until
it
on the extension housing and then tighten the bracket
mounting bolts
19
to
On 4WD (95 Nm).
bolts to 9
62.
Install
to the lbs.
slightly
ft.
and
install
70
to
and
tighten the four
the brake tube and front floor
the clutch release (slave) cylinder
Nm) and
the cylinder bolts to 9
Reconnect the exhaust pipe to the
exhaust manifold.
wiring to the
and
ft.
lbs.
its
bracket
bolts to
29
ft.
(13 Nm).
to the catalytic converter
Install
the clamps.
Install
the No.
Install
48.
On 4WD
1
models,
wires removed earlier:
Switching Valve (VSV) wire at the evapora-
Vacuum
Switching Valve (VSV) wire at the
air
condi-
compressor
•
Vacuum
•
HAC
•
Cold mixture heater wire
switch wire
wire (ex. Calif.)
•
Fuel cut solenoid wire
•
Water temperature sender gauge wire
•
EACV
•
Starter wire
•
Oil
wire
(Calif.)
pressure switch wire
Connect the accelerator cable
to the carburetor, don’t
the fan pulley, belt guide, fluid coupling and alter-
Install
Install
conditioning compressor belt
the
air
Install
the
power steering pump and
pump
belt;
pulley locknut to
and adjust
it
32
adjust the belt ft.
lbs.
(43
the radiator and shroud. Install the radiator hoses.
63.
Install
64.
Connect the two heater hoses and air
in
install
the
air
cleaner.
cleaner hoses.
the engine with
and the
65.
Refill
66.
Install
the engine undercover.
67.
Install
the battery.
68.
Install
the hood.
69.
Double check
all
oil
radiator with coolant.
installation items,
paying particular
hoses or hanging wires, untightened
hoses and wires
(too tight or rubbing)
and
at-
nuts,
poor
tools
left
the engine area. 70. With the coil wire disconnected from the distributor,
should pre-oil 71.
warm
49.
Connect the speedometer cable.
50.
On 4WD models
72.
with automatic transmission, install the
cross-shaft to the body. Connect the transfer shift linkage.
Connect the manual
all
Vacuum
routing of
the front driveshaft, stabilizer bar
and the transfer case undercover.
.
its
crank the engine with the ignition key for 5-10 seconds. This
frame crossmember. install
Connect
tention to loose
the
oxygen sensor.
47.
51
Calif.)
switch, Electronic Bleed Air Control Valve
and Vacuum Switching Valve (VS V) with
Calif,
Connect the
(13 Nm).
lbs.
manual transmission. Tighten the bracket
(39
46.
from the bracket (ex.
Nm).
heat insulators. 45.
Vacuum
correctly. Tighten the
(25 Nm).
Lower the transmission and
On 4WD models,
44.
lbs.
frame crossmember-to-side frame bolts
mount
rear engine
ft.
models, raise the transmission
tighten the No. 2 lbs.
HAC
•
correctly.
align the rear
ft.
Charcoal canister hose
•
nator drive belt.
the bolts to 9
43.
•
fuel line at the fuel inlet pipe
forget the tension spring.
tween the jack and the transmission pan.
rests
Fuel return line at the fuel return pipe
•
Tighten the bolts correctly.
42.
Main
•
tioning
not available,
is
an upright position with blocks. Never
in
leave an engine hanging from a
install
earlier:
emissions (EVAP) canister
Mount the engine on an engine stand, making sure the
41.
removed
•
•
manual transmission, remove the clutch cover (pres-
sure plate) and clutch disc.
40.
parts
Brake booster hose
bracket
engine.
36.
all
•
(EBCV)
and the exhaust pipe bracket from the
stiffener brackets
Connect
shift
73.
at least the
Reconnect the
lower part of the engine.
coil wire. Start
the engine, allowing
it
to
Check carefully for leaks. Check and adjust the engine specifications as necessary. Road test the vehicle. Recheck and top fluid levels as up.
needed.
linkage to the neutral start
switch (automatic transmission only). 52.
Install
the rear driveshaft.
53.
Install
the shift lever (manual transmission) or the shift
22R-E Engine I
See Figures
7, 8,
9 and 10
1 Disconnect the windshield washer hose. Scribe matchmarks around the hinges then remove the hood. .
lever retainer (automatic)
54.
Connect the engine ground
55.
Install
the air conditioning compressor.
56.
Install
the
straps.
power steering pump and connect the ground
strap to the bracket.
'Apply
a lubricant onto any nuts or bolts that will be removed. Allow the lubricant to sit for a short while. This will aid in the removal of tight and frozen nuts and bolts. 2.
Relieve the fuel pressure.
ENGINE AND ENGINE OVERHAUL
3-17
3.
Disable the
air
bag system.
1
6.
Remove
the
power steering pump from
bracket
its
(if
equipped).
**CAUTION systems remain under pressure after the engine has been turned OFF. Properly relieve the fuel pressure before disconnecting any fuel lines. Failure to do Fuel injected engine
17.
Disconnect the ground strap from the bracket.
18.
On models
ant lines 19.
may
so
result in fire or personal injury.
Disconnect the negative battery cable.
5.
Remove
6.
Drain the engine
and the cylinder
radiator
remove the
out of the
way
On
air
condi-
with the refriger-
attached.
and
at the rear
engine.
manual transmission, remove the
trucks with a
shift
lever from inside the truck.
the engine undercover. oil.
still
it
Disconnect the engine ground straps
right side of the
20. 4.
with air conditioning,
tioning compressor. Position
21.
Drain the engine coolant from the
block.
22.
Remove the rear driveshaft. On models with automatic transmission,
manual 23.
^CAUTION
shift
disconnect the
linkage at the neutral start switch.
On 4WD models
with automatic transmission, disconnect
the transfer shift linkage at the cross-shaft.
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize you exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.
24.
Remove
25.
Disconnect the speedometer cable. Be sure not
the
the cross-shaft assembly from the body. to lose
dust protector and washers.
felt
(4WD (4WD only). driveshaft (4WD only).
29.
Remove Remove Remove Remove
30.
Disconnect the oxygen sensor wiring. Disconnect the ex-
26. 27. 28.
the transfer case undercover
only).
the stabilizer bar the front the No.
1
frame crossmember.
haust pipe at the manifold; remove the clamp from the clutch Drain the automatic transmission
7.
fluid
on models so
Remove Remove
8. 9.
the air cleaner case
and the intake
air
hose.
the exhaust pipe from the catalytic converter. with
manual transmission, remove the
release (slave) cylinder and 32.
the radiator and shroud.
Remove On models
housing. 31.
equipped.
Remove
the No.
1
33. bolts.
When
draining coolant, keep in mind that cats and
are attracted by ethylene glycol antifreeze,
drink any that
likely to
puddles on the ground. This
in
Always drain coolant Coolant may be reused unless
and are quite
an uncovered container or
is left in
quantity.
dogs
will
prove
fatal in sufficient
into a sealable container. is
it
contaminated or sev-
years old.
eral
10.
34.
11.
Loosen the power steering pulley locknut and remove
If
On 4WD
remove the
belt.
equipped with
35.
36.
the
air
slightly with
a floor jack and then
bolts.
models, remove the four rear engine mount transmission slightly with a floor jack and then
four bolts from the side
member and remove
the
No. 2 frame crossmember. Attach an engine hoist chain to the
the engine.
power steering
models, remove the four rear engine mount
Raise the transmission
bolts, raise the
and the
only).
remove the support member mounting
slowly
the
On 2WD
(4WD
clutch
bracket from the transmission.
front floor heat insulator
brake tube heat insulator
**CAUTION
its
oil
lift
Remove
the engine
lifting
mount nuts and
brackets on bolts
and
the engine/transmission out of the truck.
Remove
the starter.
If
automatic transmission, remove
cooler lines from the transmission.
Remove
the two
remove the compressor
conditioning,
belt.
12.
fan
Remove
the alternator drive
and the fan
13.
belt, fluid
coupling for the
pulley.
Disconnect the following wires and connectors: •
Ground
•
Alternator connector
strap from the
•
Igniter
•
Alternator wires
left
fender apron
and wire
• Coil wire from distributor •
Ground
•
Electronic Control Unit
•
Starter relay connector (manual transmission only)
•
The check connector
strap at rear of engine
• Air conditioning 14.
(ECU)
compressor connector
Disconnect and label these hoses:
fuel filter
and
air pipe,
hose and cruise control vacuum hose 15.
cable
if
Disconnect the accelerator cable,
automatic transmission if
so equipped.
air
hoses from the
brake booster hose, charcoal canister
(if
so equipped. throttle
cable for the
so equipped) and the cruise control
Fig. 7
Remove
to the
engine and manifold
the bolts securing the front exhaust pipe
3-18
ENGINE AND ENGINE OVERHAUL and the exhaust pipe bracket from the
stiffener brackets
engine. 37.
Remove
38.
If
the transmission.
manual transmission, remove the clutch cover
(pres-
sure plate) and clutch disc.
Mount the engine on an engine stand, making sure the
39.
retaining bolts are tight.
support the engine
an engine stand
If
not available,
is
an upright position with blocks. Never
in
leave an engine hanging from a
lift
or hoist.
To
install:
40.
Slowly lower the engine assembly into the engine
compartment. Raise the transmission onto the crossmember with a
41.
floor jack.
mounts and the frame, remove the engine hoist chain. On 2WD models, raise the transmission slightly and the rear engine mount with the support member and Align the holes in the engine
42. install
43. align
the bolts and then
tighten the bolts to 9
ft.
lbs.
(13 Nm). Lower the transmission
on the extension housing and then tighten the bracket mounting bolts to 19 ft. lbs. (25 Nm). 44. On 4WD models, Raise the transmission slightly and until
it
rests
70
tighten the No. 2 frame crossmember-to-side frame bolts to ft.
lbs.
(95 Nm). Lower the transmission and tighten the four
rear engine 45.
mount
On 4WD
bolts to 9
models,
(13 Nm).
lbs.
ft.
the brake tube and front floor
install
heat insulators. 46. to the lbs.
Install
the clutch release (slave) cylinder and
manual transmission. Tighten the bracket
(39
Nm) and
the cylinder bolts to 9
47.
Reconnect the exhaust
48.
Install
49.
On 4WD
the No.
ft.
lbs.
bracket
its
bolts to
29
ft.
(13 Nm).
pipe.
frame crossmember.
1
models,
install
the front driveshaft, stabilizer bar
and the transfer case undercover. 50.
Connect the speedometer cable.
51.
Connect the transfer
4WD
models with
shift
linkage on
shift
linkage to the neutral start
automatic transmission. 52.
Connect the manual
switch (automatic transmission only). 53.
Install
the rear driveshaft.
54.
Install
the shift lever (manual transmission only).
55.
Connect the engine ground
56.
Install
the air conditioning compressor.
57.
Install
the
straps.
power steering pump and connect the ground
strap.
58.
Connect the accelerator cable,
matic transmission
cable 59.
if
(if
to the charcoal canister, the
booster, the cruise control
60.
Fig.
10
On 4WD models, remove these frame
crossmember
filter
and
if
so equipped and the
air
brake
hoses
air pipe.
Attach the wires and connectors: •
Ground
•
Alternator connector
strap from the
left
fender apron
and wire
•
Igniter
•
Alternator wires
•
Coil wire
•
Ground
•
Electronic control unit
from distributor
strap at rear of engine
(ECU) connectors
• Starter relay connector (manual transmission only) •
bolts
cable for the auto-
removed.
Connect the hoses
the fuel
throttle
so equipped) and the cruise control
The check connector
• Air conditioning compressor connector
to
ENGINE AND ENGINE OVERHAUL 61.
Install
3-19
the fan pulley, belt guide, fluid coupling and alter-
nator belt. 62.
Install
the air conditioning compressor drive
63.
Install
the
rectly.
power steering pump
Tighten the
pump
belt
32
pulley locknut to
belt.
and adjust ft.
lbs.
it
cor-
(43 Nm).
64.
Install
the radiator and shroud.
65.
Install
the air cleaner case and the intake duct.
66.
Install
the proper
67.
Install
the undercover or splash shield below the engine.
68.
Install
the battery.
69.
Install
the hood.
70.
Double check
tention to loose
all
amounts
oil
and coolant.
installation items,
paying particular
at-
hoses or hanging wires, untightened
nuts,
poor
and
tools
left
hoses and wires
routing of
of
(too tight or rubbing)
the engine area.
in
With the
71.
coil
wire disconnected from the distributor,
crank the engine with the ignition key
for
5-10 seconds. This
should pre-oil at least the lower part of the engine.
Reconnect the
72.
warm 73. 74.
coil wire. Start
the engine, allowing
it
to
Check carefully for leaks. Check and adjust the engine specifications as necessary. Road test the vehicle. Recheck and top fluid levels as
needed.
10. ling
11.
See Figures
11, 12, 13, 14, 15, 16
and 17
Relieve the fuel pressure.
1
Remove
and fan
3VZ-E Engine >
Hold the fan while loosening the retaining bolts
Fig. 11
up.
^CAUTION
drive belts
all
•
Igniter
•
Oil
•
Electronic Control Unit
•
Vacuum
•
Starter relay (manual transmission only)
pressure switch
Solenoid resistor
the engine has been turned OFF. Properly receive the fuel
•
Check connector
may
lines. Failure to
do
result in fire or personal injury.
• Air conditioning 12.
Disconnect the windshield washer hose. Scribe
2.
matchmarks around the hinges, then remove the hood. Disconnect the battery cables and remove the battery.
3.
•
Brake booster
•
Cruise control
•
Vacuum
Remove
Drain the engine
radiator
the engine undercover.
and the
oil.
1
3.
14.
Drain the engine coolant from the
cylinder block.
is left in
and cruise
control cable
Unbolt the power steering
throttle control
if
and are quite an uncovered container or
pump and
position
puddles on the ground. This will prove fatal in sufficient Always drain coolant into a sealable container. Coolant may be reused unless it is contaminated or sev-
On manual
Disconnect the two heater hoses from the engine.
18.
Disconnect and plug the
19.
20.
Remove Remove
21.
Disconnect the manual
fuel inlet
and
years old.
Drain the automatic transmission
fluid
on models so
23.
equipped. 24.
Disconnect the
air
cleaner hose and then remove the
air
25.
cleaner.
9.
Remove Remove
outlet lines.
the shift levers (manual transmission only). the rear driveshaft. shift
linkage (automatic transmis-
sion only). 22.
8.
out of
transmissions, disconnect the clutch release
Disconnect the speedometer cable
— don't
dust protector and washers.
7.
it
17.
in
6.
cable
equipped.
way with the hydraulic lines still connected. 15. Remove the air conditioning compressor equipped. Position is out of the way with the lines still attached.
quantity.
eral
— (automatic transmissions)
Disconnect the accelerator cable,
the
16.
draining coolant, keep in mind that cats and dogs drink any that
equipped)
(slave) cylinder hose.
are attracted by ethylene glycol antifreeze, likely to
(if
if
•'CAUTION When
vacuum hose
Switching Valve (VSV)
• Oil cooler
(auto, trans.)
5.
compressor
Tag and disconnect the following hoses: • Air hoses at the gas filter and air pipe
• Charcoal canister hose at the canister
••Apply a lubricant onto any nuts or bolts that will be removed. Allow the lubricant to sit for a short while. This will aid in the removal of tight and frozen nuts and bolts. 4.
(ECU)
Switching Valve (VSV)
•
so
coup-
fluid
Tag and disconnect the following wires and connectors: • Left side and rear ground straps • Alternator connector and wire
Fuel injected engine systems remain under pressure after
pressure before disconnecting any fuel
and then remove the
pulley.
26.
the cooling fan. 27.
the radiator.
Remove Remove Remove Remove Remove
the transfer case undercover. the stabilizer bar.
the front driveshaft. the No.1 frame
crossmember.
the front exhaust pipe.
lose the
felt
3-20
ENGINE AND ENGINE OVERHAUL 28.
Remove
the front floor heat insulator and the brake tube
heat insulator. 29.
Remove
the four rear engine
slightly with
transmission
mount bolts. Raise the and remove the bolts
floor jack
a
securing the bracket and frame crossmember. 30. Attach an engine hoist chain to the lifting brackets on the engine. slowly 31.
the
lift
Remove
the engine
mount nuts and
Remove
the starter.
If
and
automatic transmission, remove
cooler lines from the transmission.
oil
bolts
the engine/transmission out of the truck.
stiffener brackets
Remove
the two
and the exhaust pipe bracket from the
engine. 32.
Remove
33.
If
the transmission.
manual transmission, remove the clutch cover (pres-
sure plate) and clutch disc.
Mount the engine on an engine stand, making sure the If an engine stand is not available, support the engine in an upright position with blocks. Never 34.
retaining bolts are tight.
leave an engine hanging from a
Fig.
14
Remove
lift
or hoist.
the bolts securing the front exhaust
pipe to the manifold
Fig.
16
.
.
.
then remove the remaining bracket bolts
ENGINE AND ENGINE OVERHAUL 54.
55.
3-21
Connect the hoses: hoses
•
Air
•
Brake booster
•
Cruise control
•
Charcoal canister hose
•
Vacuum
at the fuel filter
and
vacuum hose
air
(if
pipe
equipped)
at the canister
Switching Valve (VSV)
Connect the
wires:
and
rear ground straps
•
Left side
•
Alternator connector
•
Igniter
•
Oil
•
Electronic Control Unit
•
Vacuum
•
Starter relay (manual transmission only)
•
Solenoid resistor
•
Check connector
and wire
pressure switch
(ECU)
Switching Valve (VSV)
• Air conditioning compressor 56.
Install
the fan pulley, belt guide, fluid coupling and drive
belt.
To
install:
After connecting the transmission to the engine
35.
and
in-
engine compartment.
Raise the transmission onto the
36.
floor jack.
Be
certain to
Align the holes
37.
38.
in
For
2WD
floor jack.
the engine mounts and the frame,
the bolts and then
install
remove the engine
hoist chain.
vehicles, install the rear engine
tighten
them
resting
it
9
to
ft.
lbs.
mount; tighten the bolts to 19 39.
On 4WD
ft.
Install
lbs.
ft.
(25
in
and
43.
Install
the front driveshaft.
44.
Install
the stabilizer bar
.
(95 Nm).
45.
and the
transfer
case under-
Connect the speedometer cable.
cover.
Connect the manual
shift
ft.
the radiator and attach the shroud.
60.
Install
the air cleaner.
Refill
the ground
lbs.
the engine with
(43 Nm).
oil
and the
the engine undercover.
61.
Install
62.
Install
and adjust the hood.
63.
Install
the battery.
64.
Double check
all
paying particular
installation items,
at-
hoses or hanging wires, untightened
nuts,
poor
and
tools
left
hoses and wires
(too tight or rubbing)
the engine area.
With the
coil
wire disconnected from the distributor, ignition
key
for
5-10 seconds. This
should pre-oil at least the lower part of the engine. 66.
frame crossmember-to-side frame bolts to 70
42.
41
32
Install
65.
warm 67.
rear engine
40.
pulley locknut to
crank the engine with the
Lower the transmission and tighten the four mount bolts to 9 ft. lbs. (13 Nm). Install the brake tube and front floor heat insulators. Reconnect the exhaust pipe. Install the No. 1 frame crossmember.
lbs.
pump
belt.
pump and connect
59.
routing of
the bracket to the
Nm)
vehicles, raise the transmission slightly
tighten the No. 2
and
(13 Nm). Lower the transmission,
on the extension housing.
the power steering
tention to loose
mount and
bracket. Install the bolts holding the bracket to the support
Install
radiator with coolant.
with a
use a broad piece of wood between
pan and the
the transmission
crossmember
Inspect and replace the air conditioning
58.
strap. Tighten the
lower the engine assembly into the
stalling the starter, slowly
57.
68.
Reconnect the
coil wire. Start
the engine, allowing
it
to
Check carefully for leaks. Check and adjust the engine specifications as necessary. Road test the vehicle. Recheck and top fluid levels as up.
needed.
5VZ-FE Engine
2WD MODELS >
See Figures
18, 19, 20, 21
and 22
linkage (automatic transmission
^Apply
only).
46.
Install
the rear driveshaft.
47.
Install
the
48.
Install
the fuel
49.
Connect the heater hoses.
shift
levers (manual transmission only). inlet
and
a lubricant onto any nuts or bolts that will be removed. Allow the lubricant to sit for a short while. This will aid in the removal of tight and frozen nuts and bolts.
outlet lines. 1
50.
Connect the clutch release
51
.
Install
the air conditioning compressor.
52.
Install
the
(slave) cylinder hose.
.
Remove
the hood.
2.
Relieve the fuel pressure.
3.
Disable the
power steering pump and connect the ground
air
bag system. Refer
to Section 6.
i'CAUTION
strap.
53.
Connect the
cables.
throttle,
cruise control
and accelerator
Work must be
started only after 90
the ignition switch
is
negative battery cable
turned to the is
seconds from the time position and the
LOCK
disconnected.
4.
Disconnect the battery and remove
5.
Raise and safely support the vehicle.
6.
Remove
the engine under covers.
it
from the vehicle.
ENGINE AND ENGINE OVERHAUL
3-22 7.
Drain the engine coolant.
8.
Drain the engine
oil.
l-i'CAUTION The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize you expo9. sure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.
Remove Remove
10.
the radiator.
power steering
the
Stretch the belt
a.
drive belt:
and loosen the fan
pulley mounting
bolts.
Loosen the
b.
lock, pivot
and adjusting
Remove
bolts.
the
drive belt from the engine. 11.
If
equipped with A/C, remove the A/C drive
ening the
idle pulley nut
Loosen the
12.
the alternator
lock, pivot
belt
by loos-
bolt.
and adjusting
bolts,
then remove
belt.
Remove
13.
and adjusting
the fan with the
fluid
coupling and the fan
pulleys.
Disconnect the power steering
14.
and
set aside.
15.
If
Do
pump
from the engine
not disconnect the lines from the
pump.
equipped with A/C, disconnect the compressor from
the engine and set aside.
Do
not disconnect the lines from the
compressor.
Remove
16.
the
air
cleaner
lid,
Mass
Air
Flow (MAF) meter
and resonator. 17.
Remove
18.
Disconnect the following cables:
the air cleaner case and
filter
assembly.
the vehicle has cruise control, disconnect the detent
•
If
•
Accelerator
cable
• Throttle cable on automatics 19.
Disconnect the heater hoses.
20.
Disconnect the following hoses: •
Brake booster vacuum
•
Evaporative emissions (EVAP)
•
Fuel return
a.
•
Fuel
b.
24.
If
inlet
Disconnect the starter wire and connectors as follows:
21. a.
Remove
b. c.
23. a.
c.
the
shift lever
knob.
the six bolts to retrieve the shift lever
Disconnect the positive battery cable.
25.
Disconnect the starter wires and connectors.
26.
Remove Remove
27.
Disconnect the speedometer cable.
Remove the engine harness as follows: Remove the four screws to the right front door
b.
Remove
clip retaining
Remove
28. scuff
the cowl panel side trim.
c.
Disconnect the Electronic Control Unit (ECU) wiring.
d.
Detach the two connectors from the cowl
e.
Disconnect the
wire.
igniter.
Detach the ground
strap.
g.
Disconnect the
engine wire clamps.
h.
Pull the
six
shift
the four screws and the shift lever boot.
and gasket.
engine wire from the compartment.
assem-
the stabilizer bar. the driveshaft from the transmission.
the front exhaust pipe as follows:
a.
Disconnect the heated oxygen sensor.
b.
Remove
plate.
f.
Remove Remove Remove
bly
the bolt retaining the ground strap.
Disconnect the alternator harness.
22.
equipped with a manual transmission, remove the
lever as follows:
the two bolts and retainer holding the front
pipe to the catalytic converter.
Remove the three bolts and the support bracket. Loosen and remove the three nuts holding the front pipe and gaskets. c.
d.
29.
If
equipped with with a manual transmission, remove the
slave cylinder. 30.
On
31
Place a jack under the transmission.
.
automatic transmissions, remove the cross-shaft.
ENGINE AND ENGINE OVERHAUL
32.
Remove
the eight bolts retaining the transmission rear
mounting bracket. 33.
If
equipped with A/C, remove the
bolt
and disconnect the
Attach the engine hoist chain to the two engine hangers.
35.
Remove Lift
To
install: Install
Do not tighten them. Remove the engine hoist from
Raise and support the transmission
Nm) along lbs.
with the bolts to the
9
install
ft.
lbs.
the slave cylinder,
(12 Nm).
and attach the pipe
nuts. Tighten the nuts to
to the
to
43
ft.
ft.
engine lbs.
(44
the support bracket and tighten the bolts to 33
(44 Nm).
lbs.
mounting bracket insulator
lbs.
Install
47.
Attach the stabilizer bar.
48.
Install
its
new
gasket, secure the
Install
the shift lever boot.
c.
Install
the shifter lever knob.
Connect the engine harness and
c.
Attach the ground strap.
and connect the
d.
Install
e.
Attach the two connectors to the cowl wire.
igniter.
Connect the Electronic Control
f.
h.
assembly
wiring:
b.
g.
Unit (ECU).
Install
the scuff plate to the vehicle.
Install
the cowl panel side trim.
Connect the alternator wires.
50.
Attach the starter wires: a.
Install
the starter clamps and connectors.
b.
Install
the nuts and attach the positive battery cable.
c.
Install
the ground strap.
Connect the hoses: •
Fuel
•
Fuel return
•
Evaporative emissions (EVAP)
inlet
• Brake booster 53.
shift lever
Push the engine wiring into the cabin. Connect the engine wire clamps.
a.
52.
to the
(48 Nm).
retainers.
b.
49.
51.
lbs.
the shift lever assembly:
Using a
with
(38 Nm).
ft.,
the driveshaft.
46.
a. ft.
35
Attach the speedometer cable.
45.
(18 Nm).
Tighten the engine mounting nuts and bolts to 28
36
Connect the two heated oxygen sensors.
d. bolt.
slightly to install the
frame
to the
Connect the exhaust pipe with a new gasket
c.
the engine hangers.
40
ft.
Install
lbs.
ft.
and
equipped with A/C, connect the A/C wire with the
If
13
to
catalytic converter. Tighten the bolts to
39.
(58 to
install bolts
the gaskets
new mounting
b.
mounting bracket. Tighten the bolts
the
Nm).
the engine assembly to the vehicle. Attach the
engine mounts to the body mountings, then
transmissions,
mounting bolts
Install
a.
with
the engine and transmission out of the vehicle.
37.
install
Attach the front exhaust pipe:
44.
the four bolts and nuts holding the front mount-
ing insulators to the frame.
38.
On manual
43.
tighten the
34.
nuts.
equipped with an automatic transmission,
If
cross-shaft.
wire.
36. 41.
42.
3-23
vacuum
Connect the heater hoses.
ENGINE AND ENGINE OVERHAUL
3-24
•
If
equipped with cruise
Disconnect the following cables: • Cruise control actuator and bracket
18.
Connect the following cables:
54.
control, attach the actuator
• Accelerator cable
cable with bracket
55.
•
Accelerator cable
•
On
Install
56.
Install
19.
the air cleaner case and
20.
Mass
the
filter.
Flow (MAF) meter, resonator and
Air
On
58.
Install
vehicles with A/C,
the fan,
install
Disconnect the following hoses:
air
the compressor.
couplings and pulleys. Tighten to 48
fluid
59.
Install
the alternator and A/C drive belts.
60.
Install
the
61.
Install
the radiator.
62.
Fill
the engine with
63.
Fill
the cooling system.
64.
Attach the engine splash shield.
65.
Start the engine
4. 66.
Top
off
power steering pump,
any
drive belt.
See Figures 1.
Disable the
2.
Remove Remove
3.
Remove Remove
c.
Disconnect the Electronic Control Unit (ECU).
d.
Disconnect the wires leading to the cowl.
e.
Remove
bag system.
from the vehicle.
it
'•-•'CAUTION seconds from the time the the LOCK position and the
started after 90
ignition switch is turned to
disconnected.
is
5.
Raise and support the vehicle safely.
6.
Remove
7.
Drain the engine coolant.
8.
Drain the engine
9.
Remove Remove
g.
Remove
h.
Pull out the
On A/C
lock, pivot
12.
14.
Disconnect the
To
install: Install
15.
On A/C
Do
Remove
the
air
Remove If
31.
Tighten the engine mounting nuts and bolts to 28
lid,
Install
the
e.
Attach the two connectors to the cowl wire.
and adjusting
g.
Install
the scuff plate to the vehicle.
h.
Install
the cowl panel side trim.
bolts.
Remove
bolts.
Remove
the
Remove
the
air
compressor from the
cleaner assembly.
bolt.
lbs.
35.
Flow (MAF) meter 36.
and connect the
igniter.
Connect the Electronic Control Unit (ECU).
Connect the alternator wires.
33.
pump.
Air
ft.
wiring:
Attach the ground strap.
and resonator. 17.
Connect the engine harness and
c.
the engine and set aside.
Mass
the engine hoist chain from engine hangers.
equipped with A/C, connect the A/C wire with the
d.
not disconnect the lines from the
cleaner
the bolts and
30.
compressor. 16.
Install
bolts.
and adjusting
vehicles, disconnect the
the vehicle. Attach the
29.
the fan, fluid coupling and pulleys.
engine and set aside.
in
nuts but do not tighten them.
drive belt.
not disconnect the lines from the
the engine assembly
engine mounts to the body mountings.
b.
and adjusting
PS pump from
to the frame.
the engine out of the vehicle.
28.
34.
Remove
the bolts and nuts holding the engine front
drive belt:
drive belt.
Do
Lift
f.
13.
and disconnect the
Push the engine wiring into the cabin. Connect the engine wire clamps.
vehicles, loosen the idle pulley nut
pivot
bolt
Remove
mounting insulators
drive belt.
remove the A/C Loosen the lock,
remove the
Attach the engine hoist chain to the two engine hangers.
the radiator.
Loosen the
engine wire from the cabin.
vehicles,
26.
a.
b.
the wire clamps.
25.
32.
Loosen the fan pulley mounting
the wiring to the igniter.
compressor wire clamp.
oil.
a.
the cowl panel side trim.
(38 Nm).
the engine splash shields.
Power Steering (PS)
the right front door scuff plate.
Disconnect the ground strap.
27.
bolt to
positive battery
b.
f.
Disconnect the battery and remove
On A/C
and disconnect the
Detach the engine harness:
a.
**Apply a lubricant onto any nuts or bolts that will be removed. Allow the lubricant to sit for a short while. This will aid in the removal of tight and frozen nuts and bolts.
11.
the nuts
23.
for leaks.
the hood.
the
the ground strap.
Disconnect the three starter wire clamps.
24.
10.
Removq Remove
Disconnect the alternator harness.
and 22
negative battery cable
inlet
22.
the transmission from the vehicle.
Work must be
Fuel
c.
oil.
fluid levels.
air
Fuel return
•
cable.
and check
18, 21
Evaporative emissions (EVAP) hose
•
b.
4WD MODELS I
Brake booster vacuum hose
•
a.
and
pulley
•
Disconnect the starter wire:
21.
inch lbs. (5 Nm).
automatics, remove the throttle cable
Disconnect the heater hoses.
cleaner cover. 57.
On
•
A/T, connect the throttle cable
Attach the starter wires: the starter clamps and connectors.
a.
Install
b.
Install
the nuts and attach the positive battery cable.
c.
Install
the ground strap.
Connect these hoses: •
Fuel
•
Fuel return
•
Evaporative emissions (EVAP)
•
Brake booster vacuum
inlet
Connect the heater hoses.
ENGINE AND ENGINE OVERHAUL 37.
c.
equipped with cruise
d.
•
If
control, attach the actuator
the bolts retaining the
cable with bracket • Accelerator cable
On
• 38.
Install
the air cleaner case and
39.
Install
the
Mass
Air
filter.
the A/C compressor
41
Install
the fan, coupling and pulleys. Tighten the nuts to
g.
equipped.
i.
Nm).
lbs. (5
the A/C drive
43.
Install
the power steering pump, pulley and drive
44.
Install
the radiator.
45.
Fill
the engine with
46.
Fill
the cooling system.
belt.
10.
oil.
pump
the hood.
Install
48.
Attach the engine splash shield. the transmission
Install
50.
Start the
51.
Top
off
in
for leaks.
a. b.
Loosen the
fluid levels.
d.
1 1
23, 24, 25, 26, 27,
28 and 29
.
OFF. Disable the
ignition
bag system,
air
not already done, disconnect the battery cables, nega-
is
tive battery terminal is
the removal of tight and frozen nuts and bolts.
5.
Remove
6.
Drain the engine
the engine splash shield. oil,
transmission
fluid
and cooling
system.
[-CAUTION The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including can-
You should make every
cer!
sure to used engine
when changing
the
oil.
oil.
effort to
minimize you expo-
Protective gloves should be
Wash your hands and any
worn
other
exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.
To remove the
7. a. b.
Remove Remove
radiator:
the parking lights from the the two
fillers.
mount
nuts.
pump
transmissions, disconnect the accelerator
automatics, disconnect the accelerator and throttle throttle
body.
For vehicles with cruise control, remove the actuator
the air cleaner top,
16.
air
Mass
Flow (MAF) meter
Air
cleaner assembly.
intake air connector. with A/C, disconnect the
compressor and
bracket: a.
Disconnect the A/C compressor wiring.
b.
Remove
the mounting bolts
and mounting bracket. Do
A/C pressure lines from the compressor. Suspend the compressor away from the engine.
'»Apply a lubricant onto any nuts or bolts that will be removed. Allow the lubricant to sit for a short while. This will aid in
pulley
not disconnect the
disconnected.
Matchmark the hood hinges, then remove the hood. Relieve the fuel system pressure.
3.
On
Remove the On vehicles
15.
equipped with a back-up power source. To avoid possible air bag deployment, do not start working on the vehicle until 90 seconds has elapsed from the time the ignition switch is turned OFF and the nega-
4.
pump
the fan (with clutch) and the water
and resonator. Remove the
!-CAUTK)N bag system
alternator drive belt.
the water
On manual
Remove
14.
air
bolts.
bolts for the alter-
cover and disconnect the cable.
tive first.
The
and adjusting
,
cables from the 13.
If
adjust-
if
equipped. 2.
and
cable from the throttle body. 12.
Turn the
1.
lock, pivot
remove the
Remove Remove
c.
2RZ-FE and 3RZ-FE Engines See Figures
and
fan clutch, water
belt, fan,
and fan shroud as follows: Loosen the water pump pulley mounting
pulley.
>
idler pulley nut
bolt
drive belt.
pulley,
nator and
the vehicle.
engine and check
any
On A/C vehicles, loosen the Remove the drive belt. Remove the alternator drive
9.
remove the
ing bolt.
47.
49.
equipped with power steering, loosen the lock
If
adjusting bolt to the idler pulley, then
belt.
pull
the radiator from the vehicle. 8.
Install
42.
if
h.
Install
48 inch
Remove the No. 2 fan shroud equipped. On automatics, disconnect the oil cooler hoses. Remove the lower radiator hose. Remove the four bolts retaining the radiator, and
f.
air
40. .
remove
hose.
Flow (MAF) meter, resonator and
if
to
air pipe.
Disconnect the upper radiator hose and the reservoir
e.
ATT, connect the throttle cable
cleaner cover. '
Remove the grille from the vehicle. On some California models you may need
Connect the following cables:
3-25
grille.
c.
Remove
the compressor bracket.
17.
Detach the alternator
18.
Remove
wiring.
the heater hoses at the cowl.
ENGINE AND ENGINE OVERHAUL
3-26
Disconnect the following hoses:
19.
•
Brake booster vacuum
•
Evaporative emissions (EVAP)
•
On
vehicles with
power
Disconnect the front exhaust pipe from the exhaust man-
22.
and
ifold
catalytic converter
Disconnect the two heated oxygen sensors connectors.
b.
Remove
steering, disconnect the two
exhaust pipe
hoses •
Fuel return
•
Fuel
a.
the
the two bolts and retainer holding the front to the catalytic converter.
Loosen the clamp
c.
bolt
and disconnect the clamp from
the support bracket.
inlet
Remove
20.
as follows:
a.
power steering pump: tool 09960-10010
Using special service
or an
d.
Remove
e.
Disconnect the three nuts, front exhaust pipe and gas-
the two bolts to release the support bracket.
equivalent spanner wrench, remove the nut and power steer-
kets from the exhaust manifold.
ing pulley.
23.
b.
Remove
the two bolts and disconnect the
power
steer-
bly
On manual
transmissions,
remove the
shift lever
assem-
as follows:
ing
pump.
a.
21.
Disconnect the following engine wiring:
b.
Remove Remove
c.
Loosen the
the shift lever knob.
the
shift lever boot.
a.
Remove
b.
Disconnect the ground strap from the cowl top panel.
and
c.
Disconnect the two engine wire clamps.
24.
Remove
d.
Remove
25.
Disconnect the speedometer cable from the transmission.
the cowl panel and pull out the engine wire from the vehi-
26.
cles cabin.
27.
On manual transmissions, remove the slave On automatics, remove the cross-shaft.
28.
Disconnect the wires at the
the igniter connection
the nuts holding the engine wire retainer to
baffle,
retaining bolts for the shift lever
assembly
then remove. the driveshaft from the vehicle.
starter.
cylinder.
ENGINE AND ENGINE OVERHAUL Position a jack
29. sion,
and wooden block under the transmis-
then remove the rear engine mounting bracket.
30.
Attach a suitable engine
31
Remove
.
•Make all
hoist to the
engine hangers.
is
39.
On manual transmissions, On automatics, install the
cross-shaft. to the transmission.
Connect the speedometer Install
42.
On manual
43.
the engine/transmission out of the vehicle.
Carefully
To
install:
33.
Attach the engine hoist to the engine hangers. Carefully
lower the engine/transmission into the vehicle.
Keep
34.
mount
the engine
Install
fasteners, but
(62 Nm).
fully
the brackets to 29
Position a jack
35. sion,
then
install
bolts to the
mount 36.
to
13
mounts
to
28
to
19
lbs (18
ft.
ft.
lbs.
(58
Nm) and
d.
Install
lbs.
Connect the engine
44.
the jack and engine hoist. Tighten the engine ft.
new gasket on
a
14
to
ft.
29
Ib.s
(19 Nm).
and attach
the front pipe
Connect the heated oxygen sensor
e.
the bolts to the
Nm).
(39 Nm).
lbs.
ft.
Connect the clamp and tighten
catalytic converter. Tighten the bolts to
the rear engine mounting bracket. Tighten the
frame
Remove
and wooden block under the transmis-
ft.
lbs.
to the
(39 Nm).
wiring.
wire:
Push the engine wire through the cowl panel.
a.
lbs.
ft.
the support bracket with the two bolts. Tighten
Install
c.
tighten them.
assembly,
shift lever
the nuts and bolts, tighten the nuts to 46
the engine
b.
do not
the
install
knob.
shift
the two gaskets and the front pipe to the mani-
Install
fold. Install
while aligning the engine mounts.
level,
transmissions,
the front exhaust pipe to the manifold:
Install
a.
the slave cylinder.
install
the driveshaft.
boot and
shift lever
32.
starter wires.
40.
clear of
the wiring and hoses. lift
Connect the
38.
41.
the nuts and bolts from the engine mounts.
sure the engine/transmission assembly
37.
3-27
Install
the nuts to hold the engine wire retainer to the cowl.
(38 Nm).
b.
Attach the ground strap to the cowl panel.
c.
Attach the igniter harness to the
d.
Install
unit.
the two connectors to the cowl wire.
45.
Attach the alternator wires.
46.
Install
the power steering
the bolts to 43
pump
to the bracket, tighten
(58 Nm).
lbs.
ft.
With special service tool 09960-10010 or an equivalent
47.
spanner wrench,
install
nut to 32
(43 Nm).
lbs.
ft.
the
power steering
pulley, tighten the
Connect the following hoses:
48.
Brake booster vacuum
• •
Evaporative emissions (EVAP)
•
On
•
Fuel return
•
Fuel
vehicles with
power
two
steering, connect the
hoses
28 Remove the bolts retaining the rear engine mounting bracket Fig.
inlet
49.
Connect the engine heater hoses
50.
On
vehicles with A/C
lbs.
lbs.
ft.
Install
52.
install
the water
them
pump
pulley
pulley mounting nuts but
the alternator drive
c.
Install
Stretch the belt tight
do not
belt.
and tighten the fan nuts
to
16
ft.
Nm).
Adjust the drive belt for the alternator.
e.
equipped with A/C,
53.
If
54.
Install
55.
On manual
the adjust the
to the throttle
On
install
and adjust the drive
power steering
belt.
drive belt.
transmissions, connect the accelerator cable
body.
automatics, connect the accelerator and throttle
cables to the 57.
pump
at this time.
d.
lbs. (21
56.
pulley, fan shroud, fan with fan
in position.
the water
Install
b.
tighten
be removed
ft.
belt:
Place a fan (with the fan clutch), water
a.
engine mount retainers must
pump
and alternator drive
and and shroud
right
(25 Nm).
the intake air connector, tighten the bolts to 13
(18 Nm).
clutch,
and
(44
lbs.
ft.
Attach the A/C compressor to the bracket, tighten the
51.
left
cowl panel.
Nm). b.
29 The
at the
the compressor:
Attach the compressor bracket, tighten to 32
a. t
bolts 18
Fig.
install
Install
throttle
the
air
body.
cleaner case.
ENGINE AND ENGINE OVERHAUL
3-28 58.
Mass
the
Install
Flow (MAF) meter, resonator and
Air
air
cleaner cap. 59.
supports through the radiator service holes.
and
tighten
them
to
9
ft.
60.
Connect the lower
61.
On
lbs.
1 1
cooler
oil
•
Heater
•
Fuel
62.
Connect the upper
63.
If
64.
Install
radiator hose.
removed, connect the the radiator
air pipe.
the
Attach the two
66.
Attach the parking lights to the
67.
Fill
68.
Connect the negative battery cable, then the
the engine
fillers.
oil,
•
Brake booster
•
Distributor
Remove
12.
griiie.
65.
ECU.
Loosen the power steering pump pulley on its shaft. idler pulley nut and bolt; remove the drive belt. Remove the pulley mounting nut, drive pulley and woodruff Loosen the
oil.
positive
70.
Check the
71.
Install
the engine splash shield.
lead.
72.
Install
the hood.
belt.
73.
Road
for leaks.
and recheck the
Loosen the
Remove
3F-E Engine
1.
Disconnect the negative battery cable.
2.
Drain the engine coolant. Drain the engine
draining coolant, keep in mind that cats and dogs drink any that
Always drain coolant
may be reused
unless
prove
will
fatal in sufficient
it
contaminated or sev-
is
years old. Scribe matchmarks around the hood hinges, then re-
attached.
Use to
it
is
well supported. Re-
the transfer case undercover.
Disconnect the speedometer cable.
18.
Disconnect the ground strap from the body.
19.
Detach the two vacuum hoses from the diaphragm
the front and rear driveshafts.
cylin-
der for the transfer case. 20. a.
Remove the transfer case shift lever. Remove the clip and pin, disconnect
the
shift
rod from
the transfer case. b. shift
Remove
the nut, then disconnect the washers and the
lever with the shift rod.
21.
Disconnect the transmission control rod.
22.
Disconnect the exhaust pipe at the manifold.
23.
Position a floor jack under the transmission with a broad
wood
Remove
the eight bolts and
piece of
Relieve the fuel pressure.
two nuts that attach the frame crossmember and then remove
Remove
the battery and
its
Disconnect the accelerator and Disconnect the
air
throttle cables.
flow meter connector
connect the ISC hose, the
air
pump
and clamp.
Dis-
hose, distributor hose,
hose, the 3 hoses from the rear of the intake chamber,
and the 2 vacuum hoses from the charcoal nect the
air
intake
canister. Discon-
hose clamp.
Remove the air Remove
cleaner cap.
intake hose, air flow meter
the air cleaner element.
and
air
Remove
the
three bolts and the air cleaner case.
Remove
the coolant reservoir tank;
Tag and detached the
remove the
following wires
•
Oil
•
High tension cord at the
radiator.
and connectors:
pressure sensor coil
• Neutral start switch and transfer near the starter •
Front differential lock
•
Starter wire
and connector
to protect the pan.
the crossmember.
tray.
7.
9.
still
the hood.
6.
8.
hoses
do not allow the compressor
Remove
into a sealable container.
'•Apply a lubricant onto any nuts or bolts that will be removed. Allow the lubricant to sit for a short while. This will aid in the removal of tight and frozen nuts and bolts.
PCV
with the
unit;
17.
an uncovered container or
is left in
puddles on the ground. This
10. 5.
way
16. oil.
are attracted by ethylene glycol antifreeze, and are quite
4.
remove the
adjuster, then
Raise the vehicle, making sure
15.
**CAUTION
3.
of the
wire to support the
move
Coolant
and
hang by the hoses.
I See Figures 30, 31, 32, 33, 34, 35, 36, 37 and 38
quantity.
idler pulley
the 4 compressor mounting bolts. Position the
compressor out
fluids.
stiff
likely to
from the
At the air conditioning compressor, disconnect the wiring
14.
ignition timing.
test the vehicle
it
bracket.
Start the
move
power steering pump and remove
key. Unbolt the
engine and check
69.
eral
the glove box. Unplug the four connectors from
Carefully pull the wiring harness through the firewall.
13.
grille.
coolant and transmission
cable.
When
Case
• Transfer
hoses.
in
Cooling fan
Disconnect the following hoses:
.
radiator hose.
automatic transmissions, connect the
Oxygen sensor
•
the bolts
Install
(12 Nm).
Starter
•
• Alternator wire and connector
the radiator to the vehicle with the tabs on the
Install
ground strap
•
ENGINE AND ENGINE OVERHAUL
3-29
86823p45
Fig. 31
Remove
the compressor mounting bolts and
position out of the
way
with the hoses attached.
Fig.
33 Use a pair of pliers to loosen the speedometer
cable
fitting
Front
86823p46
Fig. Fig.
32 Locations of the front and rear driveshafts bolts
35
Remove
the two nuts securing the control rod
on the transmission
ENGINE AND ENGINE OVERHAUL
3-30
31
.
Raise the transmission
crossmember-to-chassis bolts the two nuts to 43 32.
lbs.
ft.
34.
65
ft.
to
29
ft.
ft.
tighten the frame
lbs.
lbs.
new gasket and
Connect the speedometer cable. the front and rear driveshafts. Tighten the nuts to
Install lbs.
(88 Nm).
Install
the transfer case undercover.
36.
Install
the
air
37.
Install
the
power steering pump and
nut to 35 38.
nuts.
(62 Nm).
35.
wall.
(39 Nm). Tighten
(59 Nm).
the exhaust pipe with a
Install
Tighten the nuts to 46 33.
and
slightly
lbs.
ft.
conditioning compressor. tighten the pulley
(47 Nm).
Carefully feed the fuel injection harness through the
Engage the 4 connectors ‘
(ECU). the glove box.
39.
Install
40.
Connect the hoses removed: •
Heater
•
Fuel
• Transfer 24.
Attach an engine hoist chain to the
the engine. slowly
lift
Remove
the engine
lifting
mount nuts and
brackets on bolts,
26. 27.
Mount the engine on an engine stand, making sure the
the
oil
cooler lines from the transmission.
the transmission from the engine.
retaining bolts are tight.
support the engine
in
If
an engine stand
is
Case
Brake booster
• Air control valve
then
the engine/transmission out of the truck.
Remove Remove
25.
•
41.
not available,
an upright position with blocks. Never
•
Distributor
•
Emission
Attach the wires and connectors removed: •
Oil
•
High tension cord
•
Neutral start switch and transfer near the starter
pressure sensor at the coil
•
Front differential lock
•
Starter wire
•
Starter ground strap
Slowly lower the engine assembly into the engine
•
Oxygen sensor
compartment.
• Alternator wire
leave an engine hanging from a
To
install:
28.
Install
29.
lift
the transmission and
or hoist.
oil
cooler lines to the engine.
Raise the transmission onto the crossmember with a
floor jack.
30. install
Align the holes
the bolts
in
the engine mounts and the frame,
and then remove the engine
hoist chain.
42.
and connector
and connector
•
Cooling fan
•
Check connector
•
Connector on
Install
right
fire-
to the Electronic Control Unit
fender apron
the radiator and the coolant reservoir tank.
ENGINE AND ENGINE OVERHAUL 43.
cleaner case and the element.
Install air
and
intake hose, air flow meter
Install
the air
cleaner cap. Connect the
air
hoses:
ISC hose
•
Distributor
•
PCV
•
3 hoses from the rear of the intake chamber
• 2
1
Disconnect the ground wire and heater control valve
3.
from the cowl panel.
hose
vacuum hoses from
the canister
Connect the accelerator and
44.
throt-
Disconnect the heater hoses.
12.
hose
•
body.
Disconnect the accelerator actuator cable from the
.
body.
tle
pump hose
• Air
Disconnect the cruise control actuator cable from the
10.
throttle 1 1
3-31
Be sure
throttle cables.
to
14.
Remove
15.
Disconnect the evaporative emissions (EVAP) hoses and
fuel
the brake booster
vacuum hose.
hoses.
adjust them.
the engine with
45.
Refill
46.
Install
47.
Double check
in
and the
'•--{-CAUTION
radiator with coolant.
all
installation items,
hoses and wires
Fuel injected engines remain under constant pressure after
paying particular
hoses or hanging wires, untightened
tention to loose
routing of
oil
the battery tray and battery.
(too tight or rubbing)
and
at-
nuts,
poor
tools
left
pressure before disconnecting any fuel
the engine area.
With the
48.
coil
the ignition has been turned OFF. Properly relieve the
so may result
Disconnect the following wires and connectors:
16.
Reconnect the
50.
Check Check and
51.
Install
up.
Road
52.
coil wire. Start
•
The two heated oxygen sensors DCL1 clamp Oil pressure gauge connections Alternator wire and connector
•
Intake manifold from the fender apron connection
•
should pre-oil at least the lower part of the engine. 49.
the engine, allowing
• it
to
• carefully for leaks.
adjust the engine specifications as necessary.
the hood. test the vehicle.
Recheck and top
fluid levels
as
needed.
•
High tension cord leading to the
•
Ground strap from the No. 1 engine hanger Ground strap from the air intake chamber Ground cable from the cylinder block
• •
1FZ-FE Engine I
See Figures
do
lines. Failure to
personal injury.
wire disconnected from the distributor,
crank the engine with the ignition key for 5-10 seconds. This
warm
in
39, 40, 41, 42, 43, 44, 45, 46, 47,
48 and 49
Loosen the
17.
idler pulley
nut
ignition coil
and adjusting nut
to
remove
the A/C drive belt.
bag system.
1.
Disable the
2.
Release the
3.
Disconnect the battery cables, negative
and
battery
air
Disconnect the A/C compressor, then remove the
18.
fuel pressure.
bracket. first.
Remove
the
19.
tray assembly.
a.
No.
['CAUTION The
bag system
equipped with a back-up power air bag deployment, do not start working on the vehicle until 90 seconds has elapsed from the time the ignition switch is turned OFF and the negaair
1
b. let,
Remove the radiator pipe as follows: Remove the two nuts retaining the oil
radiator pipe to the
pan.
Disconnect the No. 2 radiator hose from the water
in-
then remove the radiator pipe.
is
source. To avoid possible
tive battery terminal is
20.
Raise and safely support the vehicle.
5.
Drain the engine coolant, transmission
fluid
and engine
**CAUTION The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize you exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.
6.
Scribe the hood hinges and remove the hood.
7.
Remove
8.
Disconnect the
9.
Remove
the radiator oil
grille
and
radiator.
cooler hose from the
oil
cooler pipe.
the air cleaner hose, cap and case assembly.
and the two gaskets, then
dis-
Disconnect the return hose from the power steering res-
ervoir tank. 4.
the union bolt
pump. 21.
disconnected.
Remove
connect the pressure hose from the power steering reservoir
ENGINE AND ENGINE OVERHAUL
3-32
Front
Matchmarks
86823p62
Fig.
42 Always matchmark the driveshaft flanges prior
to removal
23.
Remove Remove
24.
Disconnect the A/C amplifier.
25.
Disconnect the wire leading to the Electronic Control Unit
22.
the glove compartment door. the speaker panel.
(ECU) and cowl
wire.
engine wire out from the cabin
26.
Pull the
27.
Remove
28.
Matchmark the flanges
of the vehicle.
the stabilizer bar.
and rear
driveshafts,
Remove the transfer shift lever. Remove the nut retaining the transmission b. Remove the shift knob.
control rod.
of the front
then remove the shafts. 29.
a.
c.
Lift
up the console
slightly in
order to disconnect the
wire. d. e. f.
Remove Remove
the shifter console. the center console box.
Disconnect the wires, then remove the transfer
lever boot
and
shift
lever assembly.
g.
Pull out the retaining pin,
h.
Remove
then disconnect the
the hose clamp, then the transfer
shift rod.
shift lever.
Fig.
43
Remove
this nut to release the control rod
ENGINE AND ENGINE OVERHAUL
Remove
30.
3-33
the front exhaust pipe.
a.
Disconnect the heated oxygen sensor.
b.
Remove
the nuts and bolts holding the exhaust to the
catalyst. c.
Loosen the clamp then disconnect the from the No.
1
support bracket. d. e.
31
.
32.
Remove Remove
the No.
1
support bracket.
the front exhaust pipe.
Detach the ground strap from the heat
between the jack and the transmission ages
insulator.
Place a jack under the transmission. Put a wooden block oil
pan
to prevent
dam-
to the pan.
33.
Remove
34.
Attach the engine hoist chain to the two engine hangers.
35.
Remove
the frame crossmember.
the nuts holding the engine front mounting
in-
sulators to the frame. 36.
Lift
the engine with the transmission out of the vehicle
slowly and carefully. wiring
Fig.
46 Bolt locations for removing the shift lever
assembly
Fig.
Make
certain the engine
is
clear of
all
and hoses.
48 Secure the engine hoist chain to the engine as
shown
ENGINE AND ENGINE OVERHAUL
3-34 To
and the rear shaft
Keep
39.
45
Install
the front crossmember, then tighten the bolts to
Nm).
lbs. (61
ft.
54
rear mounting insulator to
ft.
crossmember
lbs.
to the
engine
(74 Nm).
54
ft.
ft.
lbs.
43.
Connect the ground strap
44.
Install
a.
to
ft.
Connect the clamp and Connect the
front
34
13
ft.
lbs.
Install
b.
lever
lbs.
ft.
shift
14
lbs.
ft.
rod
and
install
tighten the bolts to 4
Install
e.
Connect the pattern select switch.
ft.
shift lever
lbs. (5
Shift the lever into the neutral (N) position.
Fully turn the control shaft lever
46.
Install a.
On
now be
in
55.
hose
1
power steering
to the
reservoir
b.
Install
65
ft.
lbs.
Install
hose
to the
water
inlet.
ft.
lbs. (21
Nm).
the A/C bracket and tighten the bolts to 27
ft.
lbs.
Install
58.
Install
and adjust the A/C
59.
Install
the following wires and connections:
Two heated oxygen
a.
ft.
drive belt.
sensors
c.
DCL1 clamp Low oil pressure gauge connectors
d.
Alternator wires
e.
Intake manifold from the fender apron
b.
to
the A/C compressor and tighten to bolts to 18
(25 Nm).
9
High tension cord from the ignition
f.
g.
Ground
strap from the No.
h.
Ground
strap from the air intake
matchmarks on the 54 ft. lbs. (74 Nm),
(88 Nm).
radiator
the two nuts holding the radiator pipe to the No.
pan. Tighten the nuts to 15
oil
the front and rear driveshafts.
the differential side, align the
the radiator pipe as follows:
Connect the No. 2
Nrrtt.
rear shaft to
Install
a.
the neutral (N) position.
flanges, then tighten the front shaft to
and the
return
Connect the power steering pressure hose with the ft. lbs. (56 Nm).
54.
back and return two
Connect the transmission control rod and tighten (13
Connect the
the shifter console and shift lever knob.
h.
lbs.
the speaker panel and glove compartment door.
Install
53.
lbs.
assembly.
g.
i.
suspension,
Attach the A/C amplifier.
.
52.
57.
Nm).
the center console box.
will
on
(37 Nm).
the pin.
Attach the connectors to the
It
resting
is
it
(25 Nm).
lbs.
ft.
56.
c.
notches.
(19 Nm).
the transfer shift lever boot, transmission shift
assembly and
Install
that
Push the engine wire through the cowl panel and connect the wiring to the Electronic Control Unit (ECU) and the
(46 Nm).
d.
f.
19
to the rear catalyst,
(18 Nm).
Connect the
a.
tighten to
exhaust pipe
the transfer shift lever and hose clamp, tighten the
Install
its
(18
union bolt and tighten to 42
c.
tighten the bolts to
ft.
support bracket, then tighten the bolts
1
(24 Nm).
b.
bolts to
lbs.
tank.
the No.
lbs.
ft.
50.
51
to the heat insulator.
the front exhaust pipe, then tighten the nuts to 46
Install
17
45.
(74 Nm).
(63 Nm).
lbs.
13
cowl wire.
42. Tighten the nuts holding the engine front mounting insulators to the frame to
(88 Nm).
tighten the bolts holding the stabilizer bar to the axle housing to
41. Tighten the nuts holding the
lbs.
ft.
Lower the vehicle so
49.
chain hoist. 40.
65
Nm).
remove the
the engine level with a jack, then
to
stabilizer bar brackets to
Connect the
48.
frame crossmember.
tors to the
matchmarks on the 54 ft. lbs. (74 Nm),
47. Temporarily install the stabilizer bar to the axle housing.
the nuts holding the engine front mounting insula-
Install
the transfer side, align the
flanges, then tighten the front shaft to
then lower the engine and transmission into the vehicle. 38.
On
b.
install:
37. Attach the engine hoist chain to the engine hangers,
60.
i.
Starter wire
j.
Ground cable from the Connect the
the union bolt to 22
ft.
lbs.
coil
engine hanger
chamber
cylinder block
hose
fuel inlet
1
to the fuel filter
and tighten
(39 Nm). Connect the fuel return
line.
61.
Connect the evaporative emissions (EVAP) hose and
brake booster vacuum hose. 62.
Connect the heater control valve and the engine wire
to
the cowl panel. Connect the engine wire and the ground strap. 63.
Connect the heater hoses.
64.
Connect the accelerator cable to the throttle body. Connect the cruise control actuator cable to the throttle
65.
body. the
cleaner case, the hose and the cap.
66.
Install
67.
Connect the
68.
Install
the radiator.
69.
Install
the
70.
Install
the battery tray and battery. Connect the cable.
71.
Fill
air
cooler hose to
oil
cooler pipe.
grille.
the engine with
amount and type
oil
and the transmission with proper
of fluid.
the cooling system with coolant.
72.
Fill
73.
Start the
74.
Check Check
75.
oil
76.
Install
77.
Top
engine and check
for leaks.
the automatic transmission
fluid level.
the timing. the hood and test drive the vehicle.
off
any
fluid levels.
ENGINE AND ENGINE OVERHAUL
3-35
Rocker Arm (Valve) Cover
REMOVAL
& INSTALLATION
Check the hoses, could be
damaged
wiring, bolt threads
or
worn replace
and any other
part that
needed.
if
^Apply
a lubricant onto any nuts or bolts that will be removed. Allow the lubricant to sit for a short while. This will aid in the removal of tight and frozen nuts and bolts.
22R, 22R-E and 3F-E Engines I See Figures 50, 51, 52, 53, 54 and 55 1.
Disconnect the negative battery cable.
2.
On 22R and 22R-E
86823p76
engines, remove the ground strap Fig. 51
from the valve cover. 3.
On
4.
Disconnect the
5.
Remove
3F-E, remove the
cylinder head. dirt
Cover the
Lift
return hole
oil
Remove
in.
to
use a deep socket to
retaining nuts
cover.
the cover
in
may be necessary
off
the
the head to prevent
the gasket.
install:
6.
they 7.
cam
hose(s) from the
It
remove the
cleaner hose.
the nuts and washers.
or objects from falling
To if
PCV
air
Replace the rubber
seem
half
moon
seals
in
the cylinder
head
be deteriorated.
to
Replace the cover gasket
age, breaks or cracking.
Install
if
it
shows any signs
new
the nuts evenly to 43-48 inch lbs (4-5
engines and 78 inch
lbs. (9
Nm)
of
dam-
nut gaskets, then tighten
Nm)
for four cylinder
for six cylinder engines.
Do
not overtighten. 8.
or
Reconnect the
ground
PCV hose and
install
the air cleaner hose
strap.
3VZ-E Engine I
See Figures
56, 57, 58,
59 and 60
1.
Disconnect the
2.
Unsecure the canister vacuum hose from the
throttle position
sensor.
86823p77
throttle
Fig.
body.
52 Be careful not to lose the seal washers
86823p78
86823p75
Fig.
50
Remove
the valve cover
the bolt securing the ground strap to
Fig.
53 Once the retaining nuts are removed,
cover from the head.
.
.
lift
the
ENGINE AND ENGINE OVERHAUL
3-36
86823p79
Fig.
54
.
.
.
then pull the rubber gasket off the head
mating area
86823p80
Fig.
55 Inspect the half
moon
seals, replace
if
deteriorated
Take
3.
off
the
vacuum and
fuel
hoses from the pressure
regulator. 4.
Disconnect
5.
Remove
PCV
hose from the hose union.
15.
the water bypass hose from the union at the
intake manifold.
Disconnect the cold
7.
Take
8.
Remove
off
the
start injector
vacuum hose from
the union bolt
connector.
the fuel
filter.
and the two gaskets and the cold
start injector tube.
On
California vehicles, disconnect the
EGR
temperature
sensor connector. Disconnect the
10.
and
EGR vacuum
EGR vacuum
hoses from the
air
pipe
modulator.
11.
Remove
12.
Disconnect the 2 water bypass hoses from the
the nut, bolt and intake manifold stay (support).
EGR
valve. 13.
• •
6.
9.
14. fold;
the 5 nuts and
pipes and 2 gaskets.
remove the
EGR
valve with the
the 6 bolts
and 2 nuts holding the intake mani-
Disconnect and label the following Knock sensor connector Water temperature switch connector
wires:
•
Start injection timer
•
•
Water temperature sensor connector Water temperature sender gauge connector Right side engine ground strap
•
Injector
•
connector
16.
Remove
17.
Remove
the two bolts holding the engine wire harness and remove the harness. the bolts holding the valve cover(s);
remove the
cover(s) and gaskets.
To 18.
Remove
Remove
remove the gasket.
install:
Examine the gasket
closely for
deformation. Replace the gasket 19.
if
any sign
of cracking or
necessary.
Place the gasket on the cover. Apply sealant at the 4
corners of each head as shown sealant to the entire gasket.
in
the illustration.
Do
not apply
ENGINE AND ENGINE OVERHAUL EGR
Connect the
27.
vacuum modulator. For
hoses
to the air pipe
3-37
and the
California vehicles, connect the
EGR EGR
temperature sensor connector.
Use a new gasket and connect the
28.
tube. Tighten the union bolt to 13
Connect the vacuum hose
29.
ft.
lbs.
cold start injector
(18 Nm).
to the fuel
filter,
then connect
the cold start injector connector. 30.
Install
the 2 water bypass hoses,
and the other
to the
one
to the
bypass pipe
hose union.
PCV
hose
31.
Connect the
32.
Connect the vacuum and
to the fuel
hose union.
hoses
to the pressure
regulator.
86823p85
33.
Connect the canister vacuum hose
34.
Connect the
throttle position
to the throttle
body.
sensor wire.
2RZ-FE and 3RZ-FE Engines I See Figure 61 Fig.
Remove
58
harness
in
the two bolts retaining the engine
place
1.
Drain the coolant from the engine.
2.
On manual
transmissions, disconnect the accelerator
cable from the throttle body.
On
3.
automatics, disconnect the accelerator and throttle
cables from the throttle body.
On
4.
cruise control,
remove the actuator cover, then
dis-
connect the cruise control cable from the actuator. 5.
Disconnect the 3 wire clamps
6.
Unsecure the Mass
Air
for the
engine harness.
Flow (MAF) meter and Intake
Air
Temperature (IAT) sensor connections.
On
7.
air
the
3RZ-FE
engine, disconnect the
cleaner cap, then loosen the
Loosen the 4
8.
Mass
Air
air
hose from the
cleaner hose clamp.
and remove the the cleaner cap,
Flow (MAF) meter and resonator sensor.
Remove
9.
hose
clips,
air
the
air intake
sensor by disconnecting the
air
for the Idle Air Control (IAC). a.
Remove
the
vacuum sensing hose and
wire clamp for
the engine wire. b.
Loosen the hose clamp, and remove the
the air intake connector.
Place the valve cover and gaskets
20.
and
install
to 5-6
21. all
ft.
lbs. (7-8
Install
the engine wire harness with
Position a
place on the head
them evenly only
Nm), do not overtighten.
the connectors disconnected
22.
in
the small retaining bolts. Tighten
new gasket on
in
its
two
the intake manifold.
manifold, tightening the six bolts
Engage
bolts.
Step 17.
and two nuts
Install
13
to
lbs.
ft.
the (18
Nm). 23.
Connect the No.1
24.
Install
air
hose
two new gaskets
EGR
side exhaust manifold. Install the 25.
Install
reed valve.
to the
to the intake manifold
and
right
valve and pipes.
EGR
the two water bypass hoses to the
if
so
equipped. 26.
Install
the intake manifold support; tighten the groups of
bolts to the proper torque tions.
Group
Nm), group
22
ft.
lbs.
— refer
(A) bolts should (B) to
13
(29 Nm).
ft.
lbs.
to the
diagram
be tightened (18
to
9
for
ft.
Nm) and group
designa-
lbs.
(12
(C) bolts to
PCV
10.
Remove
11.
Tag and disconnect the spark plug
the
hoses. wires.
bolts retaining
ENGINE AND ENGINE OVERHAUL
3-38
Disconnect these wires:
12.
•
A/C connector
if
equipped
• Oil pressure sensor wire •
Engine coolant temperature sensor
•
Distributor wire
• 4 engine wire
Remove
13.
clamps and engine wire
the valve cover bolts, seal washers, cover and
gasket.
To
install:
14.
Clean the mating areas
15.
Install
well.
the gasket on the cover, then
Be sure
the cylinder head.
to
install
the cover to
have new seal washers, then
the bolts and tighten to the correct specification.
install
16.
Attach the wire removed previously.
17.
Install
18.
Reattach the
19.
Install
the spark plug wires.
PCV
hoses.
the air intake chamber.
the with a coolant and water mixture.
20.
Fill
21.
Start the engine
and check
for leaks.
Top
off
any
fluid
levels.
1FZ-FE Engine
5VZ-FE Engine
> See Figures 63 and 64
I See Figure 62 1
.
Disconnect the accelerator and
throttle
cables from the
1.
Remove
3.
Disconnect the engine wiring harness and heater control
throttle linkage. 2.
Remove
the air cleaner cover, air flow meter, and
duct assembly.
It
will
be necessary
to
4.
Loosen and remove the valve cover
Remove
the valve covers, work on
4. 5.
at
a time
5. 6.
To
Clean the mating areas on the cover and cylinder head.
Install
the gasket to the head and seal washers. Attach until
snug.
the air flow meter, air duct, and the air cleaner
linkage.
throttle
cables to the
install:
Clean the valve cover and mating areas on the engine.
7.
Install
a
8.
Install
and
new gasket
into the
groove
tighten the 13 bolts
of the cover.
on the valve cover
to the
correct specifications. 9.
Connect the accelerator and
Tag and disconnect the spark plug wires. Remove the cylinder head (valve) cover bolts, gasket
6.
cover. 8.
in
and cover.
the cover with the mounting bolts. Tighten 7.
strap holds the harness
to
install:
Install
A ground
place.
avoid confusion.
To
valve from the cowl panel.
bolts.
one
the throttle body.
air
disconnect the wiring to
the meter and unbolt the assembly, prior to removal. 3.
Drain the cooling system.
2.
10.
Attach the spark plug wires to there proper locations. Bolt the
engine harness
to the cowl. Attach the heater
throttle
control valve. 1 1
.
12.
Install Fill
the throttle body with a
the cooling system.
new
gasket.
ENGINE AND ENGINE OVERHAUL
3-39
Inspect the rocker arm-to-shaft wear by wiggling the
3.
laterally 4.
If
on the
no movement should be
shaft. Little or
movement
found
is
arm
felt.
the arm-to-shaft wiggle test,
in
measure the oil clearance as follows: a. Measure the outside diameter
of the rocker shaft with
a micrometer.
Measure the
b.
arms
inside diameter of the rocker
with a
dial indicator.
The
c.
difference
between the rocker arm inner diameter
and the shaft outer diameter clearance
is
is
the
oil
clearance. Correct
0.0004-0.0020 inches (0.01-0.05 mm).
allowable clearance
is
Maximum
0.0031 inches (0.08 mm).
Inspect the face of each rocker; the surface should be
5.
smooth, shiny and evenly shaped. Any sign of metal wear or scratching requires replacement of the rocker and a detailed inspection of the camshaft.
(•The condition
Start the engine
13.
and check
for leaks.
Top
off
any
fluid
levels.
of the rocker surfaces and matching camshaft lobes are your report card for oil and filter changes. If you have been less than prompt about performing routine oil changes, chances are good that the rockers and/or cam lobes are scored or damaged from poor oiling. The amount of sludge in the head is also a good indicator of poor oil change frequency.
Rocker Arm/Shafts
Reassemble the rocker
6.
shafts,
arms and towers
in their
exact original order.
REMOVAL
Remove
7.
& INSTALLATION
the head,
head removal and
install
tighten the bolts gradually
^Only
a new gasket. See cylinder
installation. Install the
and
in
the 22R, 22R-E and 3F-E engines use rocker arms.
Nm).
Other engines operate the valves through the direct action
8.
Adjust the valve clearance.
of the camshaft.
9.
Test drive the vehicle.
22R and 22R-E Engines
3F-E Engine
I See Figures 65, 66, 67, 68 and 69
I
•'WARNING
See Figures 1
Remove
.
NEVER
attempt to re-compress the
same gasket
after the
head bolts are loosened.
Install
.
ened
Remove in
cylinder
The head bolts must be loosavoid, head damage. Refer to the
the correct order to
head removal and
installation
procedure
Once the bolts are loosened and removed, move the rocker shaft assembly.
tion.
in this
sec-
carefully re-
in
Remove
the three retaining screws
parts order.
in
order; the shafts
arms
off of
and
slide the rocker
the shafts.
must be reassembled
(78
and 72
the valve cover.
the correct order.
wear by wiggling the arm no movement should be felt.
Inspect the rocker arm-to-shaft
3.
laterally If
on the
shaft. Little or
movement
found
is
in
the arm-to-shaft wiggle test,
Measure the oil clearance as follows: a. Measure the outside diameter
in
exact order.
of the rocker shaft with
a micrometer. b.
c.
2.
lbs.
Measure the
inside diameter of the rocker
arms
with a
dial indicator.
^It may be necessary to use gentle prying force at the ends of the assembly to lift it off the head. Do not damage the head during removal.
supports, springs and rocker
ft.
is held by 8 bolts and 4 nuts. These must be loosened evenly in several passes. Do not loosen any one fastener all at once. Loosen the nuts and bolts
4.
the valve cover.
58
the valve cover.
disassemble the shaft and keep every piece 1
to
The rocker assembly
2.
The rocker shaft assembly is held by the head bolts. Removal of the head to replace the head gasket is REQUIRED any time the head bolts are loosened. Refer to cylinder head removal and installation later in this section.
70, 71
rocker assembly and
sequence
in
Keep
all
the correct
The
and the
difference
clearance
is
is
the
oil
clearance. Correct
0.0004-0.0020 inches (0.01-0.05 mm).
allowable clearance 5.
between the rocker arm inner diameter
shaft outer diameter
is
Maximum
0.0031 inches (0.08 mm).
Inspect the face of each rocker; the surface should be
smooth, shiny and evenly shaped. Any sign of metal wear or scratching requires replacement of the rocker and a detailed inspection of the camshaft.
3-40
ENGINE AND ENGINE OVERHAUL »
86823p88
Fig.
65 Exploded view of the 22R and 22R-E rocker arms and shafts
ENGINE AND ENGINE OVERHAUL
Fig.
3-41
70 Exploded view of the rocker shaft assembly on the 3F-E engine
Remove
6.
the cylinder head.
'The
condition of the rocker surfaces and matching camshaft lobes are your report card for oil and filter 10. changes. If you have been less than prompt about performing routine oil changes, chances are good that the rockers and/or cam lobes are scored or damaged from poor oiling. The amount of sludge in the head is also a good indicator of poor oil change frequency.
To
install:
7.
Install
the cylinder head with a
the rocker shafts, arms and towers 8.
gasket.
Reassemble
exact original order.
Place the rocker shaft assembly on the cylinder head.
Align the adjusting screws with the 9.
new
in their
Install
heads
the retaining bolts. Tighten
of the
them
in
pushrods. the correct
in several passes to the correct torque. The 12 mm heads should be tightened to 15-17 ft. lbs. (21-24 Nm). The 14 mm bolt head and the nut should be tightened to 25
order and bolt
Fig. 71
Loosen the rocker assembly bolts
passes
in this
order
in
several
ft.
lbs.
(33 Nm). Adjust the valve clearance. Reinstall the valve cover.
ENGINE AND ENGINE OVERHAUL
3-42
86823pd6 1.
Fig.
the
Thermostat
REMOVAL & INSTALLATION > See Figures 73, 74, 75, 76, 77, 78, 79 and 80 Drain the cooling system.
**CAUTION When
draining coolant, keep
mind
in
that cats
and dogs
are attracted by ethylene glycol antifreeze, and are quite
any that is left in an uncovered container or puddles on the ground. This will prove fatal in sufficient
likely to drink in
quantity.
Always drain coolant
Coolant
may be reused unless
eral
2.
into a sealable container. is
it
contaminated or sev-
years old.
On 3F-E engines, disconnect the 2 vacuum hoses from Vacuum Switching Valve (BVSV), the cold start
the Bimetal
injector time switch wire
and the water temperature switch
connector. 3.
Unbolt the housing, then remove the water
inlet with
the
enough room to pull both housing and hose out, you may want to disconnect the hose first. On 3F-E engines, remove the clamp bolt for the ISC water bypass pipe. Make certain to remove the gasket with the water hose attached.
inlet.
Some
of
If
it
there
will
is
not
probably stick to the housing and require
scraping. 4.
To 5.
Remove
the thermostat.
install:
When
installing
a
new thermostat always use a new
Be sure that the thermostat is positioned with the spring down or into the housing. On 3VZ-E engines, the jiggle valve (looks like a small rivet in the edge of the thermostat) gasket.
must be 6.
at the top or
Install
inlet is
the water
12 o’clock position. inlet.
(13-19 Nm). Overtightening
and
Install
the bolts finger-tight
positioned exactly. Tighten the bolts to 10-14
spoil
your afternoon
will
break the ear
— don’t do
it.
off
ft.
until
the
lbs.
the housing
73 On, 3VZ-E engines the thermostat
waterpump
is
located
in
ENGINE AND ENGINE OVERHAUL
3-43
86823pal
Fig.
77 An extension
is
helpful for reaching the
housing
retainers
7.
cess.
Install
Make
the hoses and wire connectors removed for accertain the coolant
after installation.
Do
hoses are not kinked or twisted
not overtighten the hose clamps.
the cooling system with coolant.
8.
Fill
9.
Start the engine
and check
for leaks.
Top
levels.
Intake Manifold
REMOVAL & INSTALLATION 22R Engines 1
86823pa2
Fig.
78 You may need to maneuver the housing
through other hoses
in
the
way
.
Disconnect the negative battery cable
first.
off
any
fluid
ENGINE AND ENGINE OVERHAUL
3-44 2.
Drain the cooling system.
:*CAUTION When
draining coolant, keep in mind that cats and
dogs
are attracted by ethylene glycol antifreeze, and are quite drink any that
likely to in
an uncovered container or prove fatal in sufficient
is left in
puddles on the ground. This
quantity.
Always drain coolant
Coolant
may be reused unless
will
into a sealable container.
contaminated or sev-
is
it
years old.
eral
Remove
3.
the
cleaner assembly, complete with hoses,
air
9.
from the carburetor.
vacuum
Label and disconnect the
4.
remove the
fold;
Remove
5.
linkage,
EGR
lines
EGR
valve and carburetor. Disconnect the
from the
EGR
pipe from the mani-
valve with the pipe attached.
the fuel lines, electrical leads, accelerator
and water hose from the carburetor.
6.
Remove
7.
Unbolt and remove the intake manifold, complete with
the water bypass hose from the manifold.
EGR
carburetor and
Cover the cylinder head ports with clean shop cloths
8.
keep anything from
To
with a lbs.
falling into
to
the cylinder head or block.
When new
always replace the gasket
installing the manifold,
one. Tighten the mounting nuts and bolts to 14
(19 Nm). Tighten the bolts
air
1 1
Make
.
line
and
the air cleaner and
11.
Install
12.
Start the
all
refill
engine and check
the cooling system.
Top
off
any
fluid
Position a
14.
Install
15.
22R-E Engines
new gasket on
the cylinder head.
the intake manifold with the fuel delivery pipe and
Install
them evenly
the bolts and nuts. Tighten
to
14
ft.
(19 Nm).
16.
Install
the
any carbon or
and 82
injection nozzles with the manifold.
install:
13.
lbs.
81
intake manifold.
injection nozzles.
levels.
I See Figures
chamber from the and
delivery pipe
other lines and hoses.
for leaks.
hoses, lines and wires are tagged for later
ft.
To
Connect the bypass
all
fuel delivery pipe.
Unbolt the manifold from the cylinder head, removing the
12.
several stages working from
in
sure
hose from the
valve hose from the intake manifold.
and disconnected from the intake manifold. Unbolt
the air intake
the inside bolts outward. 10.
fuel
Disconnect the
installation
install:
9.
Disconnect the 10.
valve.
EGR
oil
valve. Clean the bolt threads, removing
deposits. For the bolt closest to the front of
the engine, apply sealant to the 2 or 3 threads closest to the 1.
Disconnect the negative battery cable.
2.
Drain the cooling system.
end a
**CAUTION When
draining coolant, keep
mind
in
that cats
and dogs
and nuts. chamber with the
of the bolt. Install the bolts
17.
new
Install
the
air
intake
gasket. Tighten the bolts to 14
the
EGR
18.
Install
19.
Connect the
air
ft.
lbs.
throttle
body. Use
(19 Nm).
wires and hoses. valve hose.
are attracted by ethylene glycol antifreeze, and are quite likely to drink in
any that
an uncovered container or prove fatal in sufficient
is left in
puddles on the ground. This
quantity.
Always drain coolant
Coolant
may be reused unless
will
into a sealable container. is
it
contaminated or sev-
eral years old.
3.
Disconnect the
air intake
assembly on one end and the
hose from both the air intake
air
cleaner
chamber on the
other.
Tag and disconnect all vacuum lines attached to the intake chamber and manifold. 5. Tag and disconnect the wires to the cold start injector, throttle position sensor, and the water hoses from the throttle 4.
body.
EGR
6.
Remove
7.
Tag and disconnect the actuator
the
valve from the intake chamber.
and automatic transmission
throttle
cable, accelerator cable
cable
(if
equipped) from the
86823pa7
cable bracket on the intake chamber. 8.
Unbolt the
air
intake
chamber from the
and remove the chamber with the
throttle
Fig.
intake manifold
body attached.
82 With the
manifold can
air intake
chamber removed, the
now be accessed
for
removal
ENGINE AND ENGINE OVERHAUL 20.
Connect the
21.
Install
hose
fuel
3-45
to the fuel delivery pipe.
the actuator cable, accelerator cable, and throttle
control cable (auto, trans.).
Connect the wires
22.
to the cold start injector, fuel injectors,
sensor. Connect the water hoses to the throttle
throttle position
body. 23.
Connect the vacuum
24.
Install
25.
Refill
lines.
the air intake tubing. the cooling system with coolant.
1.
Connect the negative battery cable. 27. Start the engine and check for leaks. Top 26.
off
any
fluid,
levels.
3VZ-E Engines >
See Figures 83 and 84 2.
Disconnect the negative battery cable.
^WARNING is equipped with a back-up power To avoid possible air bag deployment, do not start working on the vehicle until 90 seconds has elapsed from the time the ignition switch is turned OFF and the nega-
The
air
bag system
source.
tive battery terminal is
Remove
16.
the water bypass outlet. Progressively loosen
the retaining bolts and
disconnected.
To
install:
17.
Install
remove the
the intake manifold with
the mounting bolts to 29 Drain the cooling system.
18. to
^CAUTION When
draining coolant, keep in mind that cats and
an uncovered container or puddles on the ground. This will prove fatal in sufficient
likely to in
quantity.
Coolant
drink any that
dogs
and are quite
are attracted by ethylene glycol antifreeze,
3.
Always drain coolant
may be reused unless
air
4.
5.
into a sealable container. it
is
contaminated or sev-
air intake
Tag and disconnect all vacuum chamber and manifold. Disconnect the
move 7.
chamber on the
the fuel delivery pipes and injectors.
20.
Install
the timing belt covers and tighten the bolts to 74
inch lbs. (8.3 Nm). 21. lbs.
8.
move
lines
9.
Disconnect the cold
sensor connector at the
PCV hose
at the union.
start injector
and the vacuum hose
filter.
the union bolt and two gaskets
and then
re-
the cold start injector tube.
Disconnect the
EGR vacuum
EGR
gas temperature sensor
hoses from the
air
pipe and the
(Calif.)
and
vacuum
modulator.
EGR
10.
Remove
11.
Disconnect the
12.
Remove
the
the
air
air
valve.
hose
intake
at the
reed valve.
chamber and then remove the
engine wire harness (held with 2 13.
bolts).
Remove
the four union bolts and then
Remove Remove
the timing belt covers.
remove
fuel
pipes. 14. 15.
the fuel pipes and tighten the union bolts to 22
22.
Install
23.
Install
13
the engine wire harness. the air intake ft.
lbs.
chamber and
tighten the nuts
and
(18 Nm).
24.
Install
the
EGR
25.
Install
the
air
valve and connect
all
hoses and
lines.
cleaner duct.
the engine with coolant.
26.
Refill
27.
Connect the negative battery cable.
28.
Start the
attached to the
the bypass hose at the water bypass pipe.
Remove
Install
(29 Nm).
other.
Disconnect the water bypass hose at the manifold. Re-
at the fuel
the
throttle position
chamber. Disconnect the 6.
(18 Nm).
lbs.
Install
levels. air
tighten
intake hose from both the air cleaner
assembly on one end and the intake
new gaskets and
(39 Nm).
19.
bolts to
Disconnect the
lbs.
the water bypass outlet and tighten the two bolts
Install ft.
ft.
is left in
years old.
eral
13
intake manifold.
the fuel delivery pipes with their injectors.
engine and check
for leaks.
Top
off
any
fluid
ft.
ENGINE AND ENGINE OVERHAUL
3-46 3F-E Engine
I See Figures 85 and 86 1
.
Drain the engine coolant.
2.
Disconnect the negative battery cable.
3.
Disconnect the accelerator and
4.
Remove
the
air intake
hose,
throttle control cable.
and
flow meter
air
air
cleaner. 5.
Disconnect or reposition
the wires and hoses running
all
near or through the intake and exhaust manifolds.
Remove
the
heat shields from the exhaust manifold. 6.
Disconnect the exhaust pipes from the exhaust manifold.
7.
Progressively loosen the retaining bolts holding the
in-
take and exhaust manifold 8.
Remove
the intake and exhaust manifolds.
dividual pieces.
To 9.
Remove
They are
in-
1.
the combination gasket.
install:
Place a
new gasket so
FRONT
that the
mark
is
towards Fig.
86 Be sure to
install
the fasteners
in
the correct
the front side, facing outward. 10.
Install
the intake and exhaust manifolds with the ten
locations 2.
bolts, four plate
Use the
correctly.
(A)
17mm
•
(B)
14
•
(C) nuts
•
11.
washers and
Install
illustration for correct
mm
— 51 bolts — 37
bolts
— 41
ft.
lbs.
and
nuts. Tighten the nuts
ft.
lbs.
5VZ-FE Engine
placement:
I See Figures 87 and 88
Nm) (50 Nm)
(69
lbs.
ft.
bolts
Relieve the fuel pressure.
Nm)
(56
new gaskets and secure
the exhaust pipes to the
**CAUTION
manifold.
the heat shields
Install
13.
Connect the wires and hoses removed the
cleaner, air flow meter
14.
Install
15.
Connect the accelerator and
air
Fuel injected engine systems remain under pressure after
and manifold support.
12.
Step
in
and
the engine has been turned OFF. Properly relieve the fuel
5.
air intake duct.
throttle control cables.
pressure before disconnecting any fuel
so may
lines. Failure to
do
result in fire or personal injury.
the system with coolant.
16.
Fill
17.
Connect the negative battery cable.
18.
Start the
engine and check
for leaks.
Disconnect the negative battery cable.
Top
off
any
fluids.
^WARNING The
equipped with a back-up power air bag deployment, do not start working on the vehicle until 90 seconds has elapsed from the time the ignition switch is turned OFF and the negaair
bag system
is
source. To avoid possible
tive battery terminal is
disconnected.
3.
Drain the engine coolant.
4.
Remove
5.
Disconnect the following cables: •
On
the air cleaner hose.
cruise control vehicles, the actuator cable with
bracket • • 6.
If
Accelerator cable
On
automatics, the throttle cable
equipped with an
EGR
valve,
remove the
EGR
pipe
and gaskets.
Remove the intake chamber stay as follows: Remove the oil filler tube and the throttle cable clamp. b. Remove the intake chamber stay. 8. Remove the following connectors: • Vacuum Switching Valve (VSV) connector for the fuel
7.
a.
pressure control • Throttle positioning sensor •
Idle Air Control (IAC)
•
Disconnect the
•
Disconnect the
EGR VSV
valve
gas temperature connector connector
for the
EGR
valve
ENGINE AND ENGINE OVERHAUL
3-47
CRUISE CONTROL ACTUATOR CABLE
THROTTLE CABLE THROTTLE POSITION SENSOR CONNECTOR
ACCELERATOR CABLE
VSV CONNECTOR FOR FUEL PRESSURE CONTROL IAC AIR
VALVE CONNECTOR
VSV CONNECTOR FOR EGR
CLEANER HOSE EVAP HOSE
PS AIR HOSE
AIR INTAKE
CHAMBER ASSEMBLY
A/C IDLE-UP VALVE
CONNECTOR A/C AIR
HOSE
Non-reusable part 86823pa9
Fig.
87 Exploded view of the
air intake
chamber assembly
3-48
ENGINE AND ENGINE OVERHAUL
Fuel
Inlet
Pipe
Gasket
No. 3 Timing Belt Cover
Heater Hose
Water Bypass Hose Camshaft Position Sensor
Non-reusable part 86823pbl
Fig.
88 Exploded view of the intake manifold assembly
ENGINE AND ENGINE OVERHAUL
3-49
9.
Disconnect the following hoses: •
PCV
•
Water bypass
Two vacuum EVAP
•
• Air
hose from the power steering
On A/C
•
VS
sensing hoses from the
hose from the
vehicles, disconnect the air
idle
the bolts, nuts then the intake
chamber
assembly. 1 1
Remove
.
the
intake connector as follows:
air
a.
Disconnect the engine wire from the intake connector.
b.
Disconnect the two
c.
Disconnect the brake booster vacuum hose from the
fuel return
Remove
the bolt
hoses.
and disconnect the ground strap from
the intake air connector. 1
(DLC1) from
the bracket of the intake connector.
On A/C vehicles, disconnect the idle up valve. Remove the air intake connector from the engine.
f.
g.
Unbolt the No. 3 (rear) timing belt cover.
31.
Disconnect the fuel
the camshaft position sensor.
Unbolt the intake manifold assembly. install:
33.
Clean
all
34.
Install
new gaskets on
(9
mating surfaces.
the intake stay, tighten to 14
37.
Attach the timing cover, tighten the bolts to 80 inch
Attach Install
41.
Attach the fuel pressure regulator.
all
the heater hose.
Disconnect the upper radiator hose.
15.
17.
Remove Remove Remove
18.
Disconnect the power steering
Do
then set aside.
On A/C
19.
alternator belts.
and
pulleys.
from the engine,
pump.
remove the compressor. Do not discon-
nect the lines from the compressor, then set aside. Unbolt the
bracket from the compressor.
Remove
20.
the
strut.
Then remove
1
cylinder at
TDC
of the
it’s
groove with
mark 0 of the timing belt cover. Check the timing marks of the camshaft timing pulleys
the timing
and the timing
belt
one
shaft pulley
cover are aligned.
belt,
read the installation marks.
If
not,
match the timing marks
of
you can still place new marks on the the camshaft timing
on the camshaft with the flange lbs.
ft.
Set the No.
44.
TDC
cylinder to
1
of the
compression
stroke.
Connect the timing
Check
belt to the
that the installation
end
left
SST 09960-01000
with the timing belt
the timing belt on the Align the timing
b.
left
camshaft timing
of the timing belt
is
pulley.
aligned
or equivalent, slightly turn
camshaft timing pulley clockwise. Align the
mark
tion
mark
of the timing belt cover.
Using a
a.
left
on the camshaft
camshaft
marks
installa-
pulley.
Hang
pulley.
of the
left
camshaft pulley and
the timing belt cover.
Check
c.
make sure
camshaft with the
of the
(110 Nm).
revolution (360°).
(Hf reusing the timing belt to
not, turn the crank-
If
hose
of the timing pulley.
Slide the timing pulley
c.
the
Turn the crankshaft pulley and align
b.
Align the knock pin
side facing outward. Tighten the pulley bolt to 81
compression stroke
as follows: a.
the knock pin to the camshaft.
Install
b.
with the
Set the No.
idler.
camshaft timing pulley as follows:
left
a.
45.
power steering adjusting
the fan bracket. 21.
the timing belt
knock pin groove
not disconnect the lines from the
vehicles,
the engine wiring to the intake manifold.
39.
40.
14.
pump
lbs.
Nm).
Install
the fan shroud with the coupling
lbs.
the camshaft position sensor, tighten to 71 inch
Install
lbs. (8
Attach the
the fan shroud.
ft.
fuel inlet hose.
Nm).
43.
16.
(18 Nm).
Install
Connect the
Remove
A/C and
has tension between the
that the timing belt
crankshaft timing pulley and the
that
46.
Install
Align the installation
a.
camshaft
camshaft
left
pulley.
the right camshaft pulley and belt:
pulley.
Hang
mark
with the timing belt
on the
the timing belt on the right camshaft
pulleys. pulley with the flange facing inward. 22.
Remove
the timing belt tensioner by alternately loosening
25.
Remove Remove Remove
26.
Disconnect and remove the
27.
Disconnect the heater hose.
28.
Disconnect the engine wiring from the intake manifold:
23. 24.
•
Oil
Slide the right camshaft pulley
b.
the timing
the bolts.
the camshaft timing pulleys.
fuel
pressure sensor
• Crankshaft position sensor
knock pin groove Install
the bolt
of the pulley,
and
then
tighten to 81
a.
Using a press, slowly press
220-2205 b.
lbs.
install
lbs.
ft.
the knock pin.
(110 Nm).
Align the holes of the pushrod
1.5mm hexagon wrench through
•
ECT ECT
ting position of the
• •
Knock sensor
c.
in
and housing, pass a
the holes to keep the set-
pushrod.
Release the press and
tensioner.
the pushrod using
(981-9807 N) of force.
Injectors
sensor
belt
Set the timing belt tensioner:
47.
•
sender gauge
on the camshaft. Align
and the timing
right pulley
Align the knock pin hole of the camshaft with the
c.
pressure regulator.
marks on the
cover.
the crankshaft pulley. the timing belt idler pulley.
13
to
36.
13.
steering,
down
35.
42.
power
the intake and tighten
(18 Nm).
Disconnect the spark plug wires. the engine splash shield from under the engine.
hose, then remove the bo, to
inlet
To
12.
the
the bolts, then disconnect the engine wire
Remove
38.
Disconnect the Data Link Connector No.
e.
Remove
30.
lbs.
ft.
intake air connector. d.
•
position sensor
29.
32.
Remove
Disconnect the engine wire clamps
securing the intake manifold stay.
up valve 10.
Camshaft
•
from the cylinder head
• Air assist from the intake air connector
•
•
install
the dust boot to the
ENGINE AND ENGINE OVERHAUL
3-50 48.
Install
the timing belt tensioner
the bolts to 20
mm
(28 Nm). Using
lbs.
ft.
and
hexagon wrench from the
69.
alternately tighten
pliers,
remove the 1.5
belt tensioner.
Check the valve
50.
Install
the fan bracket.
51.
Install
the
52.
Install
the timing belt cover. Tighten the bolts to 80 inch
timing.
power steering adjusting
strut.
EGR pipe. Tighten EGR pipe nuts
the
the clamp
Nm), and the
lbs. (8
to
14
ft.
70.
Connect the cables removed
71.
Install
72.
Fill
73.
Start the
earlier.
the air cleaner hose.
and water. Top off any fluids.
the radiator with a mixture of coolant
engine and check
for leaks.
Nm).
lbs. (9
Connect the clamps
53.
spark plug wires to the tim-
for the
ing belt cover.
1FZ-FE Engine >
Connect the camshaft position sensor
54.
See Figure 89
to the timing belt
Relieve the fuel pressure.
1
2.
cover.
On
55.
new gaskets on
(18 Nm).
lbs.
49.
Install
nuts to 71 inch
vehicles with A/C,
the compressor bracket and
install
•-CAUTION
compressor. Attach the fan with coupling and pulleys, tighten the nuts
56. to
48 inch 57.
Install
the fan shroud.
58.
Install
the alternator belt and cooling fan, tighten the fan
nuts to 4
ft.
Install
60.
Attach the power steering pump, pulley and drive
61.
Connect the upper
62.
Fill
63.
Connect the spark plug wires
64.
Install the intake air connector:
lines. Failure to
do
belt.
Disconnect the negative battery cable. belt.
^WARNING
radiator hose.
the radiator with a coolant/water mixture.
nuts to 14
The
to the plugs.
ft.
lbs.
bag system
is
equipped with a back-up power
working on the vehicle tive battery terminal is
on the intake
to the bracket
90 seconds has elapsed from
until
the time the ignition switch
(18 Nm).
Connect the DLC1
air
source. To avoid possible air bag deployment, do not start
the intake manifold, then tighten the bolts and
Install
b.
pressure before disconnecting any fuel so may result in fire or personal injury.
Nm).
lbs. (5
the A/C
59.
a.
Fuel injected engine systems remain under pressure after the engine has been turned OFF. Properly receive the fuel
Nm).
lbs. (5
is
turned
OFF and
the nega-
disconnected.
manifold. c.
Connect the ground strap
d.
Attach the brake booster
to the manifold.
vacuum hose
to the intake air
connector.
Connect the two
e.
On A/C
g.
65. to
Install
14
ft.
models, connect the
the
air
idle
PCV
•
Water bypass
•
Air assist
•
Two vacuum EVAP
•
7.
On A/C
air
connector
sensing hoses from the
vehicles, connect the air
Connect the following •
Vacuum
VSV
hose
to the idle
Disconnect the brake booster and
9.
Separate the
1 1
Disconnect the following
.
up
12.
•
Idle Air Control (IAC)
•
Connect the
EGR
gas temperature connector
• Connect the
VSV
connector
Install
a. lbs.
for the
chamber stay: the intake chamber stay
EGR
valve
a new O-ring
Install
c.
Push the
oil
filler
to the
tube end
Attach the
filler
rail.
electrical connections:
Engine Coolant Temperature (ECT) sender gauge
• •
ECT ECT
•
Knock sensor
•
Crankshaft position sensor
cut switch
sensor
Remove
the bolt that secures the engine harness to the
Disconnect the
Remove
PCV
hose from the
PCV
valve.
the bolt that secures the engine harness to the
intake manifold. bolts, tighten to
oil filler
into the
tube and the
hoses.
•
14.
30
ft.
15.
tube.
tube hole
in
throttle
cable clamp.
Disconnect the following: •
Engine wire clamps
•
EGR
temperature sensor connector
The fuel injector connections • The connector for the emission •
the
pan. d.
EVAP
return lines from the fuel
the intake manifold stay.
13.
(40 Nm).
b.
intake chamber.
cylinder block.
Valve
the intake
Install
and
Remove
Switching Valve (VSV) connector for the fuel
Throttle positioning sensor
fuel inlet
10.
wiring:
•
air
Detach the connection on the intake manifold from the
8.
pressure control
68.
Disconnect the engine ground strap from the engine
fender apron.
left
from the intake
valve 67.
cruise control vehicles, the actuator cable from the
body
hanger and the ground strap from the
• Air hose from the power steering •
cleaner hose and cap.
air
• Throttle cable (auto transmission)
tighten the bolts 6.
•
On
the
• Accelerator cable
up valve connector.
Attach these hoses:
66.
Disconnect the following cables: •
chamber assembly,
intake
Remove
5.
throttle
(18 Nm).
lbs.
Drain the engine coolant.
4.
hoses.
fuel return
Attach the engine wire to the intake manifold.
f.
3.
16.
Remove
the water bypass pipe.
control valve set
ENGINE AND ENGINE OVERHAUL 31 air
.
Connect the ground straps
to the
3-51
engine hanger and the
intake chamber.
32. Attach the throttle cable to the throttle body. 33.
Attach the accelerator cable to the throttle body.
and cap.
the air cleaner hose
34.
Install
35.
Connect the negative battery cable.
and water mixture
the coolant
36.
Refill
37.
Start the engine
and check
to the radiator.
for leaks.
Top
off
any
fluids.
Exhaust Manifold
REMOVAL & INSTALLATION
^'CAUTION When working on
or around a manifold,
make
ceratin
all
surfaces are cool to the touch before beginning to work.
Remove
17.
the
air
chamber and the
intake
intake manifold
assembly.
I
Disconnect the vacuum hoses at the Thermal
a.
Remove
1.
the bolts securing the intake manifold and
2.
Install
the
intake
air
chamber and
intake manifold
3.
Place a
new gasket so
that the rear
mark
is
Connect the vacuum hoses Install
20.
Connect the
Nm).
lbs. (21
TVV.
•
EGR
•
Fuel injector connections
•
The connector
for the
To 7.
emission control valve set
Install
8.
hose
to the
PCV
9.
the bolt that secures the engine wire harness to
26
ft.
26.
air
them so they
cleaner tube from the heat stove on
Use a 14
mm
wrench
remove the manifold
to
Remove
retaining
the manifold(s), complete with air injection tubes of the heat stove.
For 22 R engines, separate the inner portion of the heat
install:
Always use a new gasket. it
Install
any disassembled parts
in position.
the nuts and bolts, tightening
Install
the
Install
air
them
to
30
ft.
lbs.
cleaner and spark plug leads. Connect the
Connect the exhaust pipe
Connect the following wires:
30
•
Engine Coolant Temperature (ECT) sender gauge
bolts to
• •
ECT ECT
5VZ-FE Engine
•
Knock sensor
ft.
lbs.
(40
to the manifold, tightening the
Nm)
cut switch
sensor
I See Figures 93 and 94
LEFT SIDE
Attach the intake manifold stay and tighten the bolts to lbs.
(36 Nm).
Install
and the 27.
tie
air intake tube(s).
• Crankshaft position sensor 25.
leads. Position the
best to
(40 Nm).
valve.
the cylinder block. 24.
the
onto the manifold and place
the intake manifold.
23.
is
stove from the manifold.
the bolt that secures the engine wire harness to
PCV
4.
5.
gas temperature sensor connection
Connect the
It
10. nuts.
6.
Engine wire clamps
22.
Remove
and the inner portion
following:
•
Install
to the
ft.
the water bypass pipe.
19.
21.
Tag and disconnect the spark plug
stove.
Tighten the intake manifold bolts to 15
c.
the three exhaust pipe flange bolts and discon-
carbureted engines, and remove the outer part of the heat
toward
the rear side. b.
Remove
don’t get in your way.
assembly: a.
and 92
spark plug wires out of the way.
install:
18.
90, 91
nect the exhaust pipe from the manifold.
gasket.
To
See Figures
Vacuum
(TVV) Valve. b.
22R, 22R-E, and 3VZ-E Engines
1
the radiator
inlet
2.
alternator.
Install
the heater hose to the cylinder head, then con-
nect the pipe to the intake manifold. Tighten the bolts to 15 lbs. (21
3. ft.
4.
To
Nm).
28.
Connect the
29.
Connect the brake booster and
30.
Attach the connector on the intake manifold to the
fender apron.
.
fuel inlet
and
return
hoses
EVAP
to the fuel
rail.
Disconnect the exhaust crossover pipe from the exhaust
manifold.
hose, the water bypass hose,
5.
Remove Remove Remove
the
EGR
pipe from the manifold.
the heat insulator from the manifold. the manifold.
install: Install
the exhaust manifold to the engine with a
gasket. Tighten the nuts to 30
hoses. left
6.
Install
ft.
lbs.
the heat insulator, tighten the nuts
inch lbs. (8 Nm).
new
(40 Nm).
down
to 71
3-52
ENGINE AND ENGINE OVERHAUL
PLUG BOLT
86823pc2
Fig.
90 Exploded view of the exhaust manifold assembly found on 22R engines with Federal emissions
ENGINE AND ENGINE OVERHAUL
Fig. 91
Exhaust manifold found on 22R engines with Canadian emissions
3-53
3-54
ENGINE AND ENGINE OVERHAUL
ENGINE AND ENGINE OVERHAUL 7.
Connect the
to
14
ft.
(8
Nm). 8.
EGR
pipe to the manifold. Tighten the nuts
(18 Nm). Tighten the clamp nuts to 71 inch lbs.
lbs.
tighten the nuts to 33
ft.
lbs.
2RZ-FE and 3RZ-FE Engines See Figures 95 and 96 1
Attach the crossover pipe to the exhaust manifold,
.
2.
(45 Nm).
3-55
Raise and safely support the vehicle. Disconnect the front exhaust pipe from the manifold and
mounting bracket.
RIGHT SIDE 1
.
Disconnect the exhaust crossover pipe from the exhaust
2.
Remove
3.
Unfasten the
six nuts securing the manifold
6.
from the
(8
7.
install: Install
the exhaust manifold with the new gasket, tighten ft.
lbs.
(40 Nm).
Attach the heat insulator, tighten the nuts to 71 inch
lbs.
Connect the crossover pipe with a new gasket, to the to 33 ft. lbs. (45 Nm).
exhaust manifold. Tighten the nuts
86823pb4
Fig.
93
the exhaust manifold and gasket.
install: Install
the exhaust manifold
36
ft.
lbs.
and gasket
Remove
the bolts securing the crossover pipe
to the manifold(s)
to the engine,
(49 Nm).
Attach the heat insulator, tighten the bolts and nuts to
48 inch
lbs.
(5
Nm).
8.
Raise and support the vehicle.
9.
Install
the front exhaust pipe to the manifold with
gaskets. Apply a gasket to the front pipe,
Nm). 6.
vehicle.
the heat insulator.
tighten the nuts to
the six nuts to 30 5.
Remove Remove
To
the exhaust manifold heat insulator.
engine.
4.
Lower the
4.
5.
manifold.
To
3.
tighten to
46
ft.
lbs.
install
new
the nuts and
(62 Nm).
10.
Attach the support bracket, tighten to 29
11.
Attach the clamp and tighten to 14
ft.
ft.
lbs.
lbs.
(39 Nm).
(19 Nm).
ENGINE AND ENGINE OVERHAUL
3-56 1
Lower the
2.
vehicle.
Start the engine
13.
and check
for
exhaust leaks.
1FZ-FE Engine t See Figures 97 and 98 1
Disconnect the negative battery cable.
.
2.
Raise and safely support the vehicle.
3.
Working from underneath the
ygen sensor
Remove
4.
vehicle, disconnect the ox-
wire.
the nuts and bolts holding the front header pipe
to the catalytic converter.
Loosen the pipe clamp.
5. 6.
Remove
7.
Unbolt the front header pipe and remove the gasket.
8.
Lower the
the pipe bracket.
vehicle,
remove the exhaust manifold heat
shield insulators.
Remove
9.
the nuts from the exhaust manifolds, then the
gaskets.
To
install:
10.
Install
the exhaust manifolds to the engine with
gaskets. Uniformly tighten the nuts the nuts to 29 1 1
to
Install
.
14 12.
new 13.
ft.
lbs.
ft.
lbs.
new
several passes. Tighten
in
(39 Nm).
the exhaust manifold heat insulators, tighten
down
REMOVAL & INSTALLATION
(19 Nm).
Attach the header pipe to the exhaust manifold using gaskets, tighten the nuts to 46 Install
ft.
lbs.
(63 Nm).
the support bracket, then tighten to 17
ft.
lbs.
(24
•-•-'CAUTION
Nm). 14.
Attach the clamp, tighten to 14
15.
Connect the header pipe
ft.
lbs.
gasket to prevent leaks. Tighten to 34
ft.
lbs.
When
(19 Nm).
to the catalyst using
a
(46 Nm).
new
draining coolant, keep
any that
likely to drink
Attach the oxygen sensor wire.
in
17.
Connect the negative battery cable.
quantity.
Always drain coolant
18.
Start the engine
Coolant
may be reused unless
for
exhaust leaks.
that cats
and dogs
puddles on the ground. This
eral
an uncovered container or
is left in
16.
and check
mind
in
are attracted by ethylene glycol antifreeze, and are quite
will
prove
fatal in sufficient
into a sealable container. it
is
contaminated or sev-
years old.
22R and 22R-E Engines I See Figures 99, 100, 101, 102 and 103 1.
Discharge the A/C system using an approved recov-
ery/recycling machine. Refer to Section 2.
1
Drain the cooling system.
•-CAUTION Never remove the pressure cap while the engine
is
run-
ning or personal injury from scalding hot coolant or steam
may
result.
If
possible, wait until the engine has cooled to
remove the pressure cap. If this is not possible, wrap a thick cloth around the pressure cap and turn it slowly to the stop. Step back while the pressure is released from the cooling system. When you are sure all the pressure has been released, still using the cloth, turn and remove the cap.
3.
Remove
4.
Disconnect the reservoir hose and remove the reservoir
the engine undercover.
tank. 5.
Disconnect the radiator hoses.
6.
Remove
the fan shrouds.
ENGINE AND ENGINE OVERHAUL 7.
Disconnect the
oil
cooler lines (automatic transmission).
Plug the lines immediately to prevent 8.
Remove
remove the
3-57
oil
ioss.
the nuts and bolts holding the radiator. Carefully
radiator.
-•-'•-WARNING 9.
Use care not
to
damage
the radiator fins or the cooling
fan.
To
install: If
new
replacing with a used radiator or your old one,
install
O-ring onto the petcock.
10.
Install
certain
all
the radiator and tighten the mounting bolts.
Make
the rubber mounts and bushings are present and
correctly placed. 86823pd7
Fig.
99 Loosen the petcock and allow the coolant to
drain into a suitable container
1 1
.
Install oil
12.
Install
13.
With
14.
Install
cooler lines
if
they were removed.
the fan shrouds.
new hose clamps, connect
the radiator hoses.
the reservoir tank and connect the hoses.
86823pd5
Fig.
100 Slide the clamp up the overflow hose, then
disconnect the hose from the radiator neck
86823pd8
Fig. 102 It may be necessary to use a deep socket or an extension to access the retainers
MM
86823pd4
Fig. 101
as
some
Be
when disconnecting may be left in it
careful
coolant
the lower hose,
Fig.
103 Be careful not to damage the fins when
the radiator out
86823pd9
lifting
a
ENGINE AND ENGINE OVERHAUL
3-58 15.
Fill
the radiator with a water coolant mixture, start the
16. 17.
Top
On
off
the coolant with the engine running.
transmission
may have been
fluid
fluid
lost
and adjust as needed. Some
3F-E Engine I See Figures 104 and 105
ery/recycling machine. Refer to Section 2.
Install
ft.
remove the pressure cap. If this is not possible, wrap a around the pressure cap and turn it slowly to the stop. Step back while the pressure is released from the cooling system. When you are sure all the pressure has been released, still using the cloth, turn and remove
remove the front turn signal lamp assembly, radiator grille and headlamp doors. 4. Remove the hood lock brace, hood lock, grille center 10. support and grille. Some models need the engine under cover
Make
(12 Nm).
18.
With
19.
Install
20.
Reinstall the engine
21.
Attach the coolant reservoir hose.
22.
Install
the
air
23.
Install
the
hood lock brace, hood
and
24.
Fill
26.
27. 28. 29.
and
oil
cooler hoses.
new hose clamps, connect
the radiator hoses.
the battery and battery tray
if
removed.
under cover.
conditioning condenser. lock, grille center
sup-
grille.
the radiator to the specified level
Check the Fill
Start the
removed. battery
coupling and the fan shroud.
fluid
and check
for
leaks.
to
remove the
the fan,
Install
Attach the A/T
25.
to
lbs.
ft.
17.
needed.
On 1989-90 models you need
(B) bolts to 9
mounts and bushings are present and
16.
port
the cap.
5.
Nm) and
the rubber
all
correctly placed.
thick cloth
need
install
1
Never remove the pressure cap while the engine is running or personal injury from scalding hot coolant or steam may result. If possible, wait until the engine has cooled to
will
need a
the radiator and tighten the (A) mounting bolts to
(18
lbs.
Drain the cooling system.
On some models you
will
leak out on removal.
will
replacing with a used radiator or your old one,
If
certain
**CAUTION
3.
which
O-ring onto the petcock.
15.
13 conditioning system using a recov-
You
cooler hoses.
oil
install:
new
air
oil
The
also.
radiator.
To
Discharge the
need removal
the radiator mounting bolts, nuts and then the
Remove
13.
from the bottom of the radiator after
14.
.
will
Disconnect the A/T
12.
removal.
1
the fan shroud, fan and the fluid coupling.
Remove
.
suitable container to catch
vehicles with automatic transmissions, check the
level of the
1 1
alternator belt
engine and check for leaks.
Some
level of the transmission fluid
fluid
may have been
and adjust as
during removal.
lost
the coolant/water mixture to the appropriate amount.
engine and top
off.
Check the A/T fluid level, top Check for leaks. Recharge the A/C system.
off
if
needed.
2RZ-FE and 3RZ-FE Engines
battery case. 6.
Disconnect the A/C discharge hose and
liquid tube.
^Make
sure you cap the open fittings immediately to keep moisture from entering the system.
I
See Figures 1.
Remove
8.
Disconnect the coolant reservoir hose and tank.
9.
Remove Remove
the condenser.
3.
the radiator hoses.
the power steering and
air
conditioning belts.
and 109
Drain the engine cooling system.
Have a
large
enough
suitable container to collect the fluid. 2.
7.
106, 107, 108
Remove the grille, filler and clearance lamps. On the 3RZ-FE California models, disconnect
pipe. 4.
Disconnect the upper radiator hose.
5.
Unsecure the
radiator reservoir hose.
the air
a
ENGINE AND ENGINE OVERHAUL
3-59
3RZ-FE for California
Air Pipe
Radiator
Cap
9 Radiator
See Figures 116 and 117 Drain the engine coolant.
1.
2.
Disconnect the
3.
On
the
2WD
and
valve, gaskets
relief
On 4WD
4.
gaskets and
oil
vehicles,
cooler hoses.
oil
remove the 2
bolts,
union
bolt,
cooler.
remove the center
bolt, relief valve,
cooler.
Inspect the
5.
oil
vehicles,
oil
cooler for
damage
or clogging.
If
needed
replace.
To
install:
6.
Replace the O-rings when
7.
On
the
2WD
valve, union bolt
installing the
oil
cooler.
vehicles, install the cooler with the relief
and 3 new gaskets. Tighten down
to
43
ft.
Non-reusable part 86823pg0
Fig.
116 Exploded view of the
oil
cooler assembly found on 3VZ-E engines
ENGINE AND ENGINE OVERHAUL
3-64 lbs.
(59 Nm). Install the other 2 bolts and tighten to 29
lbs.
ft.
(39 Nm). 8.
On
the
valve and 2
4WD
new
vehicles, install the
Tighten the other 2 bolts to 29 9.
10.
Connect the Fill
oil
ft.
cooler with the
ft.
lbs.
relief
(59 Nm).
(39 Nm).
lbs.
cooler hoses.
the engine with a mixture of water and coolant. Start
the engine, top 11.
oil
gaskets. Tighten to 43
off
the fluid
Recheck the engine
and check
oil
for leaks.
level.
5VZ-FE Engine I
See Figures 118, 119 and 120 1.
Drain the engine cooling system.
2.
Disconnect the
3.
Remove
To
the
oil
cooler hoses.
bolt, relief valve,
gaskets and
4.
Replace the O-ring on the
5.
Use new gaskets for the relief valve. Mount the cooler assembly and tighten
6.
oil
cooler.
install: oil
cooler.
to
43
ft.
lbs.
(59
Nm). Fig. 7.
119 Disconnect the hoses indicated
Attach the cooler hoses.
Non-reusable part 86823pg5
Fig.
118 Exploded view of the
oil
cooler assembly found on 5VZ-FE engines
ENGINE AND ENGINE OVERHAUL
8.
Fill
the engine with a mixture of water and coolant. Start
the engine, top off the fluid 9.
Recheck the engine
and check
for leaks.
3F-E Engine I
Disconnect the heated oxygen sensor wiring.
Remove
See Figures 121 and 122
5.
Unbolt the front pipe and remove the gasket.
6.
Loosen the clamp
Remove Remove Remove
Drain the cooling system. 8.
2.
Remove
the air cleaner hose. 9.
3.
Drain the engine
oil
bolt,
then disconnect the clamp from
the support bracket. 7.
1.
the nuts and bolts holding the front header pipe
to the catalyst.
level.
oil
3.
4.
3-65
and remove the
the bolts and the support bracket. the nuts, exhaust pipe and gaskets. the bolts and the heat insulator.
filter.
Loosen the nuts
10.
for the
exhaust manifold, then remove
it
and the gasket.
}:*CAUTION
11.
Unscrew the
12.
Unbolt the
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize you exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand
cooler cover.
cleaner should be used.
falls
pressure switch.
oil
cooler and cover assembly, discard of the
oil
gasket.
Remove
13.
Remove
14.
the
the nuts,
oil
cooler and gaskets from the
the plug, gasket, spring and
relief
oil
valve from
unit.
Coat the
15.
smoothly
relief
valve with engine valve hole by
into the
its
and check
oil
own
weight.
that
it
not
If
replace the valve. 4.
Disconnect the
5.
Remove
oil
cooler hoses.
the two union bolts, gaskets,
oil
cooler and 0-
6.
7.
Check the
oil
cooler for
damages
the
oil
cooler by placing the O-rings
8.
Attach the
oil
cooler hoses.
9.
Attach the
air
cleaner hose.
new engine
ft.
lbs.
position
the crankcase with
11.
Fill
the cooling system.
12.
Start the engine, top off the coolant level.
oil.
18.
2.
oil
and new gasket along lbs.
cooler and cover with 2
a
new
gasket,
oil
new
gaskets. (17
lbs.
ft.
cooler and cooler cover assem-
Apply Loctite® or equivalent pressure sending
oil
unit,
then
to the first install
to
15
ft.
lbs. (21
2-3 threads of
the unit into the
the
20.
Using a
new
gasket, attach the exhaust manifold to the
21.
Install
22.
To
ft.
lbs.
(39 Nm).
the heat insulator, tighten to 14
install
125, 126, 127, 128
and 129
23.
Drain the engine cooling system. lid.
lbs.
Install
lbs.
ft.
the front header pipe, apply 2
(19 Nm).
new gaskets
to
46
ft.
lbs.
(63 Nm).
the support bracket, tighten to 17
ft.
lbs.
(24 Nm).
the front of the pipe attach, then tighten to
the air cleaner
with
(37 Nm).
10 bolts and 2 nuts, tighten them
engine, tighten to 29
for leaks.
Remove
Install
bly with the
Connect the clamp and (20 Nm).
24. .
Assemble the
ft.
engine.
Check
level.
See Figures 123, 124, 1
valve, spring,
Nm).
19.
1FZ-FE Engine *
the
(64 Nm).
on
the
Fill
Check
relief
Nm).
10.
13.
in
new gaskets and
union bolts. Tighten the union bolts to 47
oil
the
Attach the cover with the 4 nuts. Tighten to 12
the cooler. Install the cooler with two
engine
Install
17.
or clogging.
install: Install
install:
the plug. Tighten the plug to 27
rings from the engine.
To
To 16.
tighten the
clamp
bolt to
14
ft.
3-66
Fig. 121
ENGINE AND ENGINE OVERHAUL
Exploded view of the
oil
cooler unit found on the 3F-E engine
ENGINE AND ENGINE OVERHAUL
3-67
Accelerator Cable
Cruise Control Actuator Cable
No.1 Heat Insulator
No.1 Exhaust Manifold
Oil
Cooler
Gasket "
Gasket
Relief Valve
Spring
Gasket Plug
Non-reusable part
86823ph4
Pig-
123 Exploded view of the
oil
cooler and mounting
3-68
Fig.
124
ENGINE AND ENGINE OVERHAUL
Remove
the bolts securing the insulator
126 Use an extension to reach the mounting bolts Fig.
oil
cooler
.
.
.
Fig.
127 The cover can be separated from the
Fig.
129 Check that the
the hole under
its
relief
own weight
oil
cooler
valve falls smoothly into
ENGINE AND ENGINE OVERHAUL 25.
Attach the front header pipe to the catalyst using
gaskets. Tighten to 34 26.
Install
27.
Fill
new
(46 Nm).
lbs.
the air cleaner
lid
Check
off
the fan connection.
8.
Plug
9.
Start the vehicle
in
and check
for operation.
and hose.
the radiator with a water coolant mixture, start the
engine and top 28.
ft.
3-69
Pump
Water
the levels.
for leaks
and check the engine
oil.
REMOVAL & INSTALLATION Engine Cooling Fan
^CAUTION
REMOVAL & INSTALLATION When
draining coolant, keep
mind
in
and dogs
that cats
are attracted by ethylene glycol antifreeze, and are quite
Excluding 3F-E >
any that is left in an uncovered container or puddles on the ground. This will prove fatal in sufficient
likely to drink in
See Figure 130
Always drain coolant
quantity. 1
.
2.
Disconnect the negative battery cable.
Remove
Coolant
the alternator, A/C and power steering
(if
appli-
eral
may be reused
into a sealable container.
unless
it
is
contaminated or sev-
years old.
cable) belts. 3.
Loosen the
bolts holding the
water
pump
pulley (not the
22R and 22R-E Engines
pump). 4. ling),
To 5.
Remove
the nuts, then
remove the fan
clutch (fluid coup-
> See Figure 131
fan and pulley. install: Install
the pulley, clutch and fan; loosely
fit
the nuts
in
Drain the cooling system.
Unfasten the fan shroud securing bolts and remove the
fan shroud,
place. 6.
1.
2.
Install
the drive belt to the water
the nuts to 16
ft.
lbs. (21
pump
pulley. Tighten
Remove
4.
Install
8.
Connect the negative battery cable.
OFF, unplug the connector
ignition
2.
Remove Remove Remove
the fan shroud.
3.
4.
the
air
Detach the bypass hose from the water pump. Unfasten the water
To 5.
pump and
27
the water
Install lbs.
ft.
8.
Install
Attach the cooling fan.
9.
Refill
the air intake silencer
Install
7.
Attach the fan shroud.
and support.
retaining bolts
pump and
(37 Nm). Always use a
install:
6.
pump
and remove the
fan assembly, using care not to
damage
the
install:
7.
pump body and
assembly.
power steering pump
radiator with the fan.
and support.
remove the cooling fan
the air conditioning and/or
6.
To
intake silencer
the 3 bolts and
at the fan.
and remove the
5.
water With the
bolt
drive belt.
3F-E Engine 1.
so equipped.
drive belt.
Nm).
the belts to the other pulleys and adjust.
7.
if
Loosen the alternator adjusting
3.
its
tighten the mounting bolts to
new gasket between
the
mounting.
the drive belts and adjust the tension. the cooling system, start the engine and check for
leaks.
3F-E Engine
See Figure 132 1.
Drain the coolant from the engine and radiator.
2.
Loosen the
power steering
and adjusting
bolts to
remove the
Disconnect the coolant reservoir hose and the radiator
3. inlet
idler pulley
belt.
hose.
7.
Remove the bolts holding the fan shroud. Remove the alternator drive belt, fan, fluid pump pulley. Remove the alternator. Remove the air conditioning belt.
8.
Disconnect the four hoses from the water pump.
9.
Remove
4. 5.
water 6.
bolt,
two nuts and power steering
coupling,
and
idler pulley
with the bracket assembly. 10.
water Fig.
130 There are four nuts retaining the fan blade to
the fluid coupling
Remove the bolt and pump and gasket.
To
install:
11.
Install
a
new
nut, alternator
gasket, the water
port bracket with the bolt
and
nut.
support bracket,
pump and
alternator sup-
ENGINE AND ENGINE OVERHAUL
3-70
6D
Non
reusable part 86823pj5
Fig. 131
12.
Exploded view of the water
Install
the
power steering
— 22R
pump mounting
idler pulley with
the bracket
assembly.
and 22R-E engines 3VZ-E and 5VZ-FE Engines I
pump
13. Tighten the water
nuts and bolt to 27
ft.
lbs.
See Figures 133 and 134
(37
•^WARNING
Nm). the air conditioning belt and adjust
14.
Install
15.
Connect the hoses
to the water
16.
Install
the alternator.
17.
Install
the water
pump
it.
This procedure requires the removal of the timing
pump.
pulley along with the fan
and
coupling. Place the drive belt(s) onto each pulley; press to tighten the belts against the pulley
and
fluid
down
tighten the four nuts.
Install
19.
Attach the radiator
inlet
hose and connect the reservoir
hose. Install
21.
Install
22.
Start
—
and
Installation in this section.
Do
not attempt to remove
the belt without consulting the procedure; extreme engine
occur.
the fan shroud bolts.
18.
20.
is
damage may
Adjust the belt tension.
belt.
an extensive procedure requiring precision work, particularly at reassembly. Refer to Timing Belt Removal
This
and adjust the power steering
belt.
amount of coolant in the system. the engine and check for leaks. the proper
1.
Drain the cooling system.
2.
4.
Remove Remove Remove
5.
Disconnect the
3.
Remove
the timing belt.
the idler pulley. the thermostat. oil
cooler hose from the pump.
the seven bolts
and the tension spring bracket and then remove the water pump. 6.
ENGINE AND ENGINE OVERHAUL
3-71
Water By-pass Hose Heater Water Hose
Wate Pump Water
Water
Pump
Inlet
Plate
Hose
Pulley
Oil
Gasket
Pulley Seat
Water
Cooler Water Hose
Gasket
Pump
Fluid Coupling F an
Drive Belt
Non-reusable part 86823pj7
Fig.
132 Exploded view of the water
Fig.
133 Apply sealant to the areas
pump mounting on
shown
the 3F-E engine
ENGINE AND ENGINE OVERHAUL
3-72
2RZ-FE and 3RZ-FE Engines 1
Disconnect the negative battery cable.
.
-•-•'CAUTION On vehicles with air bags, work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative (-) battery cable is disconnected.
Drain the cooling system.
2. 3.
equipped with an
If
pump
steering
remove the
adjusting bolt,
nents) out 4.
of the
power
conditioning compressor or
air
drive belts,
may be necessary to loosen the drive belt(s) and move the compoit
way.
Remove
the
Remove
the water
coupling with the fan and water
fluid
pump
pulley. 5.
To
pump.
install:
6.
Clean the gasket mounting surfaces.
7.
Install
the replacement water
8.
Install
the water
Install
the removed engine drive belts.
pump
pulley
pump and
using a
fluid
new
gasket.
coupling with the
fan. 9.
the cooling system.
10.
Fill
11.
Connect the negative battery cable.
check
Start the engine
and
for leaks.
Bleed the cooling system.
12.
1FZ-FE Engine > See Figures 135 and 136
•'CAUTION On vehicles with air bags, work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative (-) battery cable is disconnected.
1
To 7.
install:
Remove any
old packing from the
pump and mounting
area of the engine. Be careful not to drop any
oil
on the
Apply sealer
Drain the engine coolant.
3.
Disconnect the water bypass and radiator
4.
Remove
Disconnect the
5.
to the
pump-to-block mating surface and
then tighten the bolts marked
A
(18 Nm). Tighten those marked
»^The parts must be tion of the sealant.
in
B
the illustration to 13 to
14
ft.
installed within 5
lbs.
ft.
lbs.
(20 Nm).
minutes of applica-
Otherwise you must remove and reap-
Remove
shroud.
9.
Connect the
oil
cooler hose.
Install
the thermostat with a
Remove
6.
To
11.
Install
the idler pulley.
12.
Install
the timing belt.
13.
Install
14.
Refill
the drive belts
gasket.
Install
the 4 bolts, 2 nuts, water
Install
a.
and adjust the tension.
pump, and the
the water ft.
pump
lbs. (21
the water
using a
new
gasket. Tighten the
Nm).
pump
pulley, fan shroud,
and the
drive
as follows:
belts
ley,
the cooling system and check for leaks.
cooler hose from the clamp on the fan
install:
8.
new
oil
the bolts holding the fan shroud to the
gasket.
fasteners to 15
10.
hoses.
radiator.
7.
ply the sealer.
inlet
the drive belts, fan assembly, and the fan
shroud.
mating areas. 8.
Disconnect the negative battery cable.
.
2.
Place the fan with the
and the fan shroud
b.
Temporarily
c.
Install
lbs. (5 d.
fluid
coupling, water
pump
pul-
position.
the fan pulley mounting nuts.
the fan shroud and tighten the bolts to 43 inch
Nm).
Connect the
shroud.
install
in
oil
cooler hose to the clamp on the fan
ENGINE AND ENGINE OVERHAUL
3-73
No.3 Water Bypass Hose
Fan Shroud
Non-reusable part
Radiator
Inlet
Hose 86823pk0
Fig.
135 Exploded view of the water
pump mounting on
the 1FZ-FE engine
ENGINE AND ENGINE OVERHAUL
3-74 9.
Connect the water bypass and
radiator hoses.
the
Fill
10.
cooling system. 10.
Connect the negative battery cable.
1 1
Start the engine,
.
check
for leaks
and top
off
the fluids.
Cylinder Head 1 1
.
REMOVAL & INSTALLATION
See Figures
•
EGR
•
Water temperature gauge sender
temperature sensor
•
Cold mixture heater wire
•
Temperature sensor
•
Fuel cut solenoid valve
•
EACV
(Calif,
vehicles only)
(Calif, only)
Label and disconnect these hoses and
lines:
• Charcoal canister
22R Engine I
Label and disconnect these wires:
137, 138, 139, 140, 141, 142, 143, 144, 145,
146 and 147
•
Brake booster
•
Main
•
Fuel return line
•
HAC
•
Electronic Bleed Air Control Valve
fuel line
from fuel
inlet
from the bracket
(EBCV)
Calif,
vehicles
14.
Vacuum Switching Valve (VSV) with bracket Remove the rear ground strap from the engine. Remove the distributor. Remove the spark plugs.
15.
Disconnect the power steering bracket from the head.
•
-•-'•-WARNING 12.
Do
not perform this operation on a
the engine to cool a
minimum
weather. Overnight cold
is
warm
engine. Allow
of 3 hours,
more
in
13.
hot
best.
6.
1
1.
Disconnect the negative battery cable.
2.
Drain the cooling system (both radiator and block).
coolant
is
to
be reused, place a
17. If
the
large, clean container under-
neath the drains.
until
Remove
the valve cover
the piston
is
in
dogs
draining coolant, keep in mind that cats and
any that
is left in
puddles on the ground. This
quantity.
Always drain coolant
Coolant
may be reused unless
Remove
an uncovered container or prove fatal in sufficient
into a sealable container. it
is
contaminated or sev-
gear and spacer
cam
sprocket
in
place just
off
falling
18.
Remove
the timing chain cover bolt at the front of the
head. This must be done before the head bolts are removed. 19. Remove the cylinder head bolts in Make two or three passes to loosen the bolt
all
at
the correct order. bolts.
Do
not loosen
once; improper removal could cause head
Using prybars applied evenly
the air cleaner assembly, complete with hoses,
fall
into
Drain the engine
it.
oil.
•-'•-CAUTION oil
may cause
skin cancer
if
repeatedly
left in
contact with the skin for prolonged periods. Although this is unlikely unless you handle oil on a daily basis, it is wise to thoroughly wash your hands with soap and water immediately after handling used motor oil.
6.
Disconnect the radiator
7.
If
equipped with an
air
at the front
and the rear
the valve rocker assembly, gently pry the assembly
inlet
hose from the water
pump, disconnect the
air
outlet.
hose
from the check valve. 8.
Disconnect the two heater hoses from the engine.
9.
Disconnect the accelerator cable at the carburetor.
of
off its
mounting dowels. 21.
Used motor
Slide the
bolt.
the cam. Leave the chain
off
damage.
•••Cover the carburetor with a clean shop cloth so that
5.
and remove the
the engine.
from the carburetor.
nothing can
chain,
sprocket
it
in
20.
Remove
cam cam
end of the cam or rest the sprocket on the vibration damper. Tie a string or wire to the chain to keep from
the three exhaust pipe flange nuts and separate
the pipe from the manifold. 4.
the
the
any one 3.
to the
Remove
bolt)
compression stroke. Match-
its
will
years old.
eral
on
on the sprocket; either wire the
are attracted by ethylene glycol antifreeze, and are quite likely to drink
TDC
mark the timing sprocket distributor drive
When
at
semi-circular plug.
'•-'•-CAUTION
and gasket.
Turn the engine clockwise (use the crank pulley
Lift
the head
off its
gently with small tools.
dowels.
If
it
is difficult
Do NOT damage
to
lift
off,
pry
the mating surfaces
ENGINE AND ENGINE OVERHAUL
9
7
1
3-75
4
6
86823pl0
Fig.
138 Using a
19mm
wrench, remove the
cam
Loosen the head bolts
Fig. 141
in this order, in
three
passes
sprocket bolt
of the
block;
22.
head or block. Do must be lifted.
NOT
attempt to slide the head
off
the
it
Support the head on a workbench.
EGR valve from the head on Keep the head covered and the manifold ports plugged with rags when not working on 24. Re-drain the oil pan after the head has been removed; coolant will have spilled into the pan during head removal. The 23.
Remove
the manifolds and
the workbench.
it.
coolant 25.
pollute the
will
Remove
To
install:
26.
Apply
install
27.
liquid
oil.
head gasket, never reuse the
old one.
sealer to the front corners of the block and
head gasket. Lower the head over the the
to slide
28.
the
it
locating dowels.
Do
not attempt
into place.
Install
the rocker
arm assembly over
its
positioning
dowels. 29.
Install
tially in
the cylinder head bolts. Tighten the bolts sequen-
three passes and
in
the correct order, coming to
torque on the last pass. Correct tightness
Fig.
140
Remove
is
58
ft.
lbs.
final
(78
Nm)
86823pl3
the front cover bolt before loosening
the cylinder head bolts
Fig.
142
Lift
the old gasket from the block
3-76
ENGINE AND ENGINE OVERHAUL
86823pl4
Fig.
143 Scrape and clean the area well, insert paper
into the cylinder walls to
keep
dirt
from entering 30.
Install
the chain cover
Tighten
bolt.
it
to
9
ft.
(13
lbs.
Nm). 31
.
gine
Hold the chain and sprocket; double check that the enis
set to No.
1
TDC.
necessary, manually rotate the
If
engine so that the sprocket hole 32.
is
also at the top.
the sprocket over the camshaft dowel.
Fit
the chain
If
won’t allow the sprocket to reach, rotate the crankshaft back
and
forth,
33.
while
Install
up on the chain and sprocket.
lifting
the distributor drive gear and
cam
thrust plate
over the chain sprocket; tighten the camshaft sprocket bolt to
58
ft.
34.
lbs.
(78 Nm).
Set the No.
1
piston at
TDC
of
compression stroke
its
and adjust the valves. 35.
Apply sealant only the cylinder head side
of the half-
circle plug; install the plug.
the valve cover
36.
Install
37.
Attach the power steering bracket and compressor sup-
port to the cylinder head. Tighten the bolts to
33
lbs.
ft.
(44
Nm)
10
4
2
5
power steering
38.
Install
the
39.
Install
the distributor.
40.
Connect the rear ground
41
Install
.
7
belt
Install
and adjust the tension.
the spark plugs
strap.
the lines and hoses disconnected:
•
Charcoal canister
•
Brake booster
•
Main
•
Fuel return line
•
HAC
•
Electronic Bleed Air Control Valve
fuel line
from fuel
inlet
from the bracket
(EBCV)
Calif,
vehicles • 42.
Vacuum
Switching Valve (VS V) with bracket
Connect the wires removed: •
EGR
•
Water temperature gauge sender
temperature sensor
•
Cold mixture heater wire
•
Temperature sensor
(Calif,
vehicles only)
• Fuel cut solenoid valve • Fig. 145 Tighten the head bolts passes
in this order, in
three
EACV
(Calif, only)
43. Attach the accelerator cable. 44.
Connect the
removed.
air
pump hose
to the
check valve
if
it
was
ENGINE AND ENGINE OVERHAUL
Cylinder Head Cover
Gasket 22R-E, Air Intake
Chamber
Rocker
Arm Assembly
Valve Keepers Valve Spring Retainer
Compression Spring Oil Seal
Valve Spring Seat
Valve
It
Gasket
Camshaft Bearing Cap Cylinder Head Rear Plate
Gasket No. 2 Air Injection Manifold (Federal and Canada)
X
Gasket
-
Gasket
Exhaust Manifold Plate (Calif.)
^
Exhaust Manifold and Insulator
86823pq0
Fig.
147 Exploded view of the cylinder head components on the 22R and 22R-E engines
3-77
ENGINE AND ENGINE OVERHAUL
3-78 45. to the
46.
Connect the 2 heater hoses and water
install
•
the radiator hose
Use a new gasket and connect the exhaust pipe New nuts are recommended. Install the air cleaner and connect the hoses. Refill the engine oil and engine coolant.
to the
manifold. 47. 48.
49. Double check tention to loose
routing of in
Switching Valve (VS V) hoses (with
•
Evaporative emissions (EVAP) hoses
•
EGR
•
Reed
•
Pressure regulator hose.
Vacuum hoses from throttle body Water bypass hoses from throttle body
hoses or hanging wires, untightened
nuts,
poor
•
and
tools
left
•
hoses and wires
(too tight or rubbing)
Connect the negative battery cable.
51.
Start the engine, allowing
to idle
it
valve hose
at-
valve hose
11. Tag and disconnect the EGR vacuum modulator hoses and then remove the modulator itself along with the bracket.
the engine area.
and warm up
Disconnect the following wires:
12.
•
gradually.
and wire
start injector pipe
Cold
• Throttle position sensor wire
52.
Shut the engine OFF. Readjust the valves.
53.
Restart the engine and adjust the timing as necessary.
54.
Recheck the fluid levels. Road test the vehicle for general performance and
•
EGR
temperature sensor
chamber. Remove the
(Calif,
vehicles)
start injector pipe
Disconnect the cold
13.
EGR
bolt holding the
chamber. Disconnect the chamber from the
driveability.
air
22R-E Engine
from the intake pipe to the
chamber-to-intake manifold bolts and then
ber with the
throttle
Disconnect the fuel return hose.
146 and 147
15.
Tag and disconnect the following wires: • Knock sensor • Oil pressure sender gauge or switch •
Never perform this operation on a hot engine. Allow the engine to cool a minimum of 3 hours, more weather. Overnight cold is best.
.
2.
in
hot
Drain the coolant from the radiator and the cylinder oil.
**CAUTION
•
Compressor wires
•
Injector wires
•
Water temperature sender gauge wire
•
Overdrive temperature switch wire (auto, trans.)
(with air conditioning)
•
Igniter wire
•
Vacuum
•
Cold
•
Water temperature sensor wire
Switching Valve (VSV) wires
start injector
time switch wire
dogs
16.
Disconnect the bypass hose
17.
If
draining coolant, keep in mind that cats and
an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. likely to
Coolant
drink any that
is left in
may be reused unless
it
is
contaminated or sev-
position
Remove
4.
Disconnect the oxygen sensor wire.
5.
Remove
the
air
intake connector.
it
way
out of the
18.
Remove
the
Remove
the valve cover.
power steering bracket from the cylinder
sure to cover the
oil
return hole in the cylinder head
with a clean rag to prevent anything from falling
the three nuts attaching the manifold to the
the No.
piston
at
TDC
until
Remove the oil dipstick. 7. Remove the distributor with tached. Remove the spark plugs.
Matchmark the timing sprocket
6.
the spark plug leads at-
hoses where they attach
to the
engine and then position them
the semi-circular plug.
is
Remove
on
its
just off the
Disconnect the actuator cable, the accelerator cable and
end
of the
cam
compression stroke.
cam chain, and remove cam sprocket bolt. Slide
to the
the
chain on the sprocket; either wire the
tion
out of the way. 9.
1
the distributor drive gear and spacer
Disconnect the upper radiator hose and the two heater
in.
20. Turn the engine clockwise (use the crank pulley bolt)
exhaust pipe and then separate the two.
8.
pump and
without disconnecting the hydraulic
head.
^Be 3.
at the intake manifold.
equipped with power steering, remove the
lines.
19.
10. years old. eral
the
cham-
Starter wire
are attracted by ethylene glycol antifreeze, and are quite
When
the
• Transmission wires
Disconnect the negative battery cable.
block. Drain the engine
off
body, resonator and gasket.
14.
^CAUTION
lift
air
Remove
stay.
I See Figures 137, 138, 139, 140, 141, 142, 143, 144, 145,
1
air
• fuel pressure hose
paying particular
installation items,
all
50.
55.
Vacuum
conditioning)
outlet.
off
the cam. Leave the
cam
sprocket
in
place
or rest the sprocket on the vibra-
damper.
21.
Remove
the timing chain cover bolt at the front of the
the throttle cable for the automatic transmission at their
head. This must be done before the head bolts are removed.
brackets.
22. Remove the cylinder head bolts in Make two or three passes to loosen the
Tag and disconnect the following: • Both PCV vacuum hoses •
any one
hose
(if
• Air control valve
equipped with cruise control)
hoses
Do
not loosen
once; improper removal could cause head
damage.
Brake booster hose
• Actuator
bolt all at
the correct order. bolts.
(with
power
steering)
^•Refer to the bolt removal diagram for the 22R engine. All illustrations for
the 22R are valid for the 22R-E.
ENGINE AND ENGINE OVERHAUL Using prybars applied evenly
23.
and the rear
at the front
assembly
the valve rocker assembly, gently pry the
of
off its
the head
Lift
dowels.
off its
If
head or
block;
it
block.
must be
Support the head on a workbench.
Remove
EGR
the manifolds and
oil
coolant
will
have
coolant
will
pollute the
28.
Apply
pan
30.
off
the
Connect the
45.
Position
ports
Install
Install
tially in
arm assembly over
three passes and
^ Refer to the Install
in
bolts.
Connect the hoses removed:
its
positioning
the correct order, coming to final
bolt tightening
the
diagram
22R are
the chain cover
58
is
lbs.
ft.
Nm)
(78
22R engine.
for the
is
set to No.
1
valid for the 22R-E.
Tighten
bolt.
TDC.
If
it
to 9
ft.
lbs.
(13
necessary, manually rotate the
engine so that the sprocket hole 34.
is
Brake booster hose
hose
Vacuum
If
Fuel pressure hose
valve hose
•
Reed
•
Pressure regulator hose
•
Vacuum hoses from
valve hose
51.
Install
the heater hoses and the radiator
52.
Install
the spark plugs and the distributor. Install the en-
oil
and cam
ft.
lbs.
thrust plate
(78 Nm).
Set the No.
the
piston at
TDC
of
its
compression stroke
in
and adjust the valves. 37.
Apply sealant only the cylinder head side
of the half-
the valve cover.
38.
Install
39.
Attach the power steering bracket to the head; tighten
33
ft.
lbs.
(44 Nm).
power steering pump and
40.
Install
41
Connect the bypass hose
.
42.
Connect the
33
bolt to
43.
the
ft.
lbs.
fuel
hose
belt.
Adjust the
and engine coolant.
installation items,
paying particular
hoses or hanging wires, untightened
hoses and wires
(too tight or rubbing)
and
at-
nuts, poor
tools
left
the engine area. 57.
Connect the negative battery cable.
58.
Start the engine, allowing
it
to idle
and warm up
59.
Turn the engine OFF. Readjust the valves.
60.
Restart the engine and adjust the timing as necessary.
61.
Recheck the fluid levels. Road test the vehicle for general performance and
62.
belt.
to the intake manifold.
driveability.
3F-E Engine
(44 Nm).
* See Figures 148, 149, 150, 151, 152 and 153
Knock sensor Drain the engine coolant.
1.
• Oil pressure sender •
all
oil
to the delivery pipe. Tighten the
Connect the wires removed: •
the exhaust pipe to the
gradually.
circle plug; install the plug.
the 4 bolts to
hose.
connector
air intake
the engine
tention to loose
routing of
1
inlet
dipstick.
Use new gaskets and connect
Double check
the distributor drive gear
strap.
and accelerator cables.
throttle
manifold. Don’t forget the clamp.
up on the chain and sprocket.
over the chain sprocket; tighten the camshaft sprocket bolt to
body
Connect the
56.
lifting
throttle
Connect the rear ground
Refill
36.
air
50.
53.
the chain
EGR
•
Install
58
steering)
Evaporative emissions (EVAP) hoses
55.
Install
power
(with
•
54.
35.
equipped with cruise control)
hoses
•
and
while
(if
Switching Valve (VSV) hoses (with
won’t allow the sprocket to reach, rotate the crankshaft back forth,
only)
49.
gine
also at the top.
the sprocket over the camshaft dowel.
Fit
(Calif,
• Water bypass hoses from throttle body
Hold the chain and sprocket; double check that the en-
gine
Both
•
•
not attempt
Nm). 33.
valve to the chamber.
PCV vacuum hoses
•
• Actuator
Tighten the bolts sequen-
pass. Correct tightness
All illustrations for
32.
head
the cylinder
last
EGR
body and resona-
conditioning)
the rocker
torque on the
EGR
48.
dowels. 31.
throttle
the
• Air control valve
Do
the intake manifold and
chamber,
Install
sealer to the front corners of the block and
into place.
it
new gaskets on
47.
oil.
locating dowels.
vehicles)
EGR temperature sensor wire EGR vacuum modulator.
wire and the
it.
(Calif,
hose.
Use a new gasket and install the cold start injector pipe. 46. Connect the throttle position wire, the cold start injector
pan during head removal. The
spilled into the
liquid
fuel return
the bolts holding the
Install
tor.
head has been removed;
after the
Lower the head over the
to slide
and wire
temperature sensor
44.
the head gasket.
install
29.
head
slide the
Keep the head covered and the manifold
Re-drain the
install:
start injector pipe
EGR
•
pry
off,
valve from the head on
plugged with rags when not working on
To
Cold
pipe. Install the air intake
26.
27.
lift
the mating surfaces
lifted.
25.
the workbench.
to
is difficult
it
Do NOT damage Do NOT attempt to
gently with small tools. of the
Water temperature sensor wire
•
• Throttle position sensor wire
mounting dowels. 24.
•
3-79
gauge
or switch
Starter wire
**WARNING
• Transmission wires •
Compressor wires
•
Injector wires
(with air conditioning)
When
• Water temperature sender gauge wire
likely to drink
• Overdrive temperature switch wire (auto, trans.)
in
•
Igniter wire
quantity.
•
Vacuum
Switching Valve (VS V) wires
• Cold start injector time switch wire
dogs and are quite an uncovered container or
draining coolant, keep in mind that cats and
are attracted by ethylene glycol antifreeze,
any that is left in puddles on the ground. This will prove
Always drain coolant Coolant may be reused unless eral
years old.
fatal in sufficient
into a sealable container. it
is
contaminated or sev-
ENGINE AND ENGINE OVERHAUL
3-80 2.
Disconnect the negative battery cable.
3.
Scribe matchmarks around the hood hinges and then
remove the hood. 4.
Disconnect the accelerator and
5.
Remove
throttle cables.
the hoses and parts as follows:
• Air intake •
meter
Air flow
• Air cleaner cap
ISC hose
•
pump hose
• Air •
Distributor
•
PCV
•
Remove
hose
hose the 3 hoses from the rear of the intake
chamber • 6.
The 2 hoses from the charcoal canister vacuum valve pump and position out of
Unbolt the power steering
way
the
7.
of the
it
without disconnecting the hydraulic lines.
Unbolt the
way
air
conditioning compressor and position
without disconnecting the refrigerant lines.
wire or string to support the compressor; do not allow
hang by the hoses. 8. Remove the power steering pump and
it
Use
out
stiff
to
it
conditioning
air
compressor brackets. 9.
10.
coil.
oil
outlet,
cooler and heater water pipe. Unbolt the
.
Disconnect and plug the
13.
Raise the vehicle, making certain
it
Remove Remove
order.
22.
in
fuel lines. is
well supported.
bolts in
in
in
and four nuts
that attach the
several stages and
the bottom
in
pushrods, be sure they are kept
MUST
be
in
installed
An upside-down box with holes make a good holder; number
will
the
holes to correspond with the pushrod position.
Loosen the cylinder head
bolts
in
several stages and
the opposite order of the tightening sequence.
the fuel delivery pipe along with the fuel
the correct
shaft.
which they were removed; they
the original locations.
23.
the air pump.
outlet.
the water outlet assembly.
Remove the rocker Remove the twelve
punched
Disconnect the exhaust pipe at the manifold.
15.
the spark plugs.
Loosen the eight
the order
Disconnect the upper radiator hose.
12.
14.
21.
oil
cooler water pipe from the cylinder head. 1 1
Disconnect the water bypass hose from the water
rocker shaft assembly
Disconnect and remove the hoses from the water
water pump,
Remove
Remove
Disconnect the high tension cords from the spark plugs
and the
19.
20.
pump
Remove
in
the air
bracket and engine hanger.
injectors.
17.
Remove Remove
18.
Disconnect the water bypass hose
16.
the
air injection
and then remove the
Fig.
^CAUTION
manifold.
the intake and exhaust manifolds.
outlet
at the
148 Loosen the rocker assembly bolts
passes
in this
order
water outlet
Removing the head cause damage
assembly.
in
several
Fig.
bolts in the improper order could
to the
aluminum cylinder head.
150 Tighten the head bolts using this sequence
several passes to prevent head
damage
in
ENGINE AND ENGINE OVERHAUL 32.
Install
the water outlet and connect the bypass hose.
Tighten the bolts to 18 33.
Install
ft.
lbs.
(25 Nm).
the intake and exhaust manifolds using a
Make sure
gasket.
3-81
the front mark on the gasket
is
new
towards the
front of the engine. Tighten the following:
•
17mm 14mm
•
Nuts (C)
•
34.
Install
bolts (A) bolts (B)
- 41
— 51 — 37 ft.
lbs.
ft.
lbs.
(69
ft.
lbs.
(50
Nm)
(56
the heat insulators and the manifold stay. Tighten
the manifold heat shield bolts to 9
manifold support bolts to 22 35.
Install
the
air injection
nuts and clamp bolts to 15
Lift
the cylinder
head
off of its off;
it
37.
Install
the air
38.
Connect the exhaust pipe
pump and connect
39.
Connect the
40.
Install
To
Lift
new
oil
the cylinder
and then in
install
them
into the
head
bolts with
head. Tighten them
the pushrods
Position the rocker shaft align the rocker
ft.
30. 31.
lbs.
in
assembly on the cylinder head
arm adjusting screws
with the
heads
of
12mm head to 14mm head to 25
(24 Nm); tighten the bolts with a
(33 Nm). Adjust the valve clearance and Install
install
the spark plugs.
the valve cover and tighten the cap nuts to 78
inch lbs. (9 Nm).
Fig.
ft.
lbs.
power
power
steer-
(47 Nm).
the air intake hose, the air flow meter and the air
Connect and adjust the accelerator and
throttle cables.
the engine coolant.
45.
Refill
46.
Double check
tention to loose
the order that they were removed.
Install
29.
lbs.
in
the order shown.
28.
17
44.
head on the cylinder block using a
the pushrods. Tighten the mounting bolts with a
ft.
35
belt tension; tighten the
Adjust them properly.
several stages,
and
pump. Adjust the
Install
coil wires.
removal procedure.
Lightly coat the threads of the cylinder
engine
cooler and heater water pipe.
cleaner cap. Connect the hoses removed during Step 5 of the
dirt
gasket.
27.
43.
radiator hose.
the air conditioning compressor and the
ing pulley nut to
from entering. Install
oil
Install
the old gasket from the block, then scrape and clean
Use a new
(62 Nm).
and the upper
42.
the area well. Insert paper into the cylinder walls to keep
26.
water pump,
steering
lbs.
cooler pipe; connect the hoses to the water
oil
must be
install:
25.
fuel lines
ft.
mounting dowels, Do
head on a workbench.
the
the
the
the air hose.
to the manifold.
Connect the spark plugs and
Support
Nm) and
Nm).
lbs. (21
41.
lifted.
(12
the fuel injector/delivery pipe assembly.
outlet,
attempt to slide the head
lbs.
(29 Nm).
manifold and tighten the union ft.
gasket and tighten the bolts to 46
24.
ft.
lbs.
ft.
Install
36.
NOT
Nm) Nm)
152 A, B and C bolt locations
routing of in
all
installation items,
paying particular
hoses or hanging wires, untightened
hoses and wires
(too tight or rubbing)
and
at-
nuts,
poor
tools
left
the engine area. 47.
Connect the negative battery cable.
48.
Start the engine, allowing
it
to idle
and warm up
gradually.
49.
Shut the engine OFF. Readjust the valves.
50.
Restart the engine and adjust the timing as necessary.
51.
Recheck the
52.
Install
fluid level.
the hood.
ENGINE AND ENGINE OVERHAUL
3-82
Air Intake
Seal
Chamber Stay
Washer Air Intake
Chamber
Cylinder
Cover Gasket
Cold Start Valve Rocker Shaft
jQ
^
Assembly
Air Injection
©
Injector Pipe
Manifold
Keeper Spring Retainer (IN)
EGR
Pipe
Air Intake \
Chamber
alve Rotator (EX)
Stay
Push Rod -
No
2 Fuel Pipe with
Engine Hanger
Pulsation
Damper
Water Outlet Assembly
Valve
Delivery Pipe
—
Intake
Manifold
Cylinder Head
Gasket
Gasket
—Manifold Stay
Exhaust Manifold
Heat Insulator
kg -cm
(ft
-
lb.
N m)
Non -reusable
:
Specified torque
part 86823pql
Fig.
153 Exploded view of the cylinder head components on the 3F-E engine
ENGINE AND ENGINE OVERHAUL Road
53.
performance and
test the vehicle for general
fuel
hoses from the pres-
sure regulator.
driveability.
3VZ-E Engine »
Disconnect the vacuum and
c.
3-83
See Figures
154, 155, 156, 157, 158, 159, 160, 161, 162,
163, 164, 165, 166, 167, 168, 169, 170
PCV hose
d.
Remove
e.
Disconnect the water bypass hose from the intake
the
from the hose union.
manifold hose union.
and 171
Remove
f.
the water bypass hose from the water bypass
pipe. 1.
Disconnect the negative battery cable.
2.
Remove
the
air
Disconnect the cold
h.
Disconnect the vacuum hose from the
Drain the engine coolant.
3.
Remove
i.
On
j.
dogs and are quite an uncovered container or
draining coolant, keep in mind that cats and drink any that
is left in
puddles on the ground. This
in
quantity.
Always drain coolant
Coolant
may be reused unless
will
prove
fatal in sufficient
into a sealable container. it
is
Remove
and fan •
16.
the radiator. it
out of
fluid
coup-
strap from
•
and wire
connector
Igniter
17.
pressure switch connector
•
Oil
•
Ground
•
Electronic Control Unit
•
Vacuum
•
fender apron
left
• Alternator connector
18.
strap at rear of engine
19.
(ECU) connectors
20.
Switching Valve (VS V) connectors
Starter relay connector (manual trans. only)
Remove
the two
so equipped. its
pipes.
the six bolts and two nuts;
remove the
intake
Disconnect the following, then when
all
are released,
•
Cold
•
Water temperature sensor
•
Water temperature sender gauge connector
time switch connector
start injector
•
Right ground strap
•
Injector
Remove Remove Remove Remove
connectors
the fuel pipes. the timing belt cover. the idler pulley and the timing belt cover. the right side fuel delivery pipe (fuel
rail)
with
Remove
22.
Disconnect the hose and remove the water bypass
•
Power
•
Brake booster hose
23. 24.
steering air hoses
Vacuum
25.
hose
throttle
and cruise
control
Disconnect the two heater hoses and the two fuel side scuff plate (inside the
left
lines.
door).
Disconnect the oxygen sensor. Disconnect the exhaust pipe at the manifold
and
at the catalytic converter.
Remove
the front
Remove
this section.
the timing
This
is
belt.
Follow the procedure given later
a complicated operation requiring accu-
rate work.
Remove
14.
Remove b.
the knock sensor wire.
the exhaust crossover pipe.
Remove the reed valve with the air injection manifold. Remove the water bypass pipe mounting bolt. 28. Remove the alternator. 29. Remove the right valve cover. 30. Remove the two bolts and camshaft housing rear cover. Loosen each cam bearing cap bolt a little at a time and in the correct order.
move 31
.
32.
When
all
are loose, remove the bolts and re-
the camshaft along with the
Remove
the 6-point
head
Loosen the cylinder head
oil
bolt
seal
and housing
from the head
plug.
first.
bolts in several stages, in the
i-WARNING
it
the
cause damage
bolts in the improper order could
to the cylinder head.
out of the way. air
intake
chamber as
follows: Lift
a.
the intake manifold.
Removing the head the distributor with the spark plug leads at-
tached; position 15.
Remove Remove Remove
correct order.
exhaust pipe. 13.
injectors.
33. 27.
vacuum hose
Disconnect the clutch release (slave) cylinder hose (man-
left
and the
26.
at the canister
Switching Valve (VSV)
the
fuel delivery pipe
left
Right side:
vacuum hose
Disconnect the accelerator,
Remove
the
outlet.
ual transmission only).
in
support. if
21.
cables.
.
EGR valve EGR valve with
Solenoid resistor connector
•
12.
pipe
The check connector Compressor connector
• Charcoal canister
1 1
air
•
• Cruise control
10.
chamber
the intake
the
hoses from the
the injectors.
Disconnect the following hoses:
9.
EGR vacuum
modulator.
•
• 8.
tempera-
remove the two bolts and the engine wire harness: • Knock sensor • Water temperature sensor
pulley.
Ground
start injec-
chamber.
Disconnect the following wires and connectors:
7.
Remove Remove
m. n.
Unbolt the power steering pump and position way with the hoses still attached. 6. Remove the alternator drive belt; remove the
ling
Remove
l.
contaminated or sev-
5.
the
EGR vacuum
water hoses from the
air
4.
EGR
California vehicles, disconnect the
Disconnect the
k.
and
years old.
eral
filter.
ture sensor.
are attracted by ethylene glycol antifreeze, likely to
fuel
remove the cold
the union bolt and
tor tube.
W-CAUTION When
start injector connector.
g.
cleaner hose and case.
Disconnect the
throttle position
the cylinder
sensor connector
Disconnect the canister vacuum hose from the
attempt to slide
it
off.
throttle
pry with a small tool
head
body.
Take great care not
off of its
mounting dowels; do
NOT
head is difficult to remove, gently between the head and block projection. If
to
the
damage
the mating faces of the block
ENGINE AND ENGINE OVERHAUL
3-84
Camshaft Housing Rear Cover
Camshaft Housing Plug Camshaft No. 3 Camshaft Bearing Cap No 2 Camshaft Bearing Cap
t Oil
-
Shim Valve Lifter
g g
Keepers
— ft
Camshaft Bearing Cap No.
O
Valve Spring Retainer
-Oil
Seal
1
j
Seal
\\
LH Exhaust Manifold
No. 2 Exhaust Manifold Heat Insulator Alternator Bracket
No. 3 Timing Belt Cover
[
kgcm
(ft lb,
N mj]
:
Specified torque
Non-reusable part 86823pq3
Fig.
154 Exploded view of the cylinder head
— 3VZ-FE
engine
ENGINE AND ENGINE OVERHAUL and/or head. Support the head on
3-85
wooden blocks on
the
workbench.
Remove
34.
the exhaust manifold from the cylinder head.
Left side: 35. 36.
Remove Remove
the alternator. the
oil
dipstick.
Remove
the bolt and
remove
the dipstick guide tube.
Remove the left valve cover. Remove the two bolts and camshaft housing rear cover. Loosen each cam bearing cap bolt a little at a time and in the 37. 38.
correct order.
move
When
all
are loose, remove the bolts and re-
the camshaft along with the
39.
Remove
40.
Loosen the cylinder head
the 6 point cylinder
oil
seal
head
and housing
plug.
bolt.
bolts in several stages, in the
correct order.
[-'{-WARNING Removing the head bolts in the improper order could cause damage to the cylinder head.
RH
Side 6 Pointed Head Bolt
[mi
r
3
5
86823po4
Fig. Fig.
156
Remove
the 6 point head bolt
17
first
158 Release the camshaft retaining bolts
order
— LH
shown
RH Side
Fig.
157
Remove
several passes
5
LH Side
3
the head bolts using this sequence in Fig.
159 Left side 6 point head bolt location
in this
ENGINE AND ENGINE OVERHAUL
3-86
41.
Lift
the cylinder head
attempt to slide
it
off.
2
Take great care not 8
6
4
off of its
the head
to
damage
NOT
mounting dowels; do
is difficult
to
remove, gently
between the head and block
pry with a small tool
LH Side
If
projection.
the mating faces of the block
and/or head. Support the head on
wooden blocks on
the
workbench.
Remove
42.
To
the exhaust manifold from the cylinder head.
install:
43.
Lift
the old gasket from the block, then scrape and clean
the area well. Insert paper into the cylinder walls to keep
dirt
from entering. 44.
new 3
5
7
1
86823pnl
Install
th$ cylinder head on the cylinder block using a
gasket.
45.
Lightly coat the threads of the cylinder
engine
oil
and then
them
install
bolt 6-pointed bolt at this time.
stages, Fig. in
160
Remove
several passes
the head bolts following this pattern
initial
paint.
in
the order
tightening,
shown
mark the
to
into the
mark
is
now
Do
Tighten the bolts
33
ft.
lbs.
in
bolts with
not
install
several
(44 Nm). After the
front side of the top of the bolt with
Tighten the bolts an additional 90°
that the
head
head.
('A turn)
and check
facing the side of the head. Tighten the
j
ENGINE AND ENGINE OVERHAUL
3-87
165 Position the new gaskets on the cylinder
Fig.
heads as shown an additional 90° and check
bolts
mark
that the
is
now
facing
the rear of the head. 46.
Install
the 6-pointed head bolts. Tighten to 30
Install
the camshaft.
ft.
lbs. (41
Nm). 47.
a
Install
new
oil
seal
and
install
the
camshaft housing plug. Apply sealant
48.
to the
Nos.
and 5 cam bearing caps.
1
Place the caps on each journal with the arrows correctly
On
igned. left
head, to the rear.
cap
49. Temporarily tighten the bearing at
little
a time and
Tighten the bearing caps to the correct torque.
.
several passes
que
bolts just snug, a
the correct order.
in
Use a seal driver of the correct diameter to install the oil Use the same tool to install the camshaft housing plug.
50. seal.
51
al-
the right head, they should point to the front; on the
is
52.
12
ft.
and proceed
lbs.
Install
Make
the proper order. Correct tor-
(16 Nm).
Check the valve clearance.
(0.18-0.28mm) and exhaust 53.
in
is
Intake 0.007-0.01
0.009-0.013
in.
1
in.
(0.22-0.32mm).
the valve covers.
RH
Side 8
2
4
6 bolt.
55.
Install
the reed valve with the injection manifold. Tighten
the bolts to the cylinder
head
to
27
ft.
5
56.
17
3
1
3
ft.
(29 Nm).
lbs.
opposite head
installation for the
if
it
was
removed.
LH Side 7
Repeat
(37 Nm); tighten
lbs.
the bolts to the exhaust manifold to 22
57.
Install
the
58.
Install
the crossover pipe
oil
dipstick tube.
and
tighten
it
to
29
ft.
5
lbs.
(39
Nm). 59.
Connect the oxygen sensor
60.
Install
the mounting bolts to 13 61. 6
Fig.
4
166 Tighten the head bolts
in this
order
2
down
8 86823pn3
in
several passes
to
13 62.
Install ft.
lbs.
Install
bolts to 9
63.
ft.
Install
wire.
the intake manifold with ft.
lbs.
new gaskets and
tighten
(18 Nm).
the water bypass outlet and tighten the two bolts
(18 Nm). the fuel delivery pipes and injectors. Tighten the lbs.
(13
Nm)
the idler pulley.
tighten the bolts to
74 inch
Install
lbs. (8
the timing belt covers and
Nm).
3-88
ENGINE AND ENGINE OVERHAUL 64.
Install
the remaining timing belt cover.
65.
Install
the fuel pipes and tighten the union bolts to 22
lbs.
Seal Packing
Install
Check and
68.
the locations shown.
Install
70.
Attach the wires and connectors removed:
•
Knock sensor Water temperature sensor
•
Cold
•
Water temperature sender gauge connector
•
Right ground strap
•
Injector
72.
and No. 5 bearing
Install
13
ft.
and
A
•
B
intake
air
chamber and
tighten the nuts
and
(18 Nm).
lbs.
EGR
valve and connect
and nuts
tighten the bolts
—9 — 13 C - 22
•
•
connectors
the
Install
time switch connector
start injector
the
Install
bolts to 1
the engine wire harness and secure the two bolts.
69.
71.
caps as shown
belt.
adjust the valve clearance.
the cylinder head covers. Apply sealant to the
Install in
•
169 Apply sealant to the No.
the timing
66.
67.
head
Fig.
ft.
(29 Nm).
hoses and
lines.
Nm) Nm) (29 Nm)
(12
lbs.
ft.
all
correctly.
ft.
lbs.
ft.
lbs.
(18
and spark plug
73.
Install
the distributor
74.
Install
the front exhaust pipe, using
nect the oxygen sensor and replace the
wires.
new
gaskets. Con-
left sill
plate.
and heater hoses.
75.
Connect the
76.
Connect the clutch release
fuel lines
hose (manual
(slave) cylinder
trans. only.)
power steering pump.
the
77.
Install
78.
Connect the
throttle control
cable (auto, trans.), cruise
and the accelerator cable. Connect the hoses detached:
control cable 79.
80.
•
Power
•
Brake booster hose
•
Cruise control
•
Charcoal canister hose
•
Vacuum
steering air hoses
at the canister
Switching Valve (VSV)
vacuum hose
Attach the wires and connectors detached: •
Ground
•
Alternator connector
strap from
left
fender apron
and wire
•
Igniter
•
Oil
•
Ground
•
Electronic Control Unit
•
Vacuum
•
Starter relay connector (manual trans. only)
connector
pressure switch connector strap at rear of engine
(ECU) connectors
Switching Valve (VSV) connectors
•
Solenoid resistor connector
•
The check connector Compressor connector
•
coupling and drive belts.
81.
Install
the fan pulley,
82.
Install
83.
Install
and adjust the air conditioning belt. the power steering belt and adjust
84.
Install
the radiator.
85.
Install
86.
Refill
87.
Double check
routing of
fluid
it.
the air cleaner case and hose.
the engine with coolant.
tention to loose
in
vacuum hose
all
installation items,
paying particular
hoses or hanging wires, untightened
hoses and wires
(too tight or rubbing)
and
at-
nuts, poor
tools
left
the engine area. 88.
Connect the battery cable.
warm up 89.
at idle.
Check and
Check
Start the engine, allowing
carefully for leaks.
adjust engine specifications as necessary.
it
to
ENGINE AND ENGINE OVERHAUL
3-89
21.
Road
90.
the intake
chamber stay by removing the two
bolts.
Check and
91.
Remove
performance and
test the vehicle for general
driveability.
adjust fluid levels.
[-{'CAUTION 2RZ-FE and 3RZ-FE Engines > See Figures 172, 173, 174, 175, 176, 177, 178, 179 and
180 1
Fuel injection systems remain under pressure after the en-
gine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so
2.
Drain the engine coolant.
3.
Remove
the
cleaner cap,
air
MAF
meter, and the
If
If
equipped with a manual transaxle, disconnect the acequipped with a automatic transaxle, disconnect the
Remove
the intake
clamp
Remove
8.
If
the
25.
Oil
^—
A D D
Pan
Gasket Drain Plug
Indicator
Switch Connector
LH Drive Shaft
Vacuum Hoses
Front Differential Assembly
Non-reusable part 86823paw
Fig.
219 Exploded view of the
oil
pan and related components on the 5VZ-FE engine
ENGINE AND ENGINE OVERHAUL
3-112
1FZ-FE Engine > See Figure 221
Disconnect the negative battery cable.
1
-CAUTION On vehicles with air bags, work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative (-) battery cable is disconnected.
2.
Raise and safely support the vehicle.
3.
Drain the engine
4.
Remove
5.
Disconnect the
oil.
the engine undercover. oil
cooler pipe bracket from the No.
1
oil
pan.
Remove Remove
6. 7.
the
level sensor.
oil
the bolts holding the No.
oil
1
pan
to the trans-
mission housing.
Remove Remove
8. 9.
22.
Reinstall the crankshaft timing pulley.
23.
On
24.
Install
25.
Lower the
the
4WD,
To
install:
10.
Install
the front differential.
install
the engine under cover. vehicle.
with engine
Fill
27.
Connect the negative battery cable.
28.
Start the
oil.
(44
the
oil
Nm) and
6
ft.
Install
lbs.
(8
Install
the
oil
Raise and support the vehicle safely.
14.
Connect the
Remove
15.
Install
4.
Drain the engine
5.
Remove
the 16 mounting bolts and two nuts to the
Remove
the
the engine under cover. oil.
oil
pan.
careful not to
No.
pan.
oil
1
the 12
mm
Nm) and
level
14
bolts to
ft.
32
bolts to
lbs.
ft.
(20 Nm).
lbs. (9
pan
oil
1
mm
pan and tighten the
oil
the nuts to 7
ft.
ft.
Nm).
to the trans-
(72 Nm).
lbs.
sensor and tighten the bolts
to
5
ft.
Nm).
lbs. (5
3.
^Be
to the
pan and tighten the 14
mission housing and tighten to 53
Disconnect the negative battery cable from the battery.
oil
pan.
oil
the bolts holding the No.
2.
6.
1
Apply seal packing to the No. 2
13. .
the No.
Install
12.
2RZ-FE and 3RZ-FE Engines 1
pan.
b.
bolt to
for leaks.
pan.
oil
1
Apply seal packing
11.
engine and check
oil
the No.
a.
lbs.
26.
the No. 2
cooler pipe bracket to the No.
oil
1
oil
pan.
the engine under cover.
with engine
16.
Fill
17.
Connect the negative battery cable.
18.
Start the
oil.
engine and check
for leaks.
pan from the engine.
damage
the
pan flanges of the
oil
oil
Pump
Oil
pan and cylinder block.
To 7.
REMOVAL & INSTALLATION
install:
Before installing the
oil
pans, thoroughly clean the con-
tact surfaces. 8.
10.
Apply sealant 08826-00080 or equivalent,
'Parts must be assembled tion.
to the
oil
pan.
within 5 minutes of applica-
Otherwise the material must be removed and
reapplied. 9.
Install
and nuts
to
10.
Install
11.
Fill
the
9
ft.
oil
pan and mounting
lbs.
the engine under cover.
> See Figures 222 and 223 1.
Raise and support the vehicle.
2.
Drain the
3.
6.
Remove Remove Remove Remove
7.
If
Tighten the bolts 4.
(13 Nm).
Lower the
5.
vehicle.
Connect the negative battery the engine and check for leaks.
the engine with
cable, start
bolts.
22R and 22R-E Engines
oil
the
from the engine. pan.
oil
the four bolts holding the
oil
strainer.
the drive belts. the crankshaft pulley.
oil.
equipped with
air conditioning,
remove the compressor
compressor out of the way with the hoses attached. Do not discharge the system or loosen the compressor lines. and
its
bracket. Support the
8.
Loosen the
9.
Remove
oil
pump
relief
valve
bolt.
the five retaining bolts and
remove the
oil
pump
assembly with the O-ring.
Remove
the
oil
pump
drive spline from the crankshaft.
ENGINE AND ENGINE OVERHAUL
3-113
A/C Compressor
A/C Compressor Bracket
Oil
Pan
Baffle Plate
No.1
Oil
Oil
Pan
Pump
(Timing Chain Cover)
\ Gasket
Cankshaft Pulley
- Gasket
Non-reusable part 8682 3 gww
Fig. 221
Exploded view of the
oil
pan and related components on the 1FZ-FE engine
ENGINE AND ENGINE OVERHAUL
3-114
19.
Lower the
20.
Start then engine,
vehicle,
the engine with
fill
check
oil.
for leaks.
3VZ-E Engine I See Figures 224, 225 and 226 1.
Raise and support the vehicle.
2. 3.
Remove Remove
4.
Drain the
5.
the engine under cover. the front differential. oil.
6.
Remove Remove
7.
Raise the engine
8.
Remove
the timing belt.
the crankshaft timing pulley.
and remove the
slightly
the two bolts and nuts;
oil
remove the
pan. oil
strainer
and gasket. a
Insert
9.
drift
between the cylinder block and the
baffle plate, cut off the sealer
'When
removing the
damage
the baffle plate flange.
Remove pump is
10. If
'Pack
petroleum
prime the
will
11.
new 12.
pump
gears. This
Apply sealant
startup.
of the all
to the first
upper retaining
bolt of
all
the bolts. Tighten each to the correct tightness.
Bolt (a): 18
lbs.
bolts (c) 9 14.
lbs.
ft.
Install
(25 Nm); bolts (b) 14
ft.
lbs.
(19
Nm) and
(13 Nm).
and tighten the
relief
valve plug to 27
ft.
lbs.
(37
the crankshaft pulley.
Install
the drive belts, then adjust
17.
Install
the
lbs.
Install
oil
a
strainer.
new
18.
Install
the
oil
Make
sure
them it
correctly.
has been thoroughly
gasket, then tighten the bolts to 9
(13 Nm).
jelly
pump
Apply sealer
the groove
oil
O-ring.
plastic mallet to
pump.
between the
during
to the
oil
pump
oil
pump
mating surface, running the
inside of the bolt holes. Position a
in
the cylinder block
gears. This
startup.
initial
and
the spline teeth of the drive gear
install
the
engage the
new O-ring in pump so that
large teeth on
the crankshaft. Tighten the mounting bolts to 14
12.
paint.
16.
cleaned.
petroleum
prime the
Remove any
surfaces. Install
pump and
remove, use a small
of the
do not
ft.
lbs.
(20
Nm).
Nm). 15.
^Pack
bead on the
2 or 3 threads of the upper
body
oil
pan
install:
11.
the bolts holes.
the seven bolts, then the
oil
baffle plate.
baffle plate with the drift,
difficult to
carefully tap the
will
bolt. Install all ft.
the
To
drive spline onto the crankshaft. Place a
or debris. Clean
oil
oil
pump
initial
the groove.
Clean the threads
grease, 13.
in
between the
during
Slide the
O-ring
jelly
pump
and remove the
ft.
If
solvent
old sealer on the baffle plate is
make
used,
sure
it
Dry the surfaces completely. Apply sealant
(3mm) bead around the baffle. Run the bead the bolt holes and avoid excess sealant. 13.
Install
the baffle plate.
14.
Install
the
oil
strainer
the
oil
pan.
pan. lbs. (7
15.
Nm). Install
and
and block
does not in
affect the
a 0.1
in.
to the inside of
tighten the bolts to 61 inch
ENGINE AND ENGINE OVERHAUL
Oil
Fig.
224 Exploded view of the
oil
Pump
Cover
pump components on
the 3VZ-E engine
Seal Packing
Fig.
225 Do not apply too
surface,
it
can block the
much
oil
sealant on the
passage
pump Fig.
226 Align the
pump
drive
and the pump
3-115
ENGINE AND ENGINE OVERHAUL
3-116
Remove
19.
16.
Install
the crankshaft pulley.
17.
Install
the timing
18.
Install
the front differential and the undercover.
19.
Lower the
20.
Fill
and 2
belt.
the engine with
oil
and check
Remove Remove
21. a.
oil
If
the two bolts, two nuts,
3.
Raise and safely support the vehicle.
4.
Remove
5.
If
oil
SST 09213-54015 and 09330-00021 remove the crankshaft
3RZ-FE
engine, remove
the two bolts and disconnect the air pipe.
Disconnect the upper hose from the radiator.
8.
Remove
9.
If
oil
dipstick guide
bolt.
equipped with power steering, remove the drive
belt
by
lief
idler pulley
nut and
drive belt from the engine.
Remove the alternator drive belt, fan (with pump pulley, and the fan shroud: a. Loosen the water pump pulley mounting Loosen the
nator and
remove the
Remove Remove
c.
d.
lock, pivot
and adjusting
pump
fan clutch),
Remove
To
install: Install
bolts for the alter-
14.
If
equipped with A/C, disconnect the compressor and
26.
the four mounting bolts and disconnect the
pressure lines from the compressor. Suspend the compres-
away from
Remove
b.
the engine.
the A/C compressor bracket by removing the
four bolts.
Remove
15.
the alternator, adjusting bar and bracket: bolt, pivot bolt,
nut
bolt
After loosening the adjusting bolt,
remove the
alternator
c.
Disconnect the alternator wiring.
d.
Remove
f.
Disconnect the wire harness with the
clip.
Remove
and the
the lock bolt, pivot bolt, nut,
Unbolt and remove the adjusting bar. Unbolt and remove the bracket.
equipped with 2WD, remove the
Remove
petroleum
Install
retainer to the
pliers, install
the snapring to hold the
between the
jelly
pump
during
initial
pump
oil
gears. This
startup.
the drive and driven rotors as follows:
pump
Place the drive and driven rotors
b.
Place a
the
Install
with the nine screws.
c.
new O-ring to the pump cover
pump
into the
body.
body.
Install
the timing chain cover.
28.
Install
the 2 rear timing chain cover mounting bolts and
water bypass pipe mounting nuts. Tighten to 13
ft.
lbs.
(18
Align the pulley set key with the key groove of the pulley
and
slide
193
ft.
30.
on the
lbs. If
lbs.
pulley. Install
and
tighten the pulley bolt to
(260 Nm).
equipped with A/C,
install
the crankshaft pulleys with
Install
the
stiffener plates
by
the flywheel housing undercover and dust seal.
lbs.
i
(25 Nm).
13
oil
strainer, then tighten the fasteners to
Clean the
oil
pan and cylinder block mating surfaces.
Apply seal packing to the
33.
Install
34.
If
ft.
sor, tighten to
36.
Install a.
lbs.
Install
the
oil
new
ft.
lbs.
install
the stiffener plates. Tighten
(37 Nm).
O-ring, install the crankshaft position sen-
74 inch
lbs. (9
Nm).
the alternator to the engine as follows:
Attach the alternator to the engine, then
pivot bolt,
pan and
(13 Nm).
the flywheel housing undercover and dust seal.
Using a
35.
pan.
oil ft.
equipped with 2WD,
the eight bolts to 27
bolts.
ft.
(18 Nm).
32. alternator
Unbolt and remove the crankshaft position sensor.
•removing the eight 18.
and
valve.
tighten the fasteners to 9
h.
If
valve, spring(s)
a.
31.
the nut, then disconnect the alternator wire.
g.
17.
relief
the four bolts. Tighten the bolts to 18
from the engine.
16.
valve as follows:
relief
,
drive belt from the engine.
e.
valve from the
relief
27.
29.
and adjusting
at the alternator. b.
for the re-
Nm).
Loosen the lock
a.
the retainer, spring(s) and
the
prime the
will
compressor from the bracket. Do not disconnect the A/C sor
remove the snapring
pliers,
and the water pump
the cylinder head from the engine.
Remove
pump
valve as follows:
relief
Using snapring
b. relief
bracket: a.
the front cover,
valve cover.
^Pack
Remove
the
Install
a.
pulley.
13.
pump from
valve.
25. nuts.
pulley mounting nuts.
the fan (with fan clutch)
the
Using snapring
b.
alternator drive belt from the engine.
the four water
oil
front cover.
water
b.
Remove
24. a.
the fan shrouds.
remove the
Disassemble the
cover, drive rotor, driven rotor and O-ring.
bolt.
equipped with A/C, loosen the
Using a rubber hammer, loosen the chain cover, timing
d.
23.
by removing the
loosening the lock bolt and adjusting
12.
pulley.
chain cover and three gaskets.
7.
If
or
pulley bolts.
nuts from the timing chain cover.
For the California vehicles with
adjusting bolt, then
and gasket.
Remove the timing chain cover as follows: a. Remove the two water bypass pipe mounting nuts. b. Remove the two timing chain cover mounting bolts. c. Remove the nine mounting bolts and two mounting
and
front differential
halfshaft assembly.
the
Remove, the crankshaft
c.
22.
the engine under cover.
equipped with 4WD, remove the
strainer,
oil
equipped with A/C, remove the No. 2 and No. 3
Using
b.
and cooling system.
Drain the engine
11.
pan and
crankshaft pulleys by removing the four bolts.
Disconnect the negative battery cable.
2.
Remove
oil
the crankshaft pulley:
equivalents,
10.
the flanges of the
for leaks.
pump assembly is mounted in the timing chain To properly service the oil pump, the timing chain cover must be removed from the cylinder block.
6.
bolts
cylinder block.
cover.
.
damage
i"»Be careful not to
20.
1
pan by removing the 16 mounting
oil
vehicle.
2RZ-FE and 3RZ-FE Engines
^The
the
nuts.
and the
at this time.
lock bolt.
Do
install
the nut,
not tighten the bolts or nut
ENGINE AND ENGINE OVERHAUL
3-117
9.
Connect the wire harness with the
b.
clip to
Disconnect the starter wire clamp.
the
alternator.
the alternator wire with the nut.
c.
Install
d.
Connect the alternator harness. the drive belt to the engine.
Install
e.
Tighten the drive belt with the adjusting
f.
bolt.
Belt ten-
New
•
Old
Once
g.
155-175
belt:
75-125
belt:
the belt
37.
If
equipped with A/C,
ft.
install
32
ft.
lbs.
lbs.
ft.
38.
Install
the cylinder head.
39.
Install
the water
and the
clutch),
pump
to the bracket with the
(25 Nm).
pulley, fan shroud, fan (with fan
pump
pulley
pump
pulley mounting nuts but
do not
tighten the nuts at this time.
the alternator drive belt to the engine.
c.
Install
d.
Stretch the alternator belt
nuts to 16
tight,
then tighten the fan
Nm).
lbs. (21
ft.
Adjust the drive belt for the alternator.
e.
the fan shrouds.
40.
Install
41
.
Install
and adjust the power steering
42.
Install
the
43.
Connect the upper hose
44.
If
removed, attach the
air pipe.
45.
If
equipped with 4WD,
install
oil
drive belt.
dipstick guide with the bolt. to the radiator.
the front differential and
halfshaft assembly.
the engine under cover.
46.
Install
47.
Lower the
48.
Fill
49.
Connect the negative battery cable.
50.
Start the engine
51.
Recheck and top
52.
Adjust ignition timing.
vehicle.
the cooling system and engine
and check
oil.
for leaks.
off all fluid levels.
Road
test the vehicle for
proper
operation.
5VZ-FE Engine >
See Figures 227, 228, 229, 230, 231, 232 and 233 1.
Disconnect the negative battery cable.
^CAUTION On vehicles with air bags, work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative (-) battery cable is disconnected.
2.
Raise and safely support the vehicle.
3.
Remove
4.
Drain the engine
5.
If
the crankshaft timing pulley. oil.
equipped with 4WD, remove the
front differential.
7.
On A/T remove the oil cooler Remove the stiffener plate!
8.
Unbolt the flywheel housing dust cover.
6.
Remove
the
oil
oil
oil
strainer
pan
Remove
To
install:
15.
Use a
All
oil
pan.
and gasket.
baffle plate.
the 8 bolts, ground strap and
hammer,
pump from the pump
oil
carefully tap the
the O-ring from the block.
razor blade or equivalent to scrape the cylinder
pan mating surfaces
of
any old sealing
tube and clamp.
material.
traces of the old gasket and sealer must be removed.
16.
Clean the pan thoroughly, using solvent
excess metal
magnet is
a sign
in
of
it,
if
necessary.
examine the catchings
excess engine wear.
to
17.
Apply multi-purpose grease
to the
oil
A few
seal
lip.
If
closely: slivers
Use good judgment in relating the amount the amount of time the pan has been in place.
special service tool
position.
the water
Install
b.
in
Unbolt the
14.
ris
Place the fan (with the fan clutch), water
a.
13.
the crankshaft position sensor.
are normal.
alternator drive belt as follows:
and fan shroud
Remove
the pan has a
(44 Nm).
four bolts, tighten to 18
12.
block and
the compressor as follows:
Connect the A/C compressor
b.
ft.
(29 Nm).
lbs.
the A/C compressor bracket with the four bolts,
Install
a.
tighten to
43
tighten the pivot bolt to
tight,
is
Unbolt and lower the
body.
lbs.
lbs.
(59 Nm); lock bolt to 21
lbs.
Remove
11.
engine. Using a plastic head
sion should be as follows:
•
10.
of
deb-
Using a
09306-37010 or equivalent, along with a
ENGINE AND ENGINE OVERHAUL
3-118
hammer, tap
pump body
(Pack will
the
in
seal
oil
until it’s
surface
is
flush with the
edge.
petroleum
prime the
between the
jelly
pump
during
initial
oil
pump
gears. This
startup.
Remove any old sealant from the surface of the pump, new sealant to the oil pump, place the new O-ring into groove of the block. Place the pump on the crankshaft with
18.
apply the
the spline teeth of the drive rotor
engaged
with the large teeth
of the crankshaft.
19. lbs.
Tighten fasteners
A
to
15
ft.
lbs.
Nm) and B
(20
to 31
ft.
(42 Nm).
20.
Install
the crankshaft position sensor.
21
Install
the
.
22.
oil
pan
baffle plate.
Apply seal packing
to the
oil
pan and
install
the pan to
the cylinder block. Tighten the nuts and bolts to 66 inch
Nm).
If
parts are not
assembled
time, the effectiveness of the seal packing
removed and
is
lost
and must be
reapplied.
23.
Attach the flywheel housing under and cover dust.
24.
Install
the stiffener plate.
lbs. (8
within 5 minutes of applying
ENGINE AND ENGINE OVERHAUL 25.
Connect the
26.
On A/T
starter wire clamp.
install
the
oil
27.
Reinstall the crankshaft timing pulley.
28.
On
29.
Install
the
4WD,
install
Remove
6.
cooler tube and clamp.
To
Fill
32.
Connect the negative battery cable.
33.
Start the
oil.
7.
engine and check
is
for leaks.
5.
Install
the
oil
pump so
oil
pump
gears. This
startup.
that the slot in the
oil
pump
shaft
Tighten the mounting bolts just snug.
Use new gaskets.
the outlet pipe and strainer,
Install
the
oil
Tighten the nuts and bolts
9.
tightening the
block.
the
the
oil oil
outlet pipe.
pump
retaining bolt(s)
and
nuts;
remove
the retaining bolt and remove the
oil
pump.
Use the
(2),
33
lbs.
(13
Nm) and the
Install
1 1
Lower the
leaks.
the order shown.
When
no gap between the strainer and
and
(44 Nm);
lbs.
10. .
is
illustration
and
ft.
in
strainer nuts (4) press the strainer onto the
oil
cylinder block so there
pan.
and gasket.
Remove
initial
again tightening the bolts just snug.
Raise and support the vehicle.
the strainer
between the
during
alignment with the protrusion on the governor shaft of the
in
distributor.
See Figures 234, 235 and 236
4.
for
vehicle.
with engine
3F-E Engines
3.
jelly
pump
prime the
will
Lower the
Remove Remove Remove
cover and inspect the parts
install:
^•Pack petroleum
the engine under cover.
30.
1.
pump
the front differential.
31.
2.
oil
nicks, scoring, grooving, etc.
8.
I
the
3-119
(5),
oil
13
ft.
tighten the nuts
(3),
lbs.
13
ft.
lbs.
and
bolts: (1)
(18 Nm);
(4),
10
ft.
(18 Nm).
pan.
vehicle,
fill
the engine with
oil
and check
for
ENGINE AND ENGINE OVERHAUL
3-120
6.
Disconnect the radiator hose from the
and remove the 8.
Remove Remove
9.
Disconnect the
7.
the water
Remove
11.
Unbolt the No.
12.
Remove
the No.
1
then unbolt
pump.
the cylinder head.
10.
mounting
inlet,
radiator pipe.
the
oil
oil
oil
1
the No. 2
bolts. Insert
and No. 2
cooler bracket from the No.
pan
oil
oil
pan.
to the transmission housing.
pan, this
a blade or oil
1
sensor and gasket.
level
is
the pan with 17
SST 09032-00100, between
pans, remove the sealer and lower the
No. 2 pan.
15.
Remove the 21 bolts retaining the No. A between the block and the No. 1 Remove the oil pan baffle plate. Remove the oil strainer.
16.
Unbolt the crankshaft pulley, then remove the drive belt
13.
portions 14.
1
oil
pan. Pry
pan.
idler pulley.
17.
Unbolt the
oil
pump
(timing chain cover), timing chain
and camshaft gear.
1FZ-FE Engine I See Figures 237, 238, 239, 240, 241, 242, 243 and 244 1.
Drain the engine
2.
Remove
3.
Drain the engine coolant.
oil.
the engine under cover.
**CAUTION When
draining coolant, keep
in
mind
that cats
and dogs
are attracted by ethylene glycol antifreeze, and are quite
any that is left in an uncovered container or puddles on the ground. This will prove fatal in sufficient
likely to drink in
quantity.
Always drain coolant
Coolant may be reused unless eral
into a sealable container. it
is
contaminated or sev-
years old.
4.
Remove
5.
Disconnect the A/C compressor and bracket. Loosen the
pulley nut
the radiator.
and adjusting
bolt,
then remove the
compressor aside but do not disconnect any
belt.
Put the Fig.
of the lines.
238 Remove the bolts securing the No. 2
oil
pan
ENGINE AND ENGINE OVERHAUL
239 A special tool oil pan
Fig.
3-121
available to cut through the
is
sealant of the
To
install:
18.
Turn the crankshaft
26. until
the set key on the crankshaft
faces downwards.
78 inch
the timing chain and camshaft gear.
19.
Install
20.
Attach the
21.
Install
oil
pump
27.
(timing chain cover).
22.
Install
the drive belt idler pulley then the crankshaft
the
oil
ft.
lbs.
the
oil
23.
Install
24.
Remove any
all
the
to the
components No.
1
strainer to the block with a
new
gasket,
(20 Nm). baffle plate, tighten to
78 inch
old sealant from the No.
1
oil
lbs. (9
Nm).
pan. Clean
with a non-residue solvent. Apply sealant
pan as shown.
Install
the pan within 5 minutes of
application.
25. cu.
No. the
in. 1
Install
15
lbs. (9
No. 2 pan, assemble within 5 min-
to the
69 inch
lbs.
Attach the bolts retaining the No.
the
53
ft.
lbs.
Connect the
30.
Install
the cylinder head using a
31
Install
the water
Connect the
lbs. (21
33.
oil
1
pan
level sensor, tighten to
Install
29.
32.
Nm) and
the nuts to
to the transmis-
(73 Nm).
28.
.
(8
Nm).
sion housing, tighten to
pulley.
tighten to 14
Apply sealant
utes. Tighten the bolts to
48 inch
pump
radiator
hose
1
new gasket. new gaskets on the
with
Nm).
lbs. (5
cooler pipe bracket to the No.
oil
pan.
engine.
to the inlet, tighten to
15
ft.
Nm).
Install
the A/C compressor and bracket, tighten the
bracket to 27
ft.
lbs.
(37
Nm) and
the compressor to 18
ft.
lbs.
(25 Nm).
a
cm 3
new gasket of
engine
pan, tighten the
12mm heads
to
14
into position.
oil
into the
14mm heads ft.
lbs.
oil
Pour approximately 0.9
pump
to 31
(20 Nm).
ft.
hole. Install the lbs.
(44
Nm) and
the radiator.
34.
Install
35.
Attach the engine under cover.
36.
Lower the
37.
Start the engine
levels.
vehicle,
fill
the engine with
and check
for leaks.
oil
and coolant.
Top
off
any
fluid
3-122
ENGINE AND ENGINE OVERHAUL Timing Belt Cover and Seal
REMOVAL & INSTALLATION Refer to the timing belt procedure the timing belt cover. There
in this
section to
no replaceable
is
remove
seal.
Timing Chain Cover and Seal
REMOVAL & INSTALLATION 22R and 22R-E Engines I
See Figure 245
**WARNING may
This procedure requires tools which tool box. Pulley extractors
required.
Do
not be
your
in
and a counter-holding bar are
not attempt the procedure without these tools
available.
1.
Remove
2.
Drain the cooling system and
the cylinder head.
remove the
radiator.
^CAUTION When
draining coolant, keep
in
mind
that cats
and dogs
are attracted by ethylene glycol antifreeze, and are quite
drink any that is left in an uncovered container or puddles on the ground. This will prove fatal in sufficient
likely to in
quantity.
Always drain coolant
Coolant
may be reused unless
3.
4. 5. 6.
3
—
4
mm
is
contaminated or sev-
On 4WD vehicles, remove the front differential. Remove the oil pan. Remove the power steering belt so equipped. Remove the air conditioning belt, compressor and if
bracket
Seal Width
it
years old.
eral
A
into a sealable container.
7.
water
if
so equipped.
Remove the fan pump pulley.
clutch (fluid coupling), with the fan
and
Matchmark and remove the crankshaft pulley(s). This be very tight. Use the counter-holding bar, properly installed, to hold the crankshaft while loosening the bolt. Use the pulley extractor or gear puller to remove the pulley from 8.
bolt will
B
Seal Width 2 — 3
mm
86823pbv
the shaft. 9.
10.
Remove Remove
the lower 1 1
.
12.
the water bypass pipe. the fan belt adjusting bar.
power steering bracket
for
If
necessary, remove
access.
Disconnect the heater water outlet pipe. Unbolt the timing chain cover assembly. Be careful to
loosen only the correct
To
install:
13.
Install
bolts.
new gaskets over
the dowels on the timing chain
cover. Slide the cover assembly over the dowels Fig.
244 Apply sealant to the No. 2 pan as shown
spline. Insert the retaining bolts
8mm lbs.
bolts to 9
(39 Nm).
ft.
lbs.
(13
and
Nm) and
and pump
tighten them. Tighten the
the
10mm
bolts to
29
ft.
ENGINE AND ENGINE OVERHAUL
3-123
Camshaft Sprocket Distributor
Drive Gear
800 58 78 (
.
)
Chain Cover Assembly
1,600
(
116 157 ,
)
nB/
Chain Damper
Chain Tensioner
Chain Damper
Oil Seal
Pump
Crankshaft Pulley
kg-cm
Nm)
(ft-lb,
:
|
Oil
Drive Spline
Pan
Crankshaft Sprocket
Specified torque
Non-reusable part 86823pck
Fig.
245 Exploded view of the timing chain and cover on the 22R and 22R-E engines
14.
Temporarily
Install
install
the adjusting bar to the alternator.
the adjusting bar to the chain cover
and
1FZ-FE Engine
tighten the 1
bolts to 9
ft.
lbs.
(13 Nm).
15.
Install
the heater water outlet pipe.
16.
Install
the water bypass pipe.
17.
Install
the crankshaft pulley
and
bolt.
CAUTION Use the counter-
holding tool to hold the pulley and tighten the bolt to 116 lbs.
(157 Nm).
If
equipped with
second crankshaft 18.
Install
air conditioning, install
ft.
the
pulley.
the water
pump
and
fluid
19.
Adjust the tension on the drive belts.
20.
Install
sor and belt 21
.
Install
if
air
coupling with the
conditioning compressor bracket, compres-
they were removed.
the
power steering
belt
22.
Attach the
23.
Install
the radiator.
24.
Install
the front differential.
25.
Install
the cylinder head.
oil
On vehicles with air bags, work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative (-) battery cable is disconnected.
pulley
fan.
the
Disconnect the negative battery cable.
pan.
and adjust
it.
2.
Raise and safely support the vehicle.
3.
Drain the engine
4. 5.
Remove Remove
6.
Disconnect and remove the A/C compressor and the
oil
and the engine coolant.
the engine under cover. the radiator.
bracket. 7.
Remove
the radiator pipe by disconnecting the radiator
hose from the water 8. 9.
Remove Remove
inlet.
the water
pump and
the cylinder head.
the gasket.
ENGINE AND ENGINE OVERHAUL
3-124
Disconnect the
10.
oil
cooler pipe bracket from the No.
oil
1
2VZ-FE Engine
pan. 1 1
12.
Disconnect the negative battery cable.
1
Remove Remove
.
the
level sensor.
oil
the bolts holding the No.
pan
oil
1
^CAUTION
to the trans-
mission housing.
Remove the No. 2 and No. 1 oil pans. SST 09213-58012 and 09330-00021, or equivalent, remove the pulley bolt. Remove the crankshaft
On vehicles with air bags, work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative (-) battery cable is
pulley.
disconnected.
13.
Using
14.
Check the
15.
thrust clearance of the
pump
oil
driveshaft
gear.
2.
Raise and safely support the vehicle.
3.
Drain the engine coolant and the engine
4.
7.
Remove the cylinder head. Remove the radiator. On 4WD vehicles, remove the Remove the oil pan.
the drive belt idler pulley.
8.
If
equipped with P/S, remove the power steering
the bolts securing the timing chain cover, then
9.
If
equipped with A/C, remove the A/C
Using a
a.
measure the
thrust clearance.
b.
Maximum
c.
If
pump
oil
Remove Remove
16.
17.
thrust clearance
the thrust clearance
place the
a lever type attachment,
dial indicator with
0.0118
is
mm).
(0.30
in.
maximum,
greater than
is
5.
re-
6.
driveshaft gear and/or timing chain cover.
remove the cover. Be sure
to note the locations of the different
18.
Clean the gasket mating areas
19.
Install
pump
Install
Remove Install
23.
lbs. (21
pump. and
adjusting bar
lbs.
12. 13.
the cord from the chain.
and
tighten the bolt to
(43 Nm). the crankshaft pulley as follows:
and
b.
on the
slide
Install
pulley.
304
the pulley bolt and tighten to
and the No. 2
24.
Install
the No.
25.
Install
the bolts holding the No.
mission housing. Tighten to 53 26.
the
Install
level
oil
the bolts to 48 inch
ft.
lbs.
ft.
pans.
oil 1
lbs.
oil
pan
Connect the
28.
Install
the cylinder head.
29.
Install
the water
cooler pipe bracket to the No.
pump and
oil
tighten the bolts to 15
the nuts holding the radiator pipe to the No.
31.
27
1
install:
Clean the gasket mating areas
17.
Install
lbs.
ft.
ft.
Install lbs.
32.
the A/C compressor, tighten the bolts to 18
Install
and adjust the drive
ft.
lbs.
belt.
Refill
35.
Connect the negative battery cable.
36.
Start the engine,
oil
and the engine coolant.
check
for leaks,
the engine under cover.
off
any
well.
Slide the cover
the old cover gaskets and
spline. Tighten the
mm
install
fluid levels.
and check the
gaskets.
8
29
bolts to
mm ft.
bolts to 9
lbs.
ft.
lbs.
(13
Nm)
(13 Nm).
the fan belt adjusting bar to the chain cover and
Install
ft.
lbs.
(13 Nm).
19.
Install
the heater water outlet pipe.
20.
Install
the water bypass pipe.
21.
Install
the crankshaft pulley and tighten the bolt to 116
lbs.
(157 Nm). the water
Install
pump
pulley
and the
fluid
coupling with
the fan. Place the belt onto each pulley. While pulling the belt the four nuts.
23.
Adjust the drive belt tension.
24.
If
removed,
the
install
A/C compressor bracket, the com-
belt.
removed,
the P/S belt.
25.
If
26.
Apply seal packing
and the and ignition
new
assembly over the dowels and the
install
to the joint part of the cylinder block,
the chain cover, the cylinder block, the rear
timing. Install
Remove
b.
tight, tighten
the radiator. the engine
a.
pressor and the
34.
Top
pan, then
the A/C compressor bracket, tighten the bolts to
Install
38.
oil
Nm).
lbs. (21
33.
37.
1
Install
inlet.
(37 Nm).
Install
(25 Nm).
ft.
the bolts
the timing chain cover assembly.
the cylinder head. Tighten to 9
pan.
Remove
the chain cover assembly.
To
22.
ft.
remove the
the fan belt adjusting bar. With P/S,
16.
18.
Attach the No. 2 radiator hose to the water
tighten to 15
the water bypass pipe.
the arrows.
and the 10
(72 Nm).
Nm).
30.
the crankshaft pulley.
Remove
pump to the trans-
Nm).
27.
(21
coupling with the fan,
Disconnect the heater water outlet pipe.
(412
sensor with a new gasket and tighten
lbs. (5
oil
fluid
pulley.
15.
Nm). 1
the set nuts, the
14.
shown by
Align the pulley set key with the key groove of the
pulley
belt
and remove
lower P/S bracket.
the drive belt idler pulley
Install a.
Remove Remove Remove
11.
Nm).
Loosen the
bolts.
pivot bolt of the alternator
belt.
and the water pump
correct locations.
22. ft.
ft.
oil
and the
Remove
b.
the timing chain cover with the proper length bolts
Install
21.
32
the
oil
tighten the bolts to 15
in their
drive rotor with the
pump drive gear, and install the oil pump and the drive belt
gear of the
20.
pump
oil
belt.
compressor,
the fluid coupling with the fan and the water
Loosen the water pump pulley
a.
the drive of the
belt,
pulley.
adjusting bolt
installation.
Engage the gear
b.
well.
the timing chain cover. Apply packing seal to the
cover before a.
Remove
10.
install:
front differential.
and the bracket.
sized bolts.
To
oil.
oil
pan.
Install
tighten the nuts
the
and
bolts to 9
ft.
lbs.
27.
Install
the radiator.
28.
Install
the cylinder head.
29.
If
30.
Fill
31.
Connect the negative battery cable.
removed,
install
seal retainer
(13 Nm).
the front differential.
with engine coolant
oil
pan over the studs on the block
oil
and engine
oil.
ENGINE AND ENGINE OVERHAUL Start the engine
32.
and check the
ignition timing.
3RZ-FE Engine
If
29.
Fill
Raise and safely support the vehicle.
3.
Drain the engine coolant and the engine
4.
7.
Remove the cylinder head. Remove the radiator. On 4WD vehicles, remove the Remove the oil pan.
8.
If
equipped with P/S, remove the power steering
9.
If
equipped with A/C, remove the A/C
oil.
belt,
belt.
12. 13.
compressor,
and the
Loosen the
bolts.
5.
pivot bolt of the alternator
and remove
Remove
Install
the chain cover assembly.
If
the
pump was removed,
oil
install
new
a
O-ring behind
prior to installation.
the bolts
Unbolt and remove the
Using a
oil
pump.
knife, carefully cut off the
oil
seal
flat-bladded tool, (preferably with tape around
it)
lip.
With a
pry the seal
from the cover.
To
Slide the cover
mm
8
install
29
bolts to
bolts to 9
new
gaskets.
lbs.
(13
Nm)
Apply multi-purpose grease to the new oil seal lip. Tap the seal into place with SST 09223-50010/60011 equivalent, and a hammer. Do this until the seal surface is 4.
flush with the cover edge. 5.
(13 Nm).
lbs.
ft.
ft.
install:
3.
assembly over the dowels and the
spline. Tighten the
Install
the
oil
pump
with a
new
O-ring.
the fan belt adjusting bar to the chain cover and
the cylinder head. Tighten to 9
ft.
lbs.
(13 Nm).
18.
Install
the heater water outlet pipe.
19.
Install
the water bypass pipe.
20.
Install
the crankshaft pulley and tighten the bolt to 116
21.
.
2.
Remove
the old cover gaskets and
mm
the cover, tighten the bolts as specified for your
Install
pump
the
1
b.
lbs.
(157 Nm). Install
the water
pump
pulley
and the
fluid
coupling with
the fan. Place the belt onto each pulley. While pulling the belt tighten the four nuts.
tight,
22. Adjust the drive belt tension. 23.
If
removed,
pressor and the
install
the A/C compressor bracket, the
removed,
the P/S
If
25.
Apply seal packing
install
belt.
to the joint part of the cylinder block,
the chain cover, the cylinder block, the rear
and
oil
pan.
com-
belt.
24.
and the
or
this until the seal surface is
> See Figures 248 and 249
the timing chain cover assembly.
and the 10
ft.
and a hammer. Do
remove the
the fan belt adjusting bar. With P/S,
Remove
Install
Install new pump spline. Apply multi-purpose grease to the new oil seal lip. Tap the seal into place with SST 09223-50010/60010
Clean and inspect the timing cover area.
Cover Not Removed
the water bypass pipe.
a.
17.
tool.
the timing
pulley.
the crankshaft pulley.
shown by the arrows. To install:
pump
7.
8.
the set nuts, the fluid coupling with the fan,
Disconnect the heater water outlet pipe.
16.
pump from
engine.
belt.
Remove
15.
oil
install:
equivalent,
belt
lower P/S bracket. 14.
a good idea to remove the
flush with the cover edge.
Remove Remove Remove
.
is
gaskets around the dowel areas and
6.
and the water pump 1 1
It
To
and the water
the fluid coupling with the fan
adjusting bolt
b.
Pry out the seal from the cover with a flat-bladded
3.
4.
Loosen the water pump pulley
the drive
2.
cover and replace the O-ring. front differential.
pulley.
a.
Unbolt the timing chain cover assembly. Be careful to
loosen only the correct bolts.
and the bracket.
pump
timing.
See Figures 246 and 247 1.
2.
Remove
oil.
Cover Removed I
disconnected.
10.
and engine
SEAL REPLACEMENT
On vehicles with air bags, work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative (-) battery cable is
5.
the front differential.
Connect the negative battery cable. 31. Start the engine and check the ignition
CAUTION
6.
install
with engine coolant
30.
Disconnect the negative battery cable.
1
removed,
28.
3-125
Install
tighten the nuts
the
and
oil
bolts to 9
26.
Install
the radiator.
27.
Install
the cylinder head.
oil
seal retainer
pan over the studs on the block ft.
lbs.
(13 Nm). Fig.
246 Remove the seal with a flat-bladded tool and
hammer
or
3-126
ENGINE AND ENGINE OVERHAUL Timing Gear Cover and Seal
REMOVAL & INSTALLATION fr
See Figures 250, 251, 252, 253, 254, 255, 256 and 257
(This procedure 1
applies to the 3F-E engines only.
Disconnect the negative battery cable.
.
Disconnect the accelerator and throttle cables. Tag and disconnect, then remove the air intake hose, air flow meter and air cleaner as an assembly. 4. Loosen the power steering pump drive pulley nut. 5. Remove the fluid coupling with the fan and water pump 2. 3.
pulley.
Remove
6.
power steering pump and the A/C compres-
the
sor along with their brackets.
Remove Remove Remove Remove
7. 8. 9.
10.
power steering
the
idler pulley
and
it’s
bracket.
the distributor. the valve rocker shaft assembly. the ten bolts, two nuts, pushrod cover and gas-
ket off the pushrod cover. 1 1
Remove
.
the valve
lifters,
place them
in
the exact order
as removed.
Remove
12.
power steering
the
pulley from the crankshaft
pulley.
SST 09213-58011 and SST 09330-00021
Using
13.
equivalent, along with a
mount
socket,
remove the
or
pulley
bolt for the crankshaft.
Remove
14.
46mm
the pulley using
SST 09213-60017
or an
equivalent puller.
Remove Remove
15. 16.
To
install:
17.
Clean
grease, will
the
the gasket mating areas. With multi-purpose
all
install
cooler pipe with the hose.
oil
the timing gear cover and gasket.
a
be needed
new
seal into the timing cover.
There are three sizes
18.
adhesive
to the
A
two
A
seal installer
such as 09223-50010.
for this job
gear cover
of timing
position the cover. Finger tighten
bolts.
Apply
a new gasket and then
bolts. Install all
the bolts. Align the crank-
shaft pulley set key with the groove of the pulley; gently tap
the pulley onto the crankshaft. Tighten the cover bolts
A
to
18
ft.
(25 Nm); and the
lbs.
B and C
to
43 inch
marked lbs. (5
Nm). 19.
Tighten the pulley bolt to 253
the counter-holding tool 20.
Position the
power steering
tighten the six bolts to 13
21.
ft.
lbs.
lbs.
sure the valve
were taken Install
lifters
(343 Nm). Use of
pulley on the crankshaft
are installed
and
(18 Nm).
Insert the valve lifters into their bores
pushrod cover. Tighten the bolts
22.
ft.
required.
is
to in
35 inch the
and lbs.
same
install
(4
the
Nm) Make
order as they
out.
the pushrods, rocker shaft assembly, and the
valve cover. 23.
Install
the distributor.
24.
Install
the water
25.
Install
the
Install
pump
pulley, fluid coupling
power steering pump
the power steering
pump and
idler pulley
and
fan.
and bracket.
the A/C compressor. Ad-
just the belt tensions.
26.
Install
the
air
cleaner assembly; connect and adjust the
accelerator and throttle cables.
ENGINE AND ENGINE OVERHAUL
3-127
Push Rod Cover
Fig.
250 Exploded view of the timing gear assembly on the 3F-E engine
Fig. 251
Remove
the bolts securing the pushrod cover
Fig.
252 Place the
lifters in
the exact order of removal
3-128
ENGINE AND ENGINE OVERHAUL
the engine with coolant. Connect the battery cables.
27.
Fill
28.
Start the engine
and engine 29.
oil
if
and check
for leaks.
Top
off
the coolant
needed.
Inspect the timing (7°
BTDC
at idle),
and adjust
if
needed. 30.
Shut the engine OFF.
Remove
the valve cover and ad-
just the valves.
31
.
Check
Reinstall the valve cover for
and road
test the vehicle.
any abnormal noise, shock, slippage and smooth
operation.
Timing Gears I See Figures 258, 259, 260, 261, 262, 263 and 264
^This procedure
oil
applies to 3F-E engines only.
1.
Remove
2.
Using a flat-bladded
the timing gear cover
seal from the cover.
tool
and gasket.
and a hammer, tap out the
old
ENGINE AND ENGINE OVERHAUL
3-129
3. Check the timing gear backlash. Using a dial indicator, measure the backlash at several places while turning the camshaft clockwise and counterclockwise. Standard backlash:0. 0039-0. 0072 in. (0.100-0. 183mm) Maximum backlash:0.0098 in. (0.25mm) 4. If the backlash is greater than the maximum, replace the
camshaft and crankshaft timing gears. 5.
Align the large (camshaft) gear so that the holes allow
access
to the
camshaft retaining
very carefully remove the
damage
great care not to 6.
Tap out the gear
7.
With a puller or
cam
bolts.
Remove
the bolts and
with the gear attached.
the bearing surfaces on the
Use way
out.
set key.
SST 09213-60017, remove
the timing
gear.
remove the oil nozzle. If necessary, Use snapring pliers to remove the snapring holding the cam gear. Mount the camshaft in a press and, using the 8. 9.
proper size
install:
10.
Clean
grease, will 1 1
on the press, press the cam out
tip
To
the gasket mating areas. With multi-purpose
all
install
Install
a
new
12.
seal installer
Assemble
and timing gear. Use a press with the Align the timing gear set key with the
tool.
the gear and press
Install
A
such as 09223-50010.
the timing gear set key to the camshaft.
proper installation in
seal into the timing cover.
for this job
the cam, thrust plate
groove
the camshaft.
in
the snapring.
Use a thickness gauge to measure the thrust clearance thrust plate and camshaft. Correct clearance is 0.200mm-0.290mm (0.0079-0.0114 in.). Maximum allowance is 13.
between the
0.33mm (0.0130 14.
in.).
Put the timing gear on the crankshaft with the timing
gear facing forwards. Align the timing gear set key with the
groove
of the timing gear.
into place.
15.
Use a
Use a
small mallet to tap the gear
plastic mallet to tap in the pulley set key.
Turn the crankshaft timing gear clockwise
to place the
key groove upwards. 16. to
Insert the
damage 17.
Fig.
259 Remove the camshaft retaining bolts through
the access holes
be needed .
of the gear.
camshaft
into the block.
Take great care
the camshaft bearing surfaces on the
Align the timing
marks
Note that the one mark
is
of the crankshaft
on a
way
not
in.
and camshaft.
tooth, the other in a valley.
ENGINE AND ENGINE OVERHAUL
3-130
3VZ-E Engine t See Figures 265, 266, 267, 268, 269, 270, 271, 272, 273 and 274
^WARNING may
This procedure requires tools which tool box. Pulley extractors
required.
Do not attempt
not be
in
your
and a counter-holding bar are
the procedure without these tools
available.
1
Disconnect the negative battery cable and drain the
.
coolant.
Remove
2.
the radiator and shroud.
-CAUTION When 263 Turn the crankshaft timing gear clockwise to place the key groove upwards Fig.
be
and valley must
tooth
at
18.
TDC
compression
Install
19.
Recheck the
20.
Install
the
oil
ft.
21.
quantity.
Always drain coolant
Coolant
may be reused unless
set properly.
lbs.
nozzle
eral
into a sealable container. is
it
contaminated or sev-
years old.
it
the timing gear cover with a
4.
Remove Remove
5.
Disconnect the
6.
Disconnect the water bypass hose
3.
was removed. Make certain the gear mesh area. Use a hammer
if
chisel to stake the threads of the
Install
and dogs
(12 Nm).
timing gear backlash.
hole points towards the
and small
align exactly. Cylinder No. 6 should is
that cats
any that is left in an uncovered container or puddles on the ground. This will prove fatal in sufficient
everything
the two bolts holding the thrust washer to the
block; tighten to 9
oil
if
mind
in
likely to drink in
The
draining coolant, keep
are attracted by ethylene glycol antifreeze, and are quite
oil
new
nozzle.
seal and gasket.
power steering
belt
air
hoses
Remove
at the air pipe.
the air conditioning
drive belt, fluid coupling, guide 8.
belt.
and fan
at the air pipe
and
Remove
the alternator
pulley.
Disconnect the high tension cords and
the upper timing belt cover and then
REMOVAL & INSTALLATION
and pump.
the spark plugs.
then remove the water outlet. 7.
Timing Belt
the
their
clamps
at
remove the cover and
its
three gaskets. 9.
,
Rotate the crankshaft pulley
until
the groove on
its
lip
is
aligned with the 0 on the lower timing belt cover. This should If
you operate your vehicle under conditions
idling
as a
and or low speed taxi,
of extensive
driving for long periods of time;
such
police or delivery service, replace the belt every
60,000 miles (96,000 km).
set the No.
1
cylinder at
TDC
of
its
compression stroke. The
matchmarks on the camshaft timing pulleys must be in ment with those on the upper rear timing cover. If not, the engine 360° (one complete revolution).
align-
rotate
ENGINE AND ENGINE OVERHAUL
10.
Remove
power steering
the
removal
ing tool to aid in
of the
Use
pulley.
crank pulley
the counter-holdbolt.
Remove
the
crankshaft pulley using a puller. 1 1
.
Remove
the fan pulley bracket and then
remove the
lower timing belt cover. 12.
If
on the
the belt
on the side
marks 13.
will
to
is
be reused
showing the
belt
of the belt
of
rotation.
and the flanges
be important
Remove
after removal,
direction
at
of
mark an arrow
Make matchmarks
each
pulley.
These
reassembly.
the timing belt guide and
remove the tension
spring. 14.
as
far
Loosen the as
it
will
tension from the 15.
idler pulley bolt
and
shift
the idler to the
go. Temporarily tighten the bolt belt.
Slide the belt off the pulleys.
Protect the belt at
the belt inside out.
left
and release
Do
all
times.
Do
not bend, twist or turn
not allow the belt to contact
oil,
grease
or water. 16.
Examine the belt closely for cracking, loose teeth, sepawear on the edges. If the belt is not virtually perfect,
ration or
replace
it.
3-131
ENGINE AND ENGINE OVERHAUL
3-132
Check the
17.
idler pulleys for
smoothness
spect the tension spring; correct length
To
install:
18.
Make
marks on the
the lower belt pulley; align
19.
water
20.
as
21
.
(54.6mm).
mark
Check mark on the oil
rear belt cover.
with the
housing. the timing belt onto the
pump
pulley
Loosen the will
it
its
Install
and crank
take great care to align
•
in.
absolutely certain the marks on the camshaft pul-
leys are aligned with the
pump
of rotation. In-
2.15
is
all
If
pulleys, idler pulley,
reusing the original
belt,
made before removal. move as far to the right
the marks
idler pulley bolt;
go. Temporarily tighten
Install
cam
pulley.
the tension spring.
the point that the idler pulley
it
it
in
position.
Loosen the
moves
idle pulley bolt to
with the tension of the
spring.
22. Temporarily install the crankshaft pulley bolt. Turn the
crankshaft clockwise two complete revolutions from
TDC. Check
that the
mark on each
TDC
the matching marks on the covers or housing. 23. Tighten the idler pulley bolt to
to
pulley aligns exactly with
27
ft.
lbs.
(37 Nm).
ENGINE AND ENGINE OVERHAUL
3-133
34.
24.
Remove
the crank pulley
the crankshaft pulley. 25.
Install
bolt.
The cupped
Install
27.
for leaks.
Recheck the
the bottom belt cover with the two gaskets.tighten
5VZ-FE Engine
the fan pulley bracket and tighten
it
to
30
ft.
lbs.
Disconnect the negative battery cable.
1
Install
the upper cover and tighten the bolts 48 inch
-•-•-CAUTION
lbs.
Nm). 28.
is
Check
Nm).
(41
(5
Install
test the vehicle.
ignition timing.
the bolts to (5 Nm). 26.
Road
the belt guide on
side faces outward.
Position the crankshaft pulley so the groove
aligned with the woodruff key
bolt to
181
29.
Install
ft.
lbs.
in
in
the pulley
the crankshaft. Tighten the
(245 Nm).
the fan pulley, guide, fluid coupling and alternator
On vehicles with air bags, work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative (-) battery cable is disconnected.
drive belt. Adjust the belt tension.
30.
Install
the
power steering pump and
belt. Install
31
.
Install
Apply sealant
to the contact surface of the
water
Raise and safely support the vehicle.
2.
the air
conditioning belt. Adjust the belt tension. outlet.
3.
Remove
4.
Drain the engine coolant.
the engine under cover.
the water outlet and connect the bypass hose. Connect
i-CAUTION
the air hoses. 32.
Install
the spark plugs.
33.
Install
the radiator and
When fill
with coolant.
draining coolant, keep in mind that cats and
dogs
are attracted by ethylene glycol antifreeze, and are quite likely to drink
any
that is left in
puddles on the ground. This
in
quantity.
Always drain coolant
Coolant
may be reused unless
is
it
contaminated or sev-
Disconnect the upper radiator hose from the engine.
5.
Remove
6.
the
Power Steering
(P/S) drive belt as follows:
a.
Loosen the fan pulley mounting
nuts.
b.
Loosen the lock
and the adjusting
Remove the 7. Remove
bolt. bolt, pivot bolt,
Remove Remove
1 1
Disconnect the P/S
.
and the adjusting
bolt
alternator drive belt.
10.
9.
bolt.
the A/C drive belt by loosening the idler pulley
Loosen the lock
and the
bolt, pivot bolt,
drive belt from the engine.
and the adjusting 8.
Do
into a sealable container.
years old.
eral
nut
an uncovered container or prove fatal in sufficient
will
the fan shroud by removing the two clips. the fan with the
fluid
coupling and fan pulleys.
pump from
not disconnect the lines from the
the engine and set aside.
pump.
ENGINE AND ENGINE OVERHAUL
3-134 12.
equipped with A/C, disconnect the compressor from
If
Do
the engine and set aside.
not disconnect the lines from the
compressor.
equipped with A/C, disconnect the A/C bracket.
If
14.
Remove
30.
Disconnect the three spark plug wire clamps from the
31.
No. 2 timing belt cover.
Remove the six bolts and remove the timing belt cover. Remove the fan bracket as follows: a. Remove the power steering adjusting strut by removing
the nut.
TDC
cylinder at
1
Turn the crankshaft pulley and align
groove with the
its
mark 0 of the No. 1 timing belt cover. Check that the timing marks of the camshaft timing pulleys and the No. 3 timing belt cover are aligned. If not, turn the crankshaft pulley one revolution (360°). timing b.
make sure
Install
new
If
marks on the timing
match the timing marks
Install
not, place
remove the
or equivalent,
Remove
the timing pulley and the knock pin.
bolt,
pulley
the two
Remove
Set the No.
33.
Remove the SST Remove the starter
b.
or
tool,
and the pulley. and the No. 1 timing
the pulley bolt,
wire bracket
Check
the timing belt guide and
Remove Remove
the bolt
25.
Install
remove the timing
and the No. 2
the pivot bolt, the No.
idler pulley,
1
and the
in
Install
SST 09214-60010,
a.
and b.
dot
and a hammer,
35.
ft.
lbs.
(40 Nm).
Check Install
1
pulley.
belt is aligned
timing belt cover as follows:
marks
or equivalent, slightly turn the
of the
that the timing belt
installation
left
camshaft pulley and
has tension between the camshaft timing
left
pulley.
the right camshaft timing pulley and the timing belt
Align the installation
lbs.
(35 Nm).
Check
Check bolt.
mark
install
the timing
that the
Tighten
that the pulley bracket
pump
marks
the crankshaft
of the crankshaft timing pulley
body.
Align the installation
Align the
c.
of the crankshaft timing pulley.
belt with the
marks on the
knock
knock pin groove
belt with the
pulley,
and hang the
on the camshaft.
camshaft timing pulley
right
belt cover.
pin hole of the
of the pulley
and
the bolt and tighten to 81
camshaft with the
install
lbs.
ft.
the knock pin.
(110 Nm).
Set the timing belt tensioner as follows:
36.
a.
mm
Using a press, slowly press lbs.
in
the pushrod using
(981-9,807 N) of force.
Align the holes of the pushrod and housing, pass a 1.5 hexagon wrench through the holes to keep the setting
position of the pushrod. c.
mark on the timing
mark on the timing
camshaft timing
Slide the right camshaft timing pulley
and the No. 3 timing
b.
belt.
bolt, turn
of the right
Align the timing
220-2,205
align the timing
mark
No.
SST 09960-01000
Align the timing
Install
Using the crankshaft pulley
oil
of the
camshaft timing
on the timing
side facing inward.
idler pulley with
smoothly.
and the
belt to the left
timing belt on the right camshaft timing pulley with the flange
moves smoothly.
Temporarily
28.
ft.
1
the No. 2 timing belt idler with the
Install
moves
or equivalent,
washer and the No.
the plate
the pivot bolt and tighten to 26
27.
marks
belt
the No. 3 timing belt cover.
b.
the bolt to 30
pulley, align the timing
camshaft timing pulley clockwise. Align the
a.
the crankshaft timing gear as follows:
pulley bracket
of the
timing pulley.
the crankshaft gear.
the timing gear with the flange side facing inward.
tap 26.
end Using
timing
Using
groove with
mark on the timing belt with the timing mark of the camshaft timing pulley, and hang the timing belt on the left camshaft
the gear. b.
its
No. 3 timing belt cover.
of the
crankshaft timing pulley and the
idler pulley.
Align the timing pulley set key with the key groove of
a.
compression stroke
as follows:
Remove install:
lbs.
timing belt cover.
1
that the installation mark;
b.
Remove
To
ft.
camshaft timing pulley and the No. 3 timing
Connect the timing
34.
left
plate washer.
24.
No.
of the
Turn the camshaft timing
c.
23.
of the
Turn the camshaft, align the knock pin hole
of the
belt.
22.
mark 0
camshaft with the timing mark
belt cover.
21.
TDC
cylinder to
1
Turn the crankshaft pulley, and align
a.
equivalent, loosen the pulley bolt.
20.
of the timing pulley.
as follows:
the crankshaft pulley as follows:
SST 09213-54015 and 09330-00021,
Using
a.
camshaft timing pulley as follows:
left
the knock pin to the camshaft.
(110 Nm).
with the
timing pulleys with the timing belt. 19.
the
cover.
SST 09960-10010
Using
(250
lbs.
ft.
side facing outward. Tighten the pulley bolt to 81
b.
the timing belt tensioner by alternately loosening
184
Slide the timing pulley on the camshaft with the flange
c.
installation
of the
to
it
Align the knock pin hole of the camshaft with the
the timing
the two bolts. 18.
the pulley bolt and tighten
b.
c.
Remove
lbs. (9
Install
still
camshaft timing pulleys. 17.
80 inch
a.
a.
you can
that
read the installation marks. belt to
starter wire
the crankshaft pulley as follows:
knock pin groove
re-using the timing belt,
and
timing belt cover
Align the pulley set key with the key groove of the
b.
compression stroke
of the
as follows: a.
1
Nm).
the fan bracket by removing the bolt and nut.
Set the No.
16.
the No.
crankshaft pulley.
32.
Remove
b.
Install a.
c.
15.
Install
bracket. Tighten the timing belt cover bolts to
Nm).
from the No. 2 timing belt cover. b.
pulleys.
the timing belt guide with the cup side facing
outward.
the No. 2 timing belt cover as follows:
Disconnect the camshaft position sensor connector
a.
Install
the timing belt on the crankshaft timing pulley,
and the water pump
idler,
1
29.
13.
Install
c.
No.
Release the press and
tensioner.
install
the dust boot to the
ENGINE AND ENGINE OVERHAUL 37.
Install
the timing belt tensioner and alternately tighten
the bolts to 20
mm
ft.
lbs.
(28 Nm). Using pliers,
hexagon wrench from the
Check the valve
38.
3.
1.5
4.
belt tensioner.
5.
timing as follows:
6.
Slowly turn the crankshaft pulley two revolutions from
a.
the
remove the
TDC
TDC. Always
to
7.
water
clockwise.
Check
b.
that
each pulley aligns with the timing marks.
If
the timing marks do not align, remove the timing belt and reinstall
the fan bracket with the bolt and nut.
40.
Install
the
41.
Install
the No. 2 timing belt cover. Tighten the bolts to
power steering adjusting
strut with the nut.
Nm).
lbs. (9
be very
for the
spark plug wires to the
No. 2 timing belt cover.
Connect the camshaft position sensor connector
to the
44.
If
equipped,
install
the A/C compressor bracket.
45.
If
equipped,
install
the A/C compressor.
46.
Install
remove the
bolt.
Use
pulley from
9.
Remove Remove
the water bypass pipe. the fan belt adjusting bar.
power steering bracket
the lower
for
If
necessary, remove
access.
11.
Disconnect the heater water outlet pipe.
12.
Unbolt the timing chain cover assembly. Be careful to
14.
To
Install
the fan shroud.
Install
the alternator drive
49.
Install
the cooling fan and tighten the nuts to 4
belt. ft.
lbs. (6
Nm).
and adjust the A/C drive
50.
If
51.
Install
52.
Connect the upper radiator hose.
53.
Install
pump, pump
and the
pulley,
Remove
the chain from the crankshaft sprocket.
Remove
the
oil
pump
drive splines
and the crankshaft
Remove any gasket
16.
Turn the crankshaft
17.
Slide the sprocket over the key
aligned with the timing 18. link
Fill
55.
Connect the negative battery cable.
56.
Start the engine
material
left
on the cylinder block.
the shaft key
until
is
on
top.
on the crankshaft. Place
Place the timing chain on the
BETWEEN
within the
the two bright links
for leaks.
19.
dampers
link
mark on the sprocket.
mark on the sprocket. Make
the cooling system with coolant.
54.
install:
15.
the timing chain on the sprocket with the single bright
belt.
drive belt.
the engine undercover.
and check
Remove
sprocket.
48.
cam is
sprocket so that the
aligned with the timing
certain the chain
is
positioned
(guides).
Turn the camshaft sprocket counter-clockwise (viewed
from the
front) to
take slack out of the chain. Rest or support
the camshaft sprocket and chain at the top of the block.
Timing Chain
20.
Install
the
be necessary
REMOVAL
crankshaft while loosening the
the shaft.
13.
Nm).
lbs. (6
47.
install
pulley(s). This
the counter-holding bar, properly
the camshaft sprocket and the chain upwards.
the fan with the fluid coupling and fan pulleys.
Tighten the nuts to 48 inch
the P/S
Use
tight.
loosen only the correct bolts.
No. 2 timing belt cover.
equipped,
and
clutch (fluid coupling), with the fan
Matchmark and remove the crankshaft
bolt will
10.
Connect the three clamps
43.
8.
so equipped.
if
Remove the fan pump pulley.
the pulley extractor or gear puller to
Install
42.
if
installed, to hold the
it.
39.
80 inch
On 4WD vehicles, remove the front differential. Remove the oil pan. Remove the power steering belt so equipped. Remove the air conditioning belt, compressor and
bracket
turn the crankshaft pulley
3-135
& INSTALLATION
21.
Install
to
oil
pump
drive over the crankshaft key.
use a seal or bearing
new gaskets over
cover. Slide the cover
It
may
installing tool.
the dowels on the timing chain
assembly over the dowels and pump
spline. Insert the retaining bolts
and
tighten them. Tighten the
22R and 22R-E Engines I
See Figures 275, 276, 277 and 278
-WARNING This procedure requires tools which tool box. Pulley extractors
required.
may
not be
in
your
and a counter-holding bar are
Do not attempt the procedure without these
tools
available.
1.
Remove
2.
Drain the cooling system and remove the radiator.
the cylinder head.
-•--•-CAUTION When
draining coolant, keep
in
mind
that cats
and dogs
are attracted by ethylene glycol antifreeze, and are quite
any that is left in an puddles on the ground. This will quantity. Always drain coolant into Coolant may be reused unless it is likely to drink in
eral
years old.
uncovered container or prove fatal in sufficient 86823pcr
a sealable container.
contaminated or sev-
Fig.
275 The chain can be removed after the front
cover
is
removed
ENGINE AND ENGINE OVERHAUL
3-136
8mm lbs.
bolts to 9
ft.
(13
lbs.
Nm) and
10mm
the
bolts to
29
ft.
(39 Nm).
22. Temporarily install the adjusting bar to the alternator.
the adjusting bar to the chain cover and tighten the
Install
bolts to 9
ft.
lbs.
(13 Nm).
23.
Install
the heater water outlet pipe.
24.
Install
the water bypass pipe.
25.
Install
the crankshaft pulley and
bolt.
Use the counter-
holding tool to hold the pulley and tighten the bolt to 116 lbs.
(157 Nm).
If
equipped with
second crankshaft 26.
Install
air
ft.
conditioning, install the
pulley.
pump
the water
pulley
and
fluid
coupling with the
fan.
27.
Adjust the tension on the drive belts.
28.
Install
sor and belt
86823pcs
Fig.
276 The drive spline comes
off first
.
.
the if
conditioning compressor bracket, compres-
air
they were removed.
power steering
the
29.
Install
30.
Attach the
oil
belt
and adjust
it.
pan.
31.
Install
the radiator.
32.
Install
the front differential.
33.
Install
the cylinder head.
.
2RZ-FE and 3RZ-FE Engines > See Figures 279, 280, 281, 282, 283, 284, 285, 286, 287, 288, 289
and 290
Disconnect the negative battery cable.
1
•-CAUTION On vehicles with air bags, work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative (•) battery cable is disconnected.
86823pct
Fig.
277
.
.
then the crankshaft sprocket
2.
Raise and safely support the vehicle.
3.
Remove
4.
Drain the engine coolant and the engine
the engine under cover. oil.
On 4WD vehicles, remove the front differential. 6. Remove the alternator belt, fan with coupling and the water pump pulley. a. Loosen the water pump pulley bolts. Loosen the belt 5.
adjusting bolt and the pivot bolt of the alternator
and remove
the drive belt.
Remove
b.
the set nuts, the
and the water pump 7.
Remove
8.
If
fluid
coupling with the fan,
pulley.
the cylinder head.
equipped with A/C, remove the A/C
belt,
compressor,
and the bracket. 9.
10.
Remove
the alternator adjusting bar and bracket.
Unbolt and remove the crankshaft position sensor and
O-ring. 1 1
.
12.
On 2WD
vehicles,
remove the
stiffener plates.
Unbolt the flywheel housing under cover and dust seal.
13.
Remove
14.
Unsecure the
15.
Remove
the
oil
pan.
oil
strainer
and gasket.
the crankshaft pulley, a pulley bolt remover
will
be needed. 16. 86823pcu
Fig.
278 Using a scraper, clean the gasket areas
thoroughly
17.
Remove Remove
the water bypass pipe. the chain cover assembly.
Remove
the bolts
shown by the arrows. 18. 19.
Remove Remove
the No.
1
timing chain
and camshaft gear.
the crankshaft timing gear.
ENGINE AND ENGINE OVERHAUL
3-137
Balance Shaft Drive Gear
86823pdu
Fig.
279 Exploded view of the 2RZ-FE and 3RZ-FE engine timing chain components
ENGINE AND ENGINE OVERHAUL
3-138
Remove
and No. remove the two bolts and the damper. On the 3RZ-FE, remove the bolt, nut and No. 1 20.
1
vibration
the No.
damper.
On
1
timing chain tensioner slipper
the 2RZ-FE,
damper.
On
21. rotor
the
2RZ-FE remove
and the timing chain
On
22.
the 3RZ-FE engine, remove the No. 2 and No. 3 dampers and the No. 2 chain tensioner as follows:
vibration a.
the crankshaft position sensor
oil jet.
Install
a pin to the No. 2 tensioner and lock the
plunger. b. c.
d.
Remove the bolt and the No. 2 damper. Remove the 2 bolts and the No. 3 damper. Unsecure the nut and the No. 2 tensioner.
Remove
23.
ing chain
the balance shaft driven gear, shaft, No. 2 tim-
and the No. 2 crankshaft sprocket.
a.
Unbolt the balance shaft driven gear.
b.
Remove Remove
c.
the balance shaft gear with the shaft. the No. 2 timing chain with the No. 2 crank-
shaft timing sprocket.
24.
Remove
the No. 4 vibration damper.
ENGINE AND ENGINE OVERHAUL
To
install:
25.
Install
the No. 4 vibration dampener.
26.
Install
the No. 2 timing chain, No. 2 crankshaft timing
3-139
sprocket, balance shaft drive gear and shaft as follows: Install
a.
marked
the No. 2 chain by matching the
marks on the crankshaft sprocket and
with the timing
links
bal-
ance shaft timing sprocket. the other
Fit
b.
mark
link of
the No. 2 chain onto the
sprocket behind the large timing mark of the balance shaft gear. Insert the
c.
balance shaft gear shaft through the balance
shaft drive gear so that
the small timing the timing
18
mark
Install
d.
lbs.
ft.
mark
it
of the
into the thrust plate hole. Align
fits
of the
balance shaft drive gear with
balance shaft timing gear.
the bolt to the balance shaft gear and tighten to
(25 Nm).
Check each timing mark sponding mark link. e.
27.
Install
the No.
is
matched
with the corre-
No. 3 vibration dampers and the No. 2
2,
chain tensioner.
'•Assemble the chain tensioner with the
31.
pin installed,
1
a.
13
Install
lbs.
ft.
b.
the No. 2 chain tensioner with the nut, tighten to
damper withe the
bolts, tighten to
13
(18 Nm).
Install
Remove
ft.
lbs.
On
the rotor 29.
No.
is
1
vibration
1
and the
damper. damper, tighten
b.
Install
the slipper, tighten to 20
c.
Check
1
• •
the No.
Install
No.
mark
1
link of
the No.
timing chain to the
of the crankshaft timing
gear with
timing chain, then install the No.
1
that the slipper
to
ft.
22
lbs.
ft.
(29 Nm).
(27 Nm).
moves smoothly.
the crankshaft timing gear.
lbs.
1
chain with a wire or cord,
Install
1
make
sure
it
• •
the timing chain cover assembly.
a.
Remove
b.
Slide the cover
pump
timing chain tensioner slipper
Install
a.
30.
32.
facing forward.
the No.
of the
Tie the No.
c.
the
Install
the No.
does not come loose.
2RZ-FE engines, install the oil jet and crankshaft sensor rotor. Make sure the front mark of the cavity of
position
mark between the mark
install
Align the timing
mark
the
(27 Nm).
the pin from the No. 2 chain tensioner and
free the plunger.
28.
and
timing chain.
the No. 2 damper, tighten to 20
c.
d.
timing chain and camshaft timing gear.
1
gear. b.
the No. 3
the No.
Align the timing
timing chain,
(18 Nm).
Install
lbs.
ft.
Install a.
then remove the pin after assembly.
the old cover gaskets and
install
new
gaskets.
assembly over the dowels and the
spline. Tighten the following:
lbs. (20 Nm) 12mm A bolts — 14 12mm B bolts — 18 lbs. (25 Nm) 14mm bolts — 32 lbs. (44 Nm) lbs. (20 Nm) 14mm nut — 14 ft. ft.
ft.
ft.
c.
Attach the water bypass pipe.
d.
Remove
the cord or wire from the chain.
ENGINE AND ENGINE OVERHAUL
3-140
45.
Adjust the drive belt tension.
46.
Fill
47.
Install
48. 49.
Connect the negative battery cable. Start the engine and check the ignition
50.
Recheck
with engine coolant
and engine
oil.
the engine under cover.
and top
fluid levels
timing.
off.
1FZ-FE Engine I
See Figure 291 1
Disconnect the negative battery cable.
.
i'-f'CAUTION On vehicles with air bags, work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative (-) battery cable is disconnected.
2.
Raise and safely support the vehicle.
3.
Drain the engine
4. 5.
Remove Remove
6.
Disconnect and remove the A/C compressor and the
oil
and the engine
coolant.
the engine under cover. the radiator.
bracket.
Remove
7.
the radiator pipe. Disconnect the radiator hose
from the water
Remove Remove
8. 9.
inlet.
the water
Disconnect the
10.
pump and
the gasket.
the cylinder head. oil
cooler pipe bracket from the No.
1
oil
pan. 1 1
Remove Remove
.
12.
the
level sensor.
oil
the bolts holding the No.
oil
1
pan
to the trans-
mission housing.
Remove the No. 2 and No. 1 oil pans. SST 09213-58012 and 09330-00021, or equivalent, remove the pulley bolt. Remove the crankshaft 13.
Using
14.
pulley.
Check
15.
the thrust clearance of the
oil
pump
driveshaft
gear as follows: Using a
a.
33. lbs.
Install
the crankshaft pulley, tighten the bolt to 193
with bolts
and
the
Install
35.
Attach the
oil
ft.
ft.
lbs.
(25 Nm).
strainer, tighten to
oil
lbs.
13
lbs.
ft.
(18 Nm).
pan with fresh sealant, tighten the mount(13 Nm).
36.
Attach the flywheel housing under cover and dust seal.
37.
Attach the stiffener plates on the
27
ft.
lbs.
vehicles, tighten
(37 Nm).
new
38.
Install
the crankshaft position sensor, with a
39.
Install
the alternator, adjusting bar and bracket.
40.
For vehicles with A/C,
install
O-ring.
the compressor and
.
42.
Install
the cylinder head.
43.
Install
the water
pump
pulley
and the
fluid
coupling with
tighten the four nuts.
On 4WD
vehicles, install the front differential
driveshaft assemblies. 44.
If
Lower the
vehicle.
and
thrust clearance
the thrust clearance
place the
oil
pump
is
0.0118
in.
greater than
is
(0.30
mm).
maximum,
re-
driveshaft gear and/or timing chain cover.
18.
Remove Remove Remove
19.
Pull out the crankshaft timing gear.
20.
Remove
16.
the drive belt idler pulley. the timing chain cover. the timing chain and the camshaft timing gear.
the chain tensioner slipper
and the
vibration
damper.
Remove Remove Remove Remove
21. 22.
24.
the fan. Place the belt onto each pulley. While pulling the belt tight,
Maximum
c.
23.
bracket.
41
b.
17.
2WD
a lever type attachment,
dial indicator with
thrust clearance.
ft.
vehicles, install the crankshaft pulleys
tighten to 18
34.
ing bolts to 9
to
On A/C
(260 Nm).
measure the
the
oil jet.
the crankshaft rotor.
pump driveshaft gear. pump driveshaft gear.
the
oil
the
To
install:
25.
Clean the mating areas
26.
Set the crankshaft. Turn the crankshaft
on the crankshaft the
27.
Install
28.
Apply a
the
oil
29.
pump Install
is
facing
pump
light
well.
downward
until
the set key
(6 o’clock).
driveshaft gear.
coat of engine
driveshaft gear,
and
the crankshaft rotor.
oil
on the shaft portion
install
the gear.
of
ENGINE AND ENGINE OVERHAUL
-
3-141
A/C Compressor A/C Compressor Bracket
Chain Tensioner Slipper
Radiator Pipe
Crankshaft Pulley
Crankshaft Front Seal
Oil
Drive Belt Idler Pulley
Under Cover
Non-reusable part 86823per
Fig. 291
Exploded view of the timing chain assembly on the 1FZ-FE engine
ENGINE AND ENGINE OVERHAUL
3-142 30.
the
Install
and
oil jet
tighten the bolt to 14
ft.
comes
(20
lbs.
31. lbs.
damper and
the vibration
Install
tighten the bolts to 14
ft.
(20 Nm).
32.
51
lbs.
Make
(69 Nm).
sure that the slipper
moves
3.
33.
Install
the crankshaft timing gear.
34.
Install
the timing chain
and the camshaft timing gear as
the timing chain on the camshaft timing gear
Install
mark on the
Install
36.
Remove
37.
38.
pulley bolt
304
tighten to
lbs.
ft.
and the No. 2
39.
Install
the No.
40.
Install
the bolts holding the No.
and
tighten the bolt to
1
pans.
oil 1
the bolts to 48
in.
lbs.
oil
pan
to the trans-
ft.
lbs.
(72 Nm).
sensor with a new gasket and tighten
level
oil
(5
Nm).
42.
Connect the
43.
Install
the cylinder head.
44.
Install
the water
cooler pipe bracket to the No.
oil
pump and
1
pan.
oil
tighten the bolts to 15
ft.
lbs.
Nm).
Connect the No. 2 radiator hose
45.
tighten to 15
46.
27
ft.
lbs.
inlet.
Install
pan and
Nm).
lbs. (21
(37 Nm).
lbs.
Install
oil
1
the A/C compressor bracket and tighten the bolts
Install
47.
ft.
water
to the
the nuts holding the radiator pipe to the No.
to
the
Install
(412 Nm).
mission housing. Tighten the bolts to 53 the
the A/C compressor and tighten the bolts to 18
(25 Nm).
Install
and adjust the drive
48.
Install
49.
Refill
50.
Connect the negative battery cable.
51.
Start the engine,
ft.
belt.
the radiator. the engine
oil
and the engine coolant.
check
for leaks,
and check the
ignition
timing.
52.
Install
the engine under cover.
Camshaft Sprockets or Pulleys
REMOVAL & INSTALLATION 22R and 22R-E Engines »
See Figures 292, 293, 294, 295, 296 and 297 The cam sprocket
is
removed from the camshaft as
the rocker assembly removal.
If
the sprocket
is
to
part of
be removed
from the chain, support the chain with a piece of wood, keeping the chain
cam
the distributor drive gear and camshaft thrust
Remove
the
sprocket.
7.
cam
keep
sprocket. Using a piece of wire, supit
in
position for sprocket installation.
install:
While holding up on the sprocket and chain, turn the until
No.
1
and No. 4 cylinders reach TDC.
Place the sprocket over the camshaft dowel.
engaged
back and
sprocket.
the crankshaft pulley. Align the pulley set key with
Install
the halfmoon plug from the front of the cylinder
Remove
shaft
the cord from the chain.
and
is
Unbolt the
8.
it
(43 Nm).
Install
cylinder position
does not seem long enough on replacement,
the key groove of the pulley and slide on the pulley.
41.
that
loose.
the drive belt idler pulley
Install lbs.
ft.
make sure
the timing chain cover.
35.
Remove
crankshaft
Tie the timing chain with a cord to
come
1
5.
To
crankshaft timing gear.
doesn’t
the No.
4.
6.
the timing chain on the crankshaft timing gear
with the other bright link aligned with the timing
c.
until
compression. Matchmark the sprocket and chain.
port the chain to
camshaft timing gear. Install
the valve cover.
Turn the crankshaft
TDC
Refer to Timing
plate.
mark on the
with the bright link aligned with the timing
b.
Remove
installed.
Installation in this section.
head.
follows: a.
.
2.
set at
smoothly.
(21
the bottom sprocket, the timing chain covers must
Chain Removal and 1
the chain tensioner slipper and tighten the bolt to
Install
ft.
32
off
be removed and the chain correctly
Nm).
to the lower sprocket.
If
the chain
forth while pulling
If
the chain
turn the crank-
up on the chain and
ENGINE AND ENGINE OVERHAUL
3-143
9.
86823pcp
Fig.
294 Loosen and remove the drive gear bolt
86823gyz
297 Secure the chain
Fig.
in
place with a length of wire
Place the distributor drive gear and camshaft thrust plate
over the chain sprocket. Tighten the bolt to 58
ft.
Install
the halfmoon plug on the cylinder head.
1 1
Install
the valve cover.
.
(78 Nm).
lbs.
10.
3VZ-E Engines 1.
Remove
2.
Use a
the timing
belt.
properly installed counter-holding tool,
and the match
pulley bolt, the pulley
pin.
remove the left and
Note that the
are different; label them to avoid confusion at
right pulleys
reassembly.
-•--•-WARNING Do not attempt
to
use the timing
belt to hold tension
on
the pulley while loosening or tightening the retaining bolt.
86823pcq
Fig.
295 Pull the bolt and gear
off
the
To
install:
Align the camshaft
3.
cam
upper rear timing
match
pin hole with the
belt cover. This
marks on the
places the pin holes straight
up. 4.
the
Install
left
match
and pin.
the timing pulleys, observing correct placement of right pulleys. Install the bolts, but
Check
that the bolt
head
is
not completely tight yet). Align the timing
(Its
Install
the timing
this section. After the
tions
install
the
mark on each
marks on the No. 3 timing cover.
pulley with the 5.
do not
not touching the pulley
belt,
following the procedures given
engine has been rotated two
and the timing marks checked,
full
in
revolu-
tighten the idler pulley
bolt. 6.
ley
Remove
match
match 7.
the camshaft timing pulley bolts. Align the pul-
pin hole with the hole in the camshaft; install the
pin. Reinstall the
the pulley bolts to 80 nick or 86823pyy
Fig.
cam
296
Lift
the chain up, then slide the gear off the
8.
camshaft pulley
bolts.
Using a properly installed counter-holding
damage
ft.
lbs.
the timing
Continue with the
tool, tighten
(108 Nm). Take great care not to
belt.
re-installation of the timing belt.
ENGINE AND ENGINE OVERHAUL
3-144
Remove
the tightening sequence.
Camshaft and Bearings
Do
camshaft.
same
camshaft
••If the
(•These engines are not equipped with replaceable camshaft bearings.
the
not being
is
the 5 bearing caps and the
camshafts.
for the intake
lifted
out straight and
level,
No. 3 cap with the 2 bolts. Alternately loosen
reinstall the
then remove the bearing cap bolts with the camshaft pul-
REMOVAL 3F-E Engines
To
Gear Removal and
journal
22R, 22R-E and 3VZ-E (for
your
bolts.
If
you are going
cam
removing the camshaft, measure
Prior to
2.
If
them
Remove
Remove
the bearing cap bolts.
the caps.
13-16
Remove
5.
gage®.
cam must be
is
kept level
not kept level, the portion
a.
the intake camshaft as follows:
Apply multi-purpose grease
to the thrust portion of the
Position the intake camshaft with the pin facing
b.
upward.
a
6.
Lift
light
bolts. lbs.
ft.
(18-22 Nm).
the caps and
the clearance
If
Install
c.
measure each piece
to
12
greater than 2
coat of engine
ft.
lbs.
Install a.
b.
of the
Coat
Lay the camshaft
9.
Install
all
camshaft bearing journals with engine in
in
On
forward with No.
1
dots) c.
numerical order with their
bank arrows point 10.
Install in
11.
at the front of the engine.
to the rear with the No.
the cap bolts and tighten
the correct order, to 13-16
Complete the cylinder head
ft.
cap
1
them
lbs.
Engage
in
The
d. install
at the rear.
three passes
procedure and/or
See Figures 298, 299, 300, 301 and 302
Remove Remove
the timing chain from the engine. the exhaust camshaft by bringing the service
bolt hole of the driven
wrench head portion 3.
sub-gear upwards. Turn the hexagon
of the
exhaust camshaft with a wrench.
Secure the exhaust camshaft sub-gear
to the
main gear
The thread diameter should be 0.23 in. a thread pitch of 0.04 in. (1 .0mm) and a bolt
with a service bolt.
(6mm)
with
length of 0.63-0.79
in.
••When you remove
(16-20mm). the camshaft, be sure that the tor-
sional spring force of the sub-gear has been eliminated by
the above operation. Uniformly loosen and remove the exhaust bearing cap
bolts (10 of them), in several passes.
to the thrust portion of the intake
the exhaust camshaft gear to the intake
other.
down
the exhaust camshaft onto the bearing jour-
Apply a
in their
light
each
other. Install the
proper locations.
coat of engine
oil
to the
threads and
Use the reverse order
the cap bolts. Uniformly tighten the cap bolts
sequence shown
2RZ-FE and 3RZ-FE Engines
1.
oil
left
(18-22 Nm).
installation
on each Roll
bearing caps
valve rocker installation.
2.
shown
the exhaust camshaft as follows:
Apply engine
nals while engaging the gears with
the 3VZ-E, the right bank arrows point
cap
the cap
oil.
arrows pointing forward (toward the front of the engine) on 4 cylinder engines.
install
camshaft gear by matching the timing marks (one and two
the head.
the bearing caps
and
the sequence
camshaft.
the camshaft out of the head.
8.
in
(16 Nm).
install:
7.
proper locations. Apply
in their
to the threads
Uniformly tighten the cap bolts
(0.1mm), replace
in.
oil
of Plasti7.
is
the bearing caps
of
the head and cam.
4.
it
in
their bolts to
>
Install
6.
Keep
order, or mark them. Measure the bearing oil clearance by placing a piece Plastigage® on each journal. Replace the caps and tighten
and
If
intake camshaft.
4.
To
small, the
being installed.
is
it
is
end-play
its
Camshaft Specifications Chart the end-play is beyond this, replace
the head. 3.
while
camshafts; since the thrust clear-
installing the
ance of the shafts of the
with a feeler gauge. Consult the for the correct end-play.
be checked.
thrust clearances should
head receiving the shaft thrust may crack or be damaged. This can cause the camshaft to seize or break.
remove the head anyway, remove
to
removing the cylinder head.
after
and
damaged, The camshaft
install:
^•When
Perform the Cylinder Head Removal procedure
engine) far enough to gain access to the camshaft bearing cap
the
oil
lobes
should be
the bearings are
replace the caps and the cylinder head as a set.
procedure.
Installation
If
cam
cam and
part of the
inspected for flaking or scoring.
service the camshaft on these engines, please refer to
.
The bearings are
journals.
To
1
not pry on or force the camshaft.
Inspect the camshafts for runout. Inspect the
5.
and
the Timing
Do
led up.
& INSTALLATION
of
to 12
ft.
lbs.
(16 Nm).
in
the
ENGINE AND ENGINE OVERHAUL
3-145
7
86823pt4
302 Tighten the exhaust bearing cap bolts
Fig. Fig.
299 Intake camshaft bearing cap locations
in this
order
Remove
e.
Check
Set No.
8.
the service bolt from the driven sub-gear.
and exhaust camshafts turn smoothly. TDC compression stroke. The
that the intake
cylinder to
1
crankshaft pulley groove aligns with the 0 mark on timing
cover and camshaft timing marks with one dot and two dots
be
will
in
a straight
Install
9.
on the cylinder head surface.
line
the timing gear. Place the gear over the straight
pin of the intake camshaft.
Hold the intake camshaft with a wrench.
a.
tighten the bolt to
54
ft.
Hold the exhaust camshaft and
b.
distributor gear. Tighten the bolt to
10.
toward the
and
the bolt and
lbs.
ft.
(46 Nm).
new gasket (mark
as follows:
front)
Release the ratchet pawl,
a.
install
34
the chain tensioner, using a
Install
Install
(74 Nm).
lbs.
fully
push
in
the plunger and
apply the hook to the pin so that the plunger cannot spring out.
Turn the crankshaft pulley clockwise
b.
to provide
some
slack for the chain on the tensioner side.
Push the tensioner by hand
c.
installation surface,
to
13
is
not released.
(18 Nm).
lbs.
ft.
then
install
Check
Turn the crankshaft
d.
chain tensioner
is
until
it
touches the head
the 2 nuts. Tighten the nuts
that the
to the left
hook
of the tensioner
so that the hook of the
released from the pin of the plunger,
al-
lowing the plunger to spring out and the slipper to be
pushed 1 1
.
into the chain.
Check and
clearance
is
valve clearance 12.
adjust the valve clearance. Intake valve
0.006-0.010 inch (0.15-0.25
mm) and
exhaust
0.010-0.014 inch (0.25-0.35 mm).
is
Recheck the engine
for
proper valve timing. Check and
adjust the valve clearance.
the spark plugs and the semi-circular plug. Recheck the engine for proper valve timing. Install the valve cover and engine hangers. Tighten the engine hanger 13.
Install
14.
bolts to 15. Fill
Fig. 301
shown
Position the exhaust camshaft bearing caps as
30
ft.
Reinstall
any
lbs. all
(42 Nm).
other parts from the timing chain removal.
fluids, start
the engine, top off the fluids.
ENGINE AND ENGINE OVERHAUL
3-146
5VZ-FE Engine » See Figures 303, 304, 305, 306, 307, 308, 309, 310, 311,
and 316
312, 313, 314, 315
Remove Remove Remove
1.
2. 3.
both valve covers. the semi-circular plugs.
the right exhaust camshaft as follows:
Bring the service bolt hole of the driven sub-gear up-
a.
ward by turning the hexagon head portion
exhaust
of the
camshaft with a wrench.
mark
Align the timing
b.
drive
(2 dot
marks)
of the
camshaft
and driven gears by turning the camshaft with a
wrench.
Secure the exhaust camshaft sub-gear
c.
gear with a service
(16-20mm)
^When
bolt 0.2
bolt length
to the driven
(6mm) diameter,
in.
and 0.4
in.
(1.0mm)
in
0.6
in.
thread pitch.
removing the camshaft, make sure that the
tor-
sional spring force of the sub-gear has been eliminated by
the above operation. Uniformly loosen and remove the bearing cap bolts
d.
several passes,
Remove
e.
of the bearing
>n
in
the sequence shown.
the bearing caps and camshaft.
cap positions
for
proper
Make a
note
installation.
^WARNING Do
not pry on or attempt to force the camshaft with a tool
or other object.
Remove
4.
the right hand intake camshaft as follows:
Uniformly loosen and remove the bearing cap bolts
a.
several passes,
Remove
b.
.in
the
the bearing caps,
oil
seal
and camshaft. Make
a note of the bearing cap positions for proper
Remove
5.
the
left
installation.
exhaust camshaft as follows:
Align the timing
a.
drive
mark
(1
dot mark) of the camshaft
and driven gears by turning the camshaft with a
wrench.
86823pu7
Fig.
in
sequence shown.
303 Remove the valve covers from the engine
ENGINE AND ENGINE OVERHAUL
b.
Secure the exhaust camshaft sub-gear
gear with a service
(16-20mm)
bolt 0.2
bolt length
and 0.4
to the driven
(6mm) diameter,
in.
in.
(1.0mm)
in
0.6
in.
thread pitch.
'••When removing the camshaft, make sure that the sional spring force of the sub-gear has
tor-
been eliminated by
the above operation. c.
Uniformly loosen and remove the bearing cap bolts
several passes, d.
Remove
of the bearing
in
the
in
sequence shown.
the bearing caps
and camshaft. Make a note
cap positions
proper
for
installation.
-^WARNING Do not pry on Remove
6. a.
or attempt to force the camshaft out.
the
several passes, b.
left
hand intake camshaft as
follows:
Uniformly loosen and remove the bearing cap bolts
Remove
in
in
the sequence shown.
the bearing caps,
oil
seal
and camshaft. Make
a note of the bearing cap positions for proper installation.
3-147
ENGINE AND ENGINE OVERHAUL
3-148 To
install:
the right intake camshaft as follows:
Install
7.
Apply engine
a.
to the thrust portion of the intake
oil
camshaft. Position the intake camshaft at a 90° angle of the
b.
mar
timing
a
marks) on the cylinder head.
(2 dot
the bearing caps
Install
c.
coat of engine
light
oil
proper locations. Apply
in their
to the threads
and
install
the cap
bolts.
Apply a
d.
light
coat of engine
12
ft.
the
sequence shown
the right exhaust camshaft as follows:
Apply engine
a.
in
(16 Nm).
lbs.
Install
8.
bolts.
Uniformly tighten the cap bolts
e.
to
on the threads and
oil
under the heads of the bearing cap
to the thrust portion of the intake
oil
camshaft.
marks
Align the timing
b.
(2 dot
marks) of the camshaft
and driven gears.
drive
Roll
c.
down
the exhaust camshaft onto the bearing jour-
nals while engaging the gears with each other. Install the
bearing caps
in their
Apply a
d.
light
Apply a
light
under the heads
coat of engine
of the bearing
ft.
bolts. in
the sequence
shown
(16 Nm).
lbs.
Remove
g.
Check
the service bolt from the driven sub-gear.
that the intake
Align the timing
h.
and
on the threads and
oil
cap
Uniformly tighten the cap bolts
f.
12
to
to the threads
oil
the cap bolts.
install
e.
proper locations.
coat of engine
and exhaust camshafts turns smoothly.
marks
(2 dot
mark)
of the
camshaft
and driven gears by turning the camshaft with a
drive
wrench. 9.
Install a.
the
left
Apply engine
intake camshaft as follows: oil
to the thrust portion of the intake
camshaft. b.
Position the intake camshaft at a 90° angle of the
mar
timing c.
a
Install
light
(1
dot marks) on the cylinder head.
the bearing caps
coat of engine
oil
in their
proper locations. Apply
to the threads
and
install
the cap
bolts.
Apply a
d.
light
under the heads
oil
cap
Uniformly tighten the cap bolts
e.
12
to
coat of engine
of the bearing
10.
ft.
lbs.
Install
in
the sequence
shown
(16 Nm).
the
exhaust camshaft as follows:
left
Apply engine
a.
on the threads and bolts.
to the thrust portion of the intake
oil
camshaft.
marks
Align the timing
b.
drive
Roll
c.
(1
dot marks) of the camshaft
and driven gears.
down
the exhaust camshaft onto the bearing jour-
nals while engaging the gears with each other. Install the
bearing caps d. install
in their
Apply a
light
light
under the heads
g. 1 1
.
coat of engine
of the bearing
oil
cap
Uniformly tighten the cap bolts
f.
12
to
oil
to the threads
and
the cap bolts.
Apply a
e.
proper locations.
coat of engine
ft.
lbs.
on the threads and bolts. in
the sequence
(16 Nm).
Remove Check and
the service
bolt.
adjust the valve clearance.
shown
ENGINE AND ENGINE OVERHAUL
Fig. 315 Tightening sequence for the camshaft cap bolts
left
hand intake
Install
the semi-circular plugs.
13.
Install
the cylinder head covers. Uniformly tighten the
passes
to
53 inch
lbs. (6
317 Turn the crankshaft pulley and align
its
groove
with the 0 mark on the timing chain cover
12.
bolts in several
Fig.
3-149
Nm).
1FZ-FE Engine I See Figures 317, 318, 319 and 320
3.
Remove Remove Remove
4.
Set the No.
1.
2.
the valve cover. the semi-circular plug from the cylinder head. the spark plugs. 1
cylinder to
TDC
of the
compression stroke
as follows: a.
Turn the crankshaft pulley and align
its
groove with the
0 mark on the timing chain cover. b.
Check
that the timing
marks (one and two dots)
camshaft drive and driven gears are cylinder
head surface.
tion (360°) 5.
and
Remove
If
in
straight line
not, turn the crankshaft
of the
on the
one
revolu-
align the marks.
the chain tensioner.
Fig.
gear
319 Matchmark the position of the chain on the
ENGINE AND ENGINE OVERHAUL
3-150
j.
Place matchmarks on the camshaft timing gear and the
6.
and remove the camshaft timing gear. Hold the intake camshaft with a wrench and remove
timing chain a.
Remove
b.
Remove Do
the bolt and the distributor gear. the camshaft timing gear
intake camshaft
reverse the order of the above steps from (g) to repeat steps from (c) to (h) once again.
and leave on the
and chain from the and the damper.
slipper
the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged,
causing the camshaft to seize or break. To avoid
this,
the
the two bearing caps and exhaust camshaft.
any other
object.
Remove
8.
the intake camshaft as follows:
Set the timing mark (two dot marks) of the camshaft
drive gear at approximately a
gon wrench head portion
25° angle by turning the hexacamshaft with a
of the intake
wrench.
'•This angle allows the No.
1
and the No. 4 cylinder cam
lobes of the intake camshaft to push their valve
following steps should be carried out.
and
not pry on or attempt to force the camshaft with a tool or
a.
'Since
(e)
lifters
evenly.
Remove
7. a.
the exhaust camshaft as follows:
Bring the service bolt hole of the driven sub-gear up-
ward by turning the hexagon wrench head portion
of the
exhaust camshaft with a wrench. b.
bolt.
When
to the
main
push the intake camshaft towards the
Loosen and remove the No.
c.
Secure the exhaust camshaft sub-gear
gear with a service
Lightly
b.
nately loosening the
removing the camshaft, make
left
and the
Loosen and remove the No.
d.
1
bearing cap bolts,
3,
No.
No. 6 and the
4,
No. 7 bearing cap bolts, alternately loosening the
eliminated by the above operation.
right bolts
c.
Set the timing mark (two dot marks) of the camshaft
hexagon wrench head portion
of the intake
camshaft with a
•Do
push the camshaft towards the rear without ap-
plying excessive force. e.
Loosen and remove the No.
nately loosening the f.
left
and
1
bearing cap bolts, alter-
right bolts uniformly.
Loosen and remove the No.
2,
No.
3,
right bolts
'Do
uniformly
in
several passes,
in
left
and
h.
Alternately
the four bearing caps.
and uniformly loosen and remove the No. 4
and the No. 6 bearing cap If
the camshaft
is
retighten the four No. 4
bolts.
not being
lifted
out straight and level,
and No. 6 bearing cap
and uniformly loosen and remove the No. 2 out straight and level,
lifted
and No. 5 bearing cap bolts. Then the above steps from (e) to (c) and
reverse the order of repeat steps from
bolts.
Remove
Then
(a) to
once again.
(f)
the two bearing caps and the exhaust
camshaft.
To
install:
9.
Remove
the four bearing caps.
and the No. 5 bearing cap bolts. g. If the camshaft is not being
h.
this stage.
i.
Remove
Alternately
f.
sequence.
not remove the No. 4 and No. 6 bearing cap bolts at
g.
and
retighten the four No. 2
No. 5 and the
No. 7 bearing cap bolts, alternately loosening the
left
sequence.
in
not remove the No. 2 and No. 5 bearing cap bolts at
e.
Lightly
several passes
in
this stage.
wrench. d.
uniformly
alter-
right bolts uniformly.
sure that the torsional spring force of the sub-gear has been
driven gear at approximately a 35° angle by turning the
front with-
out applying excessive force.
Install
the intake camshaft as follows:
•Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. a.
Apply engine
oil
to the thrust portion of the intake
camshaft. b.
Lightly place the intake
head so
that the No.
1
camshaft on top
of the cylinder
and the No. 4 cylinder cam lobes
face downward. c.
Lightly
push the camshaft towards the
plying excessive force. Place the No. 2
caps
ing
d.
and
in their
front without ap-
and the No. 5 bear-
proper location.
Temporarily tighten these bearing cap bolts uniformly alternately
in
several passes
until
the bearing caps are
snug with the cylinder head. e.
caps ing
Place the No. in their
cap
3,
No.
4,
No.
6,
and the No. 7 bearing
proper location. Temporarily tighten these bear-
bolts, alternately tightening the left
and
right bolts
uniformly. f.
Place the No.
Check
that there
is
1
bearing cap
in
its
proper location.
no gap between the cylinder head and
the contact surface of the bearing cap.
ENGINE AND ENGINE OVERHAUL
3-151
19.
Uniformly tighten the 14 bearing cap bolts
g.
passes 10.
12
to
ft.
in
several
Install
the exhaust camshaft as follows:
Install
the valve cover.
(16 Nm).
lbs.
INSPECTION
Set the timing mark (two dot marks) of the camshaft
a.
35° angle by turning the hexa-
drive gear at approximately
gon wrench head portion
camshaft with a
of the intake
A
wrench.
Apply engine
b.
dial indicator,
needed to the thrust portion of the
oil
exhaust
ing.
micrometer and inside micrometer are
these instruments are available, proceed;
If
camshaft. Engage the exhaust camshaft gear to the intake
available,
camshaft gear by matching the timing marks (two dot marks)
shop. Camshaft specifications are included
on each gear.
Specifications chart
Roll
c.
down
the exhaust camshaft onto the bearing jour-
each
nals while engaging the gears with
push
other. Lightly
the intake camshaft towards the front without applying exces-
1.
lobe.
lobe
sive force.
the No. 4 and the No. 6 bearing caps
Install
d.
in their
alternately tightening the
Place the No.
caps
in their
cap
ing
and
left
No.
2,
and the No. 7 bearing
5,
proper location. Temporarily tighten these bear-
bolts, alternately tightening the left
and
3.
down
Tighten the 14 bearing cap bolts
f.
ft.
Bring the service bolt installed
g.
several passes to
in
(16 Nm).
lbs.
the driven sub-gear
in
upward by turning the hexagon wrench head portion camshaft with a wrench. Remove the service bolt.
Check
h.
of the
they are not
in
the Camshaft
section.
less than the
is
cam
minimum
V-blocks and measure
in
•
22R and 22R-E
•
3F-E
— 0.0118
of
turn
each cam
specified, the
its
run-out at
— 0.0078 in.
in.
cam
if
run-
(0.20mm)
(0.30mm)
— 0.0024
in.
(0.06mm)
Using the micrometer, measure journal diameter,
jot
compare the readings with those listed in the Camshaft Specifications chart. Measure the housing bore inside diameter with the inside micrometer, and jot the measurements down. Subtract the journal diameter measurement from the housing bore measurement. If the clearance is the readings and
greater than the
and the exhaust camshafts
that the intake
if
a reputable machine
worn and the cam must be replaced.
Place the
• All others
right bolts
uniformly.
12
a lobe height
out exceeds:
right bolts uniformly.
No.
3,
in this
at
the center journal with a dial indicator. Replace the
proper location. Temporarily tighten these bearing cap bolts,
e.
is
2.
have the parts checked
Using the micrometer, measure the height If
all
measure the camshaft and camshaft hous-
to properly
maximum
listed
under Bearing Clearance
in
the chart, replace the camshaft and/or the housing.
smoothly.
Set the No.
11.
cylinder to
1
TDC
compression stroke
of the
as follows: Turn the crankshaft pulley, and align
a.
mark 0
the timing
its
groove with
in
12.
straight line
t See Figures 321, 322, 323, 324, 325 and 326
chain cover. Turn the
of the timing
camshaft so that the timing marks with one and two dots
be
will
on the cylinder head surface.
Check that the matchmarks on the camshaft timing gear and the timing chain are aligned. Place the gear over the straight pin of the intake camshaft. Align the straight pin of the distributor gear with the
groove
straight pin c.
13.
54
ft.
touches the head
Check the valve
14. a.
camshaft gear.
ft.
mark 0
then
install
and
Nm).
timing as flows:
Turn the crankshaft pulley, and align
the timing
and
install
Push the tensioner by hand
lbs. (21
its
of the timing chain cover.
groove with
Always
turn the
crankshaft clockwise. b.
Check
that the timing
marks (one and two dots)
camshaft drive and driven gears are cylinder
head surface.
tion (360°) 1
5.
and
If
straight line
in
not, turn the
of the
on the
crankshaft one revolu-
align the marks.
Check valve clearance and
adjust
requires removal of most of the engine
head and pan. While
parts, including the in
if
necessary.
Install
the spark plugs.
17.
Install
the semi-circular plug to the cylinder head.
18.
Make
sure that the No.
it
can be per-
the vehicle, removing the engine from the vehi-
makes the job much
cle
easier.
may be
Mount the engine on an
moved about the removing the piston assemblies, connecting rod bearing clearance and side clearance should be checked. Refer to the Connecting Rod Inspection procedure in this section.
work
it
Remove Remove
3.
Position a cylinder ridge
1
.
rotated or
area. Before
2.
the cylinder head. the
oil
pan and pump. reamer
into the top of the cylin-
der bore. Keeping the tool square, ream the ridges from the top of the bore. Clean out the ridge material with a solvent-
soaked 4.
16.
compression stroke.
*This procedure
engine stand so that
installation surface,
tighten the two nuts to 15
I See Figures 327 and 328
formed
(74 Nm).
lbs.
the chain tensioner.
Install it
of the intake
Hold the intake camshaft with a wrench,
tighten the bolt to
until
REMOVAL
the camshaft timing gear as follows:
Install a.
b.
Pistons and Connecting Rods
rag, or
Remove
blow the
it
oil
out with strainer.
compressed air. Use a numbered
mark each cap and connecting rod
with
its
die set to
cylinder number.
Unbolt the connecting rod caps.
1
cylinder
is in
TDC
of the
5.
Place pieces of rubber hose over the rod
tect the cylinder walls
bolts, to pro-
and crank journals from scratches. Push
the connecting rod and piston up and out of the cylinder from
ENGINE AND ENGINE OVERHAUL
3-152
— Piston
Ring
-Snap
Ring
Piston
Snap Ring
Piston Pin 1,100 (SO, 108)
Flywheel
Connecting Rod Rear End Plate
Connecting Rod Connecting Rod
Cap I
Bearing
700(51,69)
I
Cylinder
Block Oil Sea!
Rear Oil Retainer
Gasket
Crankshaft -
-Crankshaft Thrust Washer -Crankshaft Bearing -Crankshaft Bearing Cap 1.0S0 (76, 103)
Gasket
Oil Strainer-
Oil
kg-cm
(ft-lb,
Pan
N m)
Non-reusable part 86823pkj
Fig. 321
Exploded view of the 22R and 22R-E engine block
ENGINE AND ENGINE OVERHAUL
3-153
Piston Ring
Piston
Piston Pin
Knock Sensor
5^^
Connecting Rod
Connecting
I
Rod
Bolt
No.
Connecting
1
Water By-pass
Pipe
Rod Bearing Flywheel Rear End Plate
Connecting Rod Cap Oil Seal
Rear Oil Seal Retainer
O-Ring
Oil Filter
-.Oil Filter Op” Union
Gasket Hole Cover Plate Oil
Oil Pressure Switch
Alternator Adjusting
Bar
Crankshaft
Main Bearing
Lower Thrust Washer
Crankshaft Bearing Cap
Non
(2WD)
reusable part 86823pkl
Fig.
322 Exploded view of the 3VZ-E engine block
ENGINE AND ENGINE OVERHAUL
3-154
Piston Ring (No.
1
Compression)
Piston Ring (Side Rail)
Piston Ring (No. 2 Compression) Piston Ring (Expander)
Piston
Snap Ring
Camshaft Bearing
Connecting Rod
Expansion Plug Connecting Rod Bearing
Connecting Rod Cap
Cylinder Block
Gasket
Front End Plate Crankshaft
Main Bearing Main Bearing Cap
Oil
Pump
Gasket
Oil
Pan
Gasket
Non-reusable part 86823pkxn
Fig.
323 Exploded view of the 3F-E engine block
ENGINE AND ENGINE OVERHAUL
3-155
Piston Ring (No.1 Compression) Piston Ring
(No.2 Compression) Piston Ring (Side Rail)
Piston Ring (Expander)
Piston Pin
Connecting Rod Bushing Connecting Rod Connecting Rod Bearing Oil
Drive Plate
Cooler
Cover
X 10
(with Oil Cooler)
Timing Chain
Timing Chain
Cover
Crankshaft
LH Engine Mounting
Front Oil
Bracket
Seal
(with Insulator)
O-Ring
No.1 Oil Pan
Gasket Non-reusable part
No.2
Oil
Pan 86823pkn
Fig.
324 Exploded view of the 1FZ-FE engine block
3-156
ENGINE AND ENGINE OVERHAUL
•Piston Ring (No.1 Compression)
Piston Ring (Expander)
Piston Ring (No.2 Compression)
Piston Ring (Side
Snap Ring
Piston Pin
Snap Ring
Rail)
^
Connecting Rod Bushing Crankshaft Rear Oil Seal
^*6
Rear
Oil
Seal Retainer
-Cylinder Block
Crankshaft Thrust
Washer -Crankshaft
Main Bearing Crankshaft Thrust Washer
Main Bearing Cap (Crankshaft Bearing Cap)
Non-reusable part 86823pko
Fig.
325 Exploded view of the 5VZ-FE engine block
ENGINE AND ENGINE OVERHAUL
3-157
Piston Ring (No.1 Compression) Piston Ring (No. 2 Compression)
Piston Ring (Side Rail) Piston Ring (Expander)
Snap Ring Connecting Rod
Connecting Rod Cap
Rear
Oil
Seal
,^X6
Rear
Oil
Seal Retainer
Crankshaft Thrust Washer (Upper)
Main Bearing (Upper)
Crankshaft Thrust Washer (Lower)
Main Bearing (Lower)
Main Bearing Cap
Non-reusable part 86823pkp
Fig.
326 Exploded view of the 2RZ-FE and 3RZ-FE engine block
ENGINE AND ENGINE OVERHAUL
3-158
tccs3916
327 Use a ridge cutter to remove the ridge from
Fig.
the cylinder bore
Use a wooden hammer handle
the bottom.
bottom
to
push on the
of the piston top.
**WARNING Use care not
to scratch the crank journals or the cylinder
walls.
6.
Keep the
piston
and bearing cap together.
CLEANING AND INSPECTION
Pistons I
See Figures 329, 330, 331 and 332 Clean the piston
after
removing the
any carbon from the piston
top.
Do
rings,
by
first
scraping
not scratch the piston
any way during cleaning. Use a broken piston
Fig.
ring or ring
cleaning tool to clean out the ring grooves. Clean the entire piston with solvent
Once
the piston
good piston piston) into
and a is
brush
is
No.
greater than the
Clearance if
in
328 Carefully tap the piston out of the bore using
wooden dowel
wire brush).
1
and No. 2 compression on each
respective groove. Using a feeler gauge,
sure the clearance between the ring and
ance
(NOT a
a
thoroughly cleaned, insert the side of a
ring (both its
bristle
stiff
tccs3804
in
maximum
listed
its
groove.
mea-
clear-
If
under Ring Side
the Piston and Ring chart, replace the ring(s)
and
necessary, the piston.
Place a rag over the crankshaft journals (the part the rods
connect
soaked
to).
Wipe out each
cylinder with a clean, solvent-
rag. Visually inspect the cylinder
bores
for
scoring or scuffing; also check the bores by feel.
roughness,
Measure the
cylinder bore diameter with an inside micrometer, or a tele-
scope gauge and micrometer. Measure the bore at points parallel and perpendicular to the engine centerline at the top (below the ridge) and bottom of the bore. Subtract the bottom
measurements from the top to determine cylinder taper. Measure the piston diameter with a micrometer; since particular
micrometer
may
not be part of your tool
wish to have the pistons measured the
measurements
at right
at
kit
you
skirt
may
a machine shop. Take
angles to the wrist pin center
about an inch down the piston
tccs3208
this
line,
from the top. Compare
this
Fig.
329 Clean the piston grooves using a ring groove
cleaner
ENGINE AND ENGINE OVERHAUL
3-159
tccs3210
tccs391
Fig.
332 Measure the piston’s outer diameter using a micrometer
330 You can use a piece of an old ring to clean BUT be careful the ring is sharp
Fig.
the piston grooves,
Clean away any carbon buildup
2.
with
sand paper,
clearly.
the ridge
If
pistons without ridge to
at the top of the cylinder
more remove the
order to see the extent of the ridge
in
is slight,
it
damaging the
be safe
will
to
rings or piston ring lands.
severe, and easily catches your fingernail,
is
it
the
If
will
have
be removed using a ridge reamer. 3.
Install
the ridge removal tool
in
the top of the cylinder
bore. Carefully follow the manufacturers instructions for operation.
Only remove the amount
of material
necessary
to
remove
the ridge.
['WARNING Be very
careful
reamer.
A
telescoping gauge
may be used
to
you are unfamiliar with operating a ridge
rial than you want, possibly requiring a cylinder overbore and piston replacement that may not have been necessary.
tccs3209
Fig. 331
if
very easy to remove more cylinder bore mate-
is
It
measure
After the piston
4.
the cylinder bore diameter
and connecting rod assembly have been
removed, check the clearances as explained
in
the piston and
connecting rod cleaning and inspection procedure, to determine
measurement ence
is
bore diameter of each cylinder. The
to the
the piston clearance.
that specified in the Piston
the cylinders
honed
If
the clearance
is
and Ring Specifications
or rebored
differ-
greater than
boring
have
chart,
and replace the pistons
with
whether boring and honing or
an
oversize set.
light
ever,
Wash
the connecting rods
compressed
is
is
all
that
is
air.
Check
in
cleaning solvent and dry them
for twisted or
bent rods and
if
necessary, proceed to the next step.
to the crankshaft
you do not want
connecting rod journal
away from
in-
If
If
best done with the crankshaft removed, to prevent
and
easier, as the honing process
Connecting Rods
with
honing
Honing
damage
honing are required.
just light
necessary, consult an automotive machine shop.
is
to
to
make
will
post-honing cleaning
How-
scatter metal particles.
remove the crankshaft,
for the cylinder
position the
being honed as far
the bottom of the cylinder bore as possible,
and
spect for nicks or cracks. Replace the connecting rods that are
wrap a shop
damaged.
Honing can be done either with a flexible glaze breaker type hone or with a rigid hone that has honing stones and guide shoes. The flexible hone removes the least amount of metal, and is especially recommended if your piston-to-cylinder bore
RIDGE REMOVAL AND HONING
clearance 1
.
Before the piston
is
removed from the
cylinder,
check
for
a ridge at the top of the cylinder bore. This ridge occurs
because the piston of the bore,
bore.
ring
does not
travel
all
the
way
to the top
thereby leaving an unused portion of cylinder
is
cloth
around the journal.
on the loose side. The
provide a finish on which the
hone
new
flexible
remove more material than the requires more operator skill. 5.
will
Regardless
of
which type
of
hone
piston rings
is
will
flexible
useful to
seat.
A
hone and
hone you use,
follow the manufacturers instructions for operation.
carefully
rigid
ENGINE AND ENGINE OVERHAUL
3-160
The hone should be moved up and down the bore at speed to obtain a uniform finish. A rigid hone will provide a definite cross-hatch finish; operate the rigid hone at 6.
sufficient
a speed to obtain a 45-65° included angle in the cross-hatch. The finish marks should be clean but not sharp, free from embedded particles and torn or folded metal. Periodically during the honing procedure, thoroughly
7.
clean the cylinder bore and check the piston-to-bore clearance with the piston for that cylinder. After honing
8.
completed, thoroughly wash the cylinder
is
bores and the rest of the engine with hot water and detergent.
Scrub the bores well with a
stiff
brush and rinse thor-
bristle
oughly with hot water. Thorough cleaning
any abrasive material
wear the new material
the
rings
essential, for
and the cylinder bore.
if
rapidly
will
any abrasive
If
will
it
it
be picked up by
and carried throughout the engine, damaging bearings
oil
and other
parts.
After the bores are cleaned,
9.
is
the cylinder bore,
the rest of the engine,
left in
is
left in
is
clean cloth coated with
light
wipe them down with a
engine
oil,
keep them from
to
rusting.
2. On the 3VZ-E engines, use a press and SST 09221-25024 and 09221-00181 or equivalent to press the
PISTON PIN REPLACEMENT
3.
Wrist pin and/or connecting rod (small-end) bushing
can be checked by rocking the piston by hand.
If
more than very
at right
slight
4.
wear
is felt,
Except
3VZ-E engine, the
for the
in
pistons for the engines
hot water to
must be heated
to
idea of boiling pistons to
do
it,
in
The
kept together
On
until
is
if
is
If
a matched set and must be
piston
removed
or installed
must be observed. The
must be supported on a broad
surface with an opening below the pin hole. Force must be
exerted precisely straight on to the pin; any cocking of the
may
piston
Although
result in cracking the piston. this
process can be accomplished
tools are at hand,
it
is still
recommended
to
if
risk
the correct
have the pins
pressed by either a dealer or machine shop; the outweighs the
slight cost
(and cost) of replacing an otherwise good
piston.
-•-•-CAUTION The components will be in water very close to the boiling point. Wear heavy waterproof gloves or have plenty of padding material available to protect your hands from burns or scalding. Using a small flat-bladded
all
other engines
and remove the connecting
brass bar,
lightly
tap
rod.
install:
On
the
3VZ-E engine, coat the Align the front marks
oil.
necting rod. (A1. B6, IB, 8A,
C3
equivalent from removal, press 6.
Excluding the 3VZ-E,
piston pin
and
of the piston
or etc.) Using the
in
install
pin holes
and con-
SST
or
the piston pin.
a
new
snapring on the one
side of the piston pin hole. Gradually heat the piston to the
the press must be the diameter of the pin so that force
The
hammer and
with engine
the
reassembly.
the 3VZ-E, the piston pins can be
applied evenly.
To 5.
the kitchen doesn’t appeal to you.
with a press, but special precautions tip of
four
however, remember that each piston, pin
and1. connecting rod assembly
—
rect order.
a specific temperature
range. This job can be performed at a machine shop
you decide
176-194°F (80-90°C)
expand them
before the wrist pins can be removed and installed. cylinder pistons
to:
22R-E and 5VZ-FE
11 the vehicle
air cleaner, but
from around the exhaust manifold to flow
temperature, resulting
.
2.
to the engine.
and check
that
it
runs normally.
This not only
This system improves driveability by maintaining a constant
air intake
TESTING
the time, a thermo-
all
the air cleaner housing closes
inside the air cleaner falls
in.
from around the exhaust manifold
stable fuel atomiza-
also serves to prevent carburetor icing
in
cold and
moist weather.
is
equipped with High Altitude Compensavacuum hose from the lower
tion (HAC), disconnect the
port of the
HAC
valve. Plug the hose.
vacuum hose
vacuum
I
3.
Pinch the
4.
Gradually increase the engine speed to 3000 rpm.
Check
to the
that the engine misfires slightly
switch.
between 2400 and 3000
I
rpm.
TESTING
**WARNING 1
.
Visually inspect
Remove
catalytic converter.
the air cleaner top.
Cool the thermo valve by blowing compressed
4.
With the engine
check
cleaner
cleaner.
is
Perform this procedure quickly to avoid overheating the
for cracks,
3.
(cool), air
hoses and connections
damage.
leaks or other 2.
all
to
see
if
idling
air on and the thermo valve closed
the air control valve
open and allowing
in
5. it.
the neck of the
hot air to enter the air
speed 6.
Release the hose and gradually increase the engine to
3000 rpm. Check
With the engine at
that the
that the engine operation
idle
engine misfires or
is
normal.
unplug the solenoid valve. Check
stalls.
i
DRIVEABILITY
AND EMISSION CONTROLS
Above 45° C (113°F)
Below 30° C (86° F)
Thermo Valve
Fig.
39 The thermo valve controls
This system leads a hot
from icing
in
4-23
air
Thermo Valve
air
flow according to the ambiant tempreture
supply to the carburetor
in
cold weather to improve driveability and to prevent the carburetor
extremely cold weather.
Temperature
in Air
Cleaner
Thermo Valve
Cool
Below 30°C (86°F) Hot
Above 45°C
(1
13°F)
CLOSED
OPEN
Air Control
Hot
air
Valve
passage
OPEN Cool
air
passage
OPEN
Intake Air
HOT
COOL 86824pti
Fig.
40 HAI system operating conditions
4-24
Fig.
DRIVEABILITY
AND EMISSION CONTROLS
42 Deceleration fuel cut system schematic
During deceleration this system cuts off part of the fuel
and afterburning
Engine
RPM
in
in
the slow circuit of the carburetor. This prevents overheating
the exhaust system.
Vacuum in the Vacuum SW
Vacuum
SW
Fuel Cut
Computer
Slow
Circuit in
Solenoid Valve
Carburetor
ON
OPEN
ON
OPEN
Low vacuum below 370
mmHg
ON
ON
OFF
ON
(14.71 in.Hg, 49.3 kPa)
Below 1,810 rpm
V
High vacuum
above 430
mmHg
-i
(16.93 in.Hg, 57.3 kPa)
Low vacuum below 370
mmHg
ON
ON
ON
OPEN
OFF
OFF
OFF
CLOSED
(14.71 in.Hg, 49.3 kPa)
Above 2,200 rpm
High vacuum
above 430 mmHg (16.93 in.Hg, 57.3 kPa)
86824ptl
Fig.
43 Deceleration fuel cut system operating conditions
DRIVEABILITY 7.
Stop the engine and reconnect the wiring.
Remove
the
AND EMISSION CONTROLS The problem engine
tachometer.
retor
for
System
of
a poor air/vaporized fuel mixture
of
an accelerating engine,
pump
its
to
send additional
for the
capacity
a cold engine. The Auxiliary Acceleration
designed
in
is
normal insufficient
Pump (AAP)
fuel into the acceleration
the carburetor independent of the regular acceleration
The AAP
OPERATION
is
air/fuel
mixtures are
cali-
brated to be as lean as possible. Although a lean mixture
burn readily at hotter temperatures,
when
an
integral part of the carburetor.
in
pump. It
con-
sists of
two check valves controlled by springs and a dia-
phragm
controlled by both a spring
and engine vacuum. At
constant speeds, intake manifold
used on the 22R engines only.
To reduce emissions, carburetor
itself is
is
nozzle
vacuum draws the AAP diaphragm back, enlarging the chamber and allowing gasoline to enter. When the engine is accelerated, intake manifold vacuum
> See Figures 44, 45 and 46
»*This system
a cold
accentuated when accelerating. Although the carbu-
equipped with an acceleration
demands
Pump (AAP)
Auxiliary Acceleration
is
is
4-25
it
is
reluctant to ignite
cold because fuel vaporizes less readily
Thus, increasing the amount of fuel
in
will
a cold
when air/fuel
increases the amount of vaporized fuel available.
cold.
mixture
drops, allowing the spring.
The
AAP diaphragm
resultant reduction
in
to be pushed back by the chamber volume forces the
gasoline out through the other check valve, into the acceleration nozzle.
AAP used
in
operation
is
governed by the same switching valve
the choke breaker system. At cold coolant tempera-
tures, the valve allows intake manifold
vacuum
to
reach the
The carburetor is
AND EMISSION CONTROLS
DRIVEABILITY
4-26
air-fuel
mixture
insufficient to provide
is
tion nozzle to obtain better cold engine
Coolant Temp.
BVSV
Below 55°C
OPEN
31 °F)
accelerating with a cold engine, the main acceleration for this
by forcing more
pump
capacity
fuel into the accelera-
performance.
Engine
Intake
Vacuum
Diaphragm
in
AAP
Fuel
Drawn into AAP Chamber
RPM
HIGH
Pulled by
Accelerataion
LOW
Returned by spring tension
—
—
Constant (1
When
very lean.
good acceleration. The AAP system compensates
vacuum
(J-L)
CLOSED
Above 74°C (165°F)
Forced into acceleration Nozzle
—
No operation
(J-L)
86824ptp
1.
46
Fig.
AAP
AAP system
operating conditions
diaphragm. At approximately
1
31 °F (55°C),
the passage to vacuum, thus shutting
a
warmed
fully
off
the
it
AAP
closes
off
function on
AAP hose
shut and stop the engine.
2.
Pinch the
3.
Release the hose; check that a spurt
of
gas
is
seen
from the acceleration nozzle at the instant the vacuum hose
engine.
is
released.
INSPECTION
4.
Fully
warm
the engine to normal temperature and repeat
the test.
The vacuum hose should be checked
for leaks, kinks, or
5.
No
6.
Reinstall the air cleaner.
gasoline should spurt from the acceleration nozzle.
improper connection. With the engine cold and
cap and look
idling,
remove the
air
cleaner
into the carburetor.
ELECTRONIC ENGINE CONTROLS I See Figures 47, 48, 49 and 50
When
•
inspecting during rainy days, take extra caution not
to allow entry of
Electronic Control
Module (ECM)
injection parts
OPERATION ECM
The gine.
It
will
REMOVAL
receives signals from various sensors on the en-
all
operating conditions.
The
ECM
1
.
2. is
a very fragile and expensive component. Always follow the
precautions
when
PRECAUTIONS
installation.
Always handle
with care, especially the
all
fuel injection parts
ECM. DO NOT open
the
ECM
nals, ect.,
Do
unit.
When washing
the fuel
wiring connectors.
& INSTALLATION
Disconnect the negative battery cable. Locate the
ECM
and release the
lock,
then
pull
out the
Unbolt the
ECM
from
ECM
on the vehicle
its
mounting area.
install:
4.
Mount the
5.
Fully insert the connector, then
in
the proper location.
check
that
it
is
locked.
first
disconnect the power by either disconnecting
OFF.
not be careless during troubleshooting as there are
numerous amounts
of transistor circuits;
contact can induce troubles.
even a
Oxygen Sensor
cover!
Before removing the fuel injected wiring connectors, termi-
the negative battery cable or turning the ignition switch •
on the
not permit parts to receive a severe impact during
removal or
•
and
servicing the electronic control system. 3.
Do
or
connector. Pull on the connectors only!
To
•
in
I See Figures 51 and 52
then process this information and calculate the
correct air/fuel mixture under
water
engine compartment, prevent water from getting on the
slight terminal
^During handling
of the oxygen sensor, do not hit the end of the sensor. The sensor can be easily damaged by impact or rough handling. Additionally, do not allow the sensor to come in contact with water or petroleum
products.
DRIVEABILITY
AND EMISSION CONTROLS
4-27
4-28
DRIVEABILITY
AND EMISSION CONTROLS VSV
for Fuel
Pressure Control
"
1 :
'
2 :
California Except California 86824p68
Fig.
48 Part locations of the electronic engine control system
— 5VZ-FE
shown
I
DRIVEABILITY
AND EMISSION CONTROLS
4-29
A/C Amplifier
Sensor *1: *2:
California Except California 86824p69
Fig.
49 Part locations of the electronic engine control system
— 2VZ-FE
and 3VZ-FE shown
4-30
DRIVEABILITY
AND EMISSION CONTROLS
"CHECK" Connector
(For High Temp. Line Pressure
Up System) 86824p70
Fig.
50 Part locations of the electronic engine control system
— 3F-E
shown
DRIVEABILITY
Fig. 51
The
ECM
is
usually found behind the glove box
AND EMISSION CONTROLS
— 1996
4-31
Land Cruiser shown
OPERATION The exhaust oxygen sensor haust stream where
it
The oxygen content
gas.
air/fuel
or
02S,
is
mounted
monitors oxygen content in
in
in
the ex-
the exhaust
is a measure of the The oxygen in the ex-
the exhaust
mixture going into the engine.
haust reacts with the oxygen sensor to produce a voltage
which
is
read by the
ECM.
TESTING
1
.
Start the
engine and bring
ature, then run the 2.
(set
Fig.
52 Press
connectors
down on
the lock to release the
it
to
normal operating temper-
engine above 1200 rpm
for
two minutes.
Backprobe with a high impedance averaging voltmeter to the DC voltage scale) between the oxygen sensor
(02S) and battery ground. 3.
Verify that the
0.40-0.60 volts.
02S
voltage fluctuates rapidly between
DRIVEABILITY
4-32 4.
If
the
02S voltage
is
AND EMISSION CONTROLS
stabilized at the middle of the
specified range (approximately 0.45-0.55 volts) or
if
the
02S
voltage fluctuates very slowly between the specified range
5.
If
the
may be
02S voltage
fied range, the
ECM
5 times
volts less than
(02S signal crosses 0.5 seconds), the 02S
in
ten
faulty.
end
stabilizes at either
of the speci-
probably not able to compensate for a
is
mechanical problem such as a vacuum leak or a high
float
These types of mechanical problems will cause the 02S to sense a constant lean or constant rich mixture. The mechanical problem will first have to be repaired, then the 02S test repeated. 6. Pull a vacuum hose located after the throttle plate. Voltlevel (carbureted engines).
age should drop
to
approximately 0.12 volts (while
ing rapidly). This tests the ability of the
mixture condition. Reattach the 7.
02S
rise to
approximately 0.90 volts (while
tuating rapidly). This tests the ability of the
02S
tool. still
to detect
the 02S 02S and/or
8.
voltage
If
wiring for
the
02S
any breaks,
REMOVAL
Fig.
54 Unplug the sensor harness
is
above or below the specified range,
wiring
repair as
may be
faulty.
Check the
necessary and repeat the
test.
& INSTALLATION
See Figures
53, 54, 55,
56 and 57
1.
Disconnect the negative battery cable.
2.
Ensure
that the
engine and exhaust pipes are cold. Lo-
cate the oxygen sensor.
Some
others are on the catalyst, you
sensors are on the
may have more
front pipe
than one.
ease removal.
3.
Spray a lubricant on the studs
4.
Disconnect the negative battery cable and disconnect the
oxygen sensor
Remove Remove
5. 6.
To 7.
to
wiring.
the oxygen sensor retaining nuts. 86824p86
the oxygen sensor and gasket.
install: Install
Fig.
the oxygen sensor with a
Apply a coating
8.
and
86824p85
fluc-
a
mixture condition.
rich
>
fluctuat-
a lean
vacuum hose.
Richen the mixture using a propane enrichment
Voltage should
the
still
to detect
tighten to 14
ft.
new
gasket.
55
It
may be necessary
to use a
deep socket
to
remove the mounting nuts
of anti-seize to the studs. Install the nuts
lbs.
(20 Nm).
86824p87 86824p88
Fig.
53 Use a penetrating lubricant to ease the removal
of the
mountng nuts
Fig.
56 Remove the sensor
.
.
.
DRIVEABILITY
AND EMISSION CONTROLS
Fig.
4-33
58 With battery voltage applied as shown, the
valve should be closed
Connect the oxygen sensor
9.
3. Connect the and negative lead
wiring.
Connect the negative battery cable.
10.
4.
RSO, then check
that the valve
is
+B
open.
the valve did not perform as indicated, replace the IAC
valve.
Control (IAC) Valve
Idle Air
If
positive lead from the battery to terminal to
1FZ-FE Engine
OPERATION The purpose engine
trol
idle
I See Figures 60 and 61
system
of the Idle Air Control (IAC)
speed while preventing
due
stalls
engine load. The IAC assembly, mounted on the
bypass
controls
air
around the
throttle plate.
around the
throttle plate to
rpm
If
During
idle,
ECM
Check
late
a
new
is
too low,
fully
idle
in
sequence.
the closed position.
3.
Apply ground
to terminals S4, S3, S2,
SI and S4
air is
diverted If
If
the valve does not function as indicated, replace the
IAC valve. is
calculated 5.
Install
the IAC valve.
the rpm drops below a speci-
closed.
The
ECM
then calcu-
will
affects the engine’s idle characteristics.
open,
idle If
it
air entering).
may be
speed is If
is
too high (too
stuck closed, it
is
stuck
idle
much
speed
somewhere
in
air
is
If
it
is
enters
too low (not
the middle,
rough, and the engine won’t respond to load
changes.
TESTING I See Figures 58 and 59
Excluding 1FZ-FE Engine 1
.
Using an ohmmeter, measure the resistance between
terminal
+B and
other terminals
(RSC and RSO).
It
should
read between 17.0-24.5 ohms. 2.
Connect the
and negative lead
positive lead from the battery to terminal to
in
sequence. Check that the valve moves towards the open
valve position.
the throttle bore)
enough
is
moves towards
position.
more
the proper position of the IAC valve
The IAC only stuck
that the valve
body,
throttle
By extending or amount of air can move
based on battery voltage, coolant temperature,
fied rate, the throttle plate
B1 and B2. Then,
S4 and SI
in
increase rpm.
engine load, and engine rpm.
to terminals
apply ground to terminals SI, S2, S3,
4.
by the
the IAC valve.
throttle plate.
retracting a conical valve, a controlled
around the
changes
to
Remove
Apply battery voltage
con-
to
is
1.
2.
RSC, then check
that the valve
is
+B
closed.
Fig.
59 The valve should open when connected as
shown
DRIVEABILITY
4-34
AND EMISSION CONTROLS
Fig. 60 The valve should close during the sequence
Fig.
first
62
throttle
.
.
Remove
the screws mounting the valve to the
body
Engine Coolant Temperature (ECT) Sensor
OPERATION The ECT
is
a thermistor (a resistor which changes value
based on temperature) mounted
As the temperature
of the
in
the engine coolant stream.
engine coolant changes, the resis-
tance of the coolant sensor changes.
Low
coolant temperature
produces a high resistance: 100,000 ohms
at
High temperature causes low resistance: 70
-40°F (-40°C).
ohms
at
284°F
(140°C).
The ECM supplies a 5 volt signal to the coolant sensor and measures the voltage that returns. By measuring the voltage change, the Fig. 61
.
.
.
and open during the second
REMOVAL & INSTALLATION
1
.
3.
4.
Drain the coolant to a level below the throttle body.
Remove Remove
I
the throttle body.
See Figures 63 and 64
the screws and the IAC valve. Discard the old 1.
Remove
2.
Fill
the
ECT
sensor from the engine.
a clean container with water and measure
its
install:
Using a
new gasket
or O-ring, attach the IAC valve
and
5.
Install
6.
Fill
the throttle body with
temperature. 3.
secure the mounting screws.
new
Place the sensor
tance of the gaskets.
Start the engine, top off the cooling system.
Check
ECT
tip into
the water.
Measure the
resis-
sensor with an ohmmeter. Compare the
resistance with the temperature as per the graph.
the cooling system with the proper water/coolant
4.
If
5.
Install
it
is
mixture. 7.
fuel
TESTING
gasket or O-ring.
To
determines the engine coolant temperature.
other engine operating conditions.
I See Figure 62
2.
ECM
The voltage will be high when the engine is cold and low when the engine is hot. This information is used to control management, IAC, spark timing, EGR, canister purge and
not within specifications, replace the sensor.
the
ECT
sensor.
for
leaks.
REMOVAL & INSTALLATION Excluding 5VZ-FE Engine 1.
Drain the engine cooling system.
DRIVEABILITY
AND EMISSION CONTROLS 5.
Remove
4-35
the mounting bolts for the timing belt cover and
gasket. 6.
Disconnect the camshaft position sensor harness.
7.
Remove
8.
Disconnect the
9.
Using a
the fuel pipe.
EOT sensor harness. 19mm deep socket, remove
the sensor and
gasket.
To
install:
10.
Using a new gasket and deep socket,
sensor. Tighten to 14 1 1
.
12.
25
ft.
13.
EOT
Connect the
wiring to the sensor.
new
Reinstall the fuel pipe with four lbs.
EOT
the
install
(20 Nm).
lbs.
ft.
gaskets, tighten to
(34 Nm).
Attach the timing belt cover, tighten to 80 inch
lbs. (9
Nm). tccs4p02
Fig.
63 Submerge the end of the temperature sensor
14.
Reconnect the upper
15.
Fill
radiator
hose
to the
water
the cooling system, start the engine, top
outlet.
Check
off.
for leaks.
in
cold or hot water and check resistance
Intake Air Temperature (IAT) Sensor 30
10
:
;
5
S O
2
See Figures 67, 68, 69, 70 and 71
-
•
-
• 3.
If
the test
is
22R-E Engine
1
not within specification, replace the unit.
.
2.
Disconnect the negative battery cable. Disconnect the intake
^You may
3F-E Engines
See Figure 66
3.
air
connector.
need to disconnect nearby hoses.
Unplug the
VAF meter connector. Remove VAF meter still attached.
the
air
cleaner cap with the 1
.
2.
Disconnect the wiring from the
VAF
meter.
4.
Using an ohmmeter, measure the resistance between
E2 and VC. The reading should be between 200-400 ohms.
terminals 3.
4.
If
the test
is
To 5.
not within specification, replace the unit.
Remove
the retainer bolts, 4 nuts, washers,
and gasket from the
air
VAF
meter
cleaner cap.
install:
Attach the
VAF
cleaner, then tighten
meter with a new gasket until
to the air
snug.
6.
Connect the VAF meter
7.
Install
8.
Connect the negative battery cable.
9.
Start the
wiring.
the intake air connector.
engine and check
for
proper functions.
86824p97
86824g89
Fig. Fig.
65 Attach the ohmmeter to terminals E2 and
VS
67 Loosen the clamp surrounding the intake
hose
air
DRIVEABILITY
AND EMISSION CONTROLS
4-37
86824g93
86824g90
Fig.
68 Slide the hose
off of the
sensor
Fig. 71
from the
Slip the unit
air
cleaner housing
1FZ-FE Engine 1
Disconnect the negative battery cable.
.
VAF
Disconnect the
2.
meter
electrical
connector and wire
clamp. 3.
Disconnect the cruise control actuator cable.
4.
Remove
the air cleaner cap,
VAF
meter and silencer as
follows: a.
Disconnect the
air
cleaner hose from the
b.
Disconnect the
air
hose from the
VAF
air suction
meter.
reed
valve.
Disconnect the 3 clamps, remove the wing
c.
cleaner cap,
Fig.
69 Detach the electrical harness from the sensor
nut, air
meter and silencer.
the 4 nuts, plate washers, VAF meter, gasket Remove the 2 screws, bolt and bolt bracket. Disconnect the VAF meter from the air cleaner cap. To install: 6. Install the VAF meter to the air cleaner cap. Install the bracket to the VAF meter and tighten the fasteners to 43 inch lbs. (5 Nm). Place a new gasket and 4 collars on the VAF meter. Install the VAF meter to the air cleaner cap and tighten
Remove
5.
and 4
86824g91
VAF
collars.
retainer nuts to 7 7.
Install
the
lbs.
ft.
air
(10 Nm).
cleaner cap to the
air
cleaner case with
the 3 clips and wing nut. Connect the air hose to the air suction reed valve. Connect the air cleaner hose to the
VAF
meter. 8.
VAF 9.
Connect the cruise control actuator cable. Connect the meter connector and wire clamp.
Connect the negative battery cable.
3VZ-E Engine > See Figure 72 1.
Disconnect the negative battery cable.
2.
Disconnect the
air
hose and remove the 2
bolts from the
resonator bracket. Disconnect the resonator bracket. 3.
VAF meter
Disconnect the
connector. Disconnect the air
cleaner hose connector. 4. 86824g92
Fig.
70 Remove the mounting nuts and washers
Remove the air Remove
bly attached.
meter assembly. Pry
cleaner cap with the
VAF
meter assem-
the retainers and the bracket from the
off
the locking plate and and remove the
4 nuts, washers, lock plate, volume
air
flow meter
and gasket.
DRIVEABILITY
4-38
AND EMISSION CONTROLS Volume
Air
Air
Flow Meter
Cleaner Cap -Bracket
Lock Plate
Volume
Air
Flow
Meter Connector
Resonator Bracket
Hose
Air Cleaner
86824p95
72 Exploded view of the
Fig.
To
4.
new
to the air cleaner cap. Install the
gasket, lock plate,
on the nut and
locking plate
7.
VAF meter
the
Install
meter,
6.
Install
washer and 4
install
nuts. Pry the
the bracket.
VAF
the air cleaner cap and
Connect the
VAF
air into
the
MAF
5.
Turn the
6.
install
ignition switch to the
the
air
position.
hose.
air
2RZ-FE and 3RZ-FE Engines > See Figure 74
1.
Disconnect the
2.
Remove
3.
Unbolt the
the
air
air
air
1
flow meter wiring harness.
.
Disconnect the
MAF
flow meter from the vehicle
and discard
2.
Loosen the are cleaner hose clamp.
3.
On
the 3RZ-FE, disconnect the
air
hose from the
air
cleaner cap.
install:
flow meter with a
new
4.
Attach the
5.
Connect the
air
cleaner hose.
6.
Connect the
air
flow meter harness.
air
4.
gasket.
Loosen the four
clips,
5.
6.
Flow (MAF) Meter
OPERATION '•This component is found on 2RZ-FE, 3RZ-FE, 5VZ-FE and 1FZ-FE engines. This meter measures the It
is
amount
used by the
then the
air
cleaner cap with the
meter attached.
Remove
the four nuts,
cap.
Air
harness and the IAT harness along
with the wire clamps.
cleaner hose.
the gasket.
intake system.
OFF
intake hose.
the resonator
Install
Connect the negative battery cable.
Mass
meter, then check that the voltage
REMOVAL & INSTALLATION
meter connection.
3F-E Engine
To
Blow
fluctuates.
meter assembly.
the air cleaner hose.
bracket with the 2 bolts. Connect the 8.
the 3VZ-E engine
install:
5.
Install
VAF meter on
of air flowing
ECM
through the
to calculate air/fuel
mixture.
TESTING > See Figure 73 1.
Remove
the air intake hose.
2.
Turn the
ignition switch to the
3.
Using a voltmeter, attach the positive terminal probe
ON
position.
the terminal VG, and the negative probe to terminal E3.
to
Discard the gasket.
MAF
meter and gasket from the
DRIVEABILITY
AND EMISSION CONTROLS
4-39
Non-reusable part 86824pa3
74 Exploded view of the
Fig.
To
Place a
8.
Install
(8
9.
meter on the 2RZ-FE and 3RZ-FE engines
install:
7.
lbs.
MAF
new gasket on
the
MAF
the air cleaner cap.
meter and tighten the nuts
to
74 inch
Nm). Install
the meter and cap assembly on the
air
cleaner
housing.
5VZ-FE Engine >
See Figure 75 1
.
Disconnect the
air
cleaner cap from the
2.
Detach the harness from the meter.
3.
Remove
MAF
the mounting bolts for the meter.
meter.
Lift off
the
meter and discard the gasket.
To 4.
install:
Place a
new gasket
the cap assembly, 61 inch 5.
in
position, then tighten the
lbs. (7
meter
to
Nm).
Attach the meter and cap assembly to the
air
cleaner
housing. Fig.
75 Remove the bolts securing the meter
AND EMISSION CONTROLS
DRIVEABILITY
4-40
terminals IDL and
1FZ-FE Engine 1
.
MAF
Disconnect the
Separate the cruise control actuator cable from the
3.
Loosen the
4.
Disconnect the 3
6. 10. 7.
unit.
then remove the wing nut,
clips,
2RZ-FE and 3RZ-FE Engines
air
Unbolt the meter from the cap. Discard the gasket.
Install
Confirm that the
Connect an ohmmeter is
throttle
MAF
meter
air
3.
cleaner
a 0.022
Insert
cleaner hose to the
terminals IDL and
unit.
MAF
4.
meter harness and wire clamps.
E2
Insert a 0.029
terminals IDL and
Sensor
lever.
thick feeler
Check
gauge between between
for continuity
of the sensor. Continuity
should be
(0.74mm)
in.
E2
of
thick feeler
Check the sensor. No
and
lever.
gauge between between
for continuity
continuity should
be
5VZ-FE Engine
Throttle position sensors are usually
the throttle body.
The sensor detects
The voltage
of terminal
VTA
mounted on the side
increases
The
in
proportion of
ECM
and
of the conditions for deciding the air/fuel
power increases and
fuel cut-off control.
1.
Confirm that the
2.
Connect an ohmmeter
~E2
is
throttle
3.
valve
is fully
closed.
IDL and E2.
to terminals
the bottom terminal, while terminal IDL
tioned directly above
judges the
driving conditions from the input signals of the terminals,
uses them as one
of
the throttle valve opening
the opening angle of the throttle valve.
ratio correction,
posi-
present.
OPERATION
angle.
(0.57mm)
and
the throttle stop screw
Throttle Position
is
present.
9. Attach the cruise control actuator cable.
Connect the
closed.
IDL and E2.
it.
in.
the throttle stop screw air
is fully
cap with a new gasket.
to the
the cap/meter assembly to the
Attach the
valve
to terminals
the bottom terminal, while terminal IDL
tioned directly above
housing. 8.
1.
2.
^E2
install:
Secure the
be
cleaner hose.
air
cleaner cap and meter assembly. 5.
of the sensor. Continuity should not
meter harness and wire clamps.
2.
To
E2
present.
Insert a
0.013
(0.32mm)
in.
the throttle stop screw and lever. terminals IDL and
E2
is
posi-
it.
thick feeler
Check
gauge between between
for continuity
of the sensor. Continuity should
be
present. 4.
TESTING
a 0.021
Insert
terminals IDL and
(0.54mm)
in.
the throttle stop screw
E2
and
lever.
thick feeler
Check
of the sensor.
No
gauge between between
for continuity
continuity should
be
present.
22R-E Engine 3F-E Engine 1.
Confirm that the
2.
Connect an ohmmeter
throttle
valve
is
fully
to terminals
closed. 1
IDL and E2.
.
2.
^E2
is
the bottom terminal, while terminal IDL
is
throttle
Connect an ohmmeter
it.
is
3.
Insert
a 0.0224
(0.57mm)
in.
terminals IDL and
E2
thick feeler
Check
gauge between between
a 0.0303
Insert
the throttle stop screw
should be
terminals IDL and
present. 4.
3.
for continuity
of the sensor. Continuity
Insert
a 0.0335
(0.85mm)
in.
the throttle stop screw and lever. terminals IDL and
E2
gauge between continuity between
thick feeler
Check
of the sensor.
No
for
is fully
closed.
IDL and E2.
the bottom terminal, while terminal IDL
tioned directly above the throttle stop screw and lever.
valve
to terminals
posi-
i~E2
tioned directly above
Confirm that the
continuity should
be
posi-
in.
(0.77mm)
and
lever.
thick feeler
Check
gauge between between
for continuity
of the sensor. Continuity
should be
present. 4.
a 0.0429
Insert
in.
(1.09mm)
the throttle stop screw and lever.
terminals IDL and
present.
E2
is
it.
E2
thick feeler
Check
gauge between
for continuity
of the sensor. Continuity
between
should not be
present.
3VZ-E and 1FZ-FE Engines 1
.
2.
^E2
Confirm that the
is
REMOVAL & INSTALLATION
throttle valve is fully closed.
Connect an ohmmeter
to terminals
IDL and E2.
the bottom terminal, while terminal IDL
tioned directly above
is
posi-
>
See Figures 76 and 77
it.
1
3.
Insert
a 0.020
in.
(0.50mm)
the throttle stop screw and lever. terminals IDL and
E2
thick feeler
Check
gauge between between
for continuity
of the sensor. Continuity
should be
Insert
a 0.031
in.
(0.80mm)
the throttle stop screw and lever.
thick feeler
Check
gauge between between
for continuity
Disconnect the negative battery cable.
sensor
Unplug the
3.
Loosen the sensor attaching screws and remove the
throttle position
electrical connector.
sensor.
To
present. 4.
.
2.
4.
install:
Make
sure the tangs to the sensor are
in
good shape,
not bent. Place the sensor on the the throttle body. 5.
Attach the sensor mounting screws.
DRIVEABILITY
AND EMISSION CONTROLS
4-41
TESTING
1
Disconnect the sensor harness.
.
Measure the resistance between the sensor should be between 835-1400 ohms. 2.
3.
If
terminals.
It
not within specifications, replace the sensor.
REMOVAL & INSTALLATION > See Figure 78 1
86824g94
Drain the engine cooling system.
.
2.
Disconnect the upper radiator hose from the water
3.
Disconnect the power steering
4.
Disconnect the three cord clamps
from the
77 The sensor
is
secured by screws
Connect the negative battery cable.
7.
Start the
engine and check
tor
of the
spark plug wires
the mounting bolts for the timing belt cover
and
gasket.
Disconnect the camshaft position sensor harness.
6. 6.
outlet.
hose from the clamp.
belt cover.
Remove
5.
Fig.
air
Remove
7.
any problems.
To 8.
Camshaft Position Sensor
Attach the camshaft position sensor to the engine,
tighten to 9.
69 inch
lbs. (8
Nm).
Attach the wiring harness to the sensor.
10.
OPERATION
the sensor.
install:
Install
the timing belt cover tightening the six mounting
bolts. 1 1
.
Attach the power steering
pump hose
to the belt
cover
clamp.
The camshaft position sensor is installed on the front of the head of the 5VZ-FE engine. The timing rotor has
right cylinder
been integrated with the
right
bank camshaft timing
While the camshaft rotates, the
air
on the timing rotor and the pick-up fluctuation in the in
the pick-up
magnetic
coil.
field
pulley.
gap between the protrusion coil
changes. This causes
and generates a voltage signal
12.
Install
the spark plug wire clamps to the timing belt
cover. 1
3.
14.
Attach the upper radiator hose. Fill
the cooling system, start the engine
coolant. 1
5.
Check
for leaks.
and top
off
the
DRIVEABILITY
4-42
AND EMISSION CONTROLS
Camshaft Position Sensor Connector
3.
Fig.
78 Exploded view of the camshaft position sensor mounting
If
not as specified, replace the sensor.
Crankshaft Position Sensor 5VZ-FE, 2RZ-FE and 3RZ-FE Engines
OPERATION
1.
Unplug the sensor connector.
2.
Measure the resistance between the sensor
terminals.
should be between 2065-3225 ohms. This sensor
is
essentially a pick-up coil. While the crankshaft
gap between the protrusion on the timing rotor and the pick-up coil changes. This causes fluctuation in the magnetic field and generates a varying voltage signal in the
3.
If
not as specified, replace the sensor.
rotates, the air
pick-up
coil.
It
is
used by the
ECM
to
REMOVAL & INSTALLATION
determine crankshaft
angle and speed based upon the voltage received.
5VZ-FE Engine I See Figures 79 and 80
TESTING 1
.
2.
To
1FZ-FE Engine
3. 1.
Unplug the sensor connector.
2.
Measure the resistance between the sensor
should be between 240-325 ohms.
(8
terminals.
It
Disconnect the crankshaft position sensor harness.
Remove
the bolt retaining the sensor to the vehicle.
install:
Attach the sensor to the vehicle, tighten to 69 inch
Nm). 4.
Attach the sensor harness.
lbs.
It
DRIVEABILITY
Fig.
80 The sensor
is
AND EMISSION CONTROLS
secured by a single bolt
>
See Figure 81
10.
Install
the alternator on the engine.
11.
Install
the engine under cover.
the engine under cover.
1FZ-FE Engine
the alternator.
I
2.
Remove Remove
3.
Unbolt the alternator bracket.
4.
Disconnect the crankshaft position sensor harness.
1
5.
Remove
2.
Unbolt the sensor protector.
3.
Disconnect the crankshaft position sensor bracket and
1
.
See Figure 82
•
the bolts securing the sensor and the sensor.
Discard the O-ring.
To 6.
7.
Apply a
light
coat of engine
oil
on the O-ring,
install
4.
on
To
Attach the sensor to the engine, tighten to 74 inch
lbs.
to
Nm). 8.
Attach the sensor harness.
9.
Install
(75
Nm) and
.
Remove
the engine under cover.
harness.
install:
the sensor.
(9
Alternator bracket bolt identification
Fig. 81
2VZ-FE and 3VZ-FE Engines
4-43
the alternator bracket, tighten bolt (A) to 55 bolt (B) to
13
ft.
lbs.
(18 Nm).
ft.
14
the
bolt,
nuts and sensor.
5.
Attach the sensor with the nuts and
14
ft.
6.
Attach the bracket and harness.
7.
lbs.
Remove install:
ft.
8.
lbs.
Install lbs.
(20
Nm) and
Tighten the bolt lbs.
(9
Nm).
the sensor protector, tighten the mounting bolts to
(20 Nm).
Install
bolt.
the nuts to 78 inch
the engine under cover.
4-44
DRIVEABILITY
AND EMISSION CONTROLS
DRIVEABILITY
AND EMISSION CONTROLS
4-45
5VZ-FE Engines
Knock Sensor 4RUNNER
OPERATION
1.
Drain the engine cooling system.
2.
7.
Remove Remove Remove Remove Remove Remove
8.
Using the appropriate
3.
Located
in
the engine block or cylinder head, the
Sensor (KS) retards tion to allow the
under most
ignition timing during
ECM
to maintain
4.
Knock
5.
a spark knock condi-
maximum
timing
6.
advance
conditions.
9.
To See Figure 83
10.
29 1.
Remove
2.
Using an ohmmeter, check that there
the knock sensor(s).
between the terminal and the body.
If
there
is
no continuity
is
continuity re-
place the sensor.
REMOVAL & INSTALLATION > See Figure 84
ft.
.
Disconnect the sensor wire.
Remove
tool or
To
the intake manifold. the water bypass pipe
SST
and knock sensor
wire.
an equivalent, remove the
or
Inspect the sensors. install:
Using the sensor lbs.
tool, install
the two sensors. Tighten to
(39 Nm).
11.
Attach the water bypass pipe and knock sensor wiring.
12.
Install
the fuel pressure regulator.
13.
Install
the intake air connector.
14.
Attach the timing belt cover.
15.
Attach the
16.
Refill
17.
Start the engine, top off the cooling system.
air
cleaner hose.
the engine cooling system.
1.
Drain the engine cooling system.
2.
4.
Remove Remove Remove
5.
Unbolt the timing belt and camshaft
6.
Unbolt the timing belt
7. 8.
Remove Remove
9.
Unbolt and remove the water bypass pipe. Disconnect
3.
Excluding 5VZ-FE Engines 1
the fuel pressure regulator.
EXCLUDING 4RUNNER
Toyota special tool or an equivalent socket, may be needed to remove and install the knock sensor. On the 2RZ-FE, 3RZ-FE and 1FZ-FE engines use SST 09816-30010. For the 5VZ-FE use SST 09817-16011.
2.
the intake air connector.
two knock sensors.
TESTING >
the air cleaner hose.
the timing belt cover.
the sensor with the aid of the appropriate
the equivalent.
SST
the air cleaner hose. the intake air connector. the spark plug wires and the ignition coils. idler pulleys.
idler.
the fuel pressure regulator. the intake manifold assembly.
the knock sensor wire.
install:
the sensor, tighten to
3.
Install
4.
Attach the sensor wire.
33
ft.
lbs.
(44 Nm).
10.
With the aid of the
socket, 11.
SST 09816-30010
or equivalent
remove the sensor(s).
Inspect the sensor(s) for continuity.
To
install:
12.
Install
the sensor(s), tighten to 29
ft.
lbs.
(39 Nm).
13.
AND EMISSION CONTROLS
DRIVEABILITY
4-46
bypass pipe and the knock sensor
Reinstall the water
wires.
Install
19.
Attach the intake
20.
Attach the
14.
Attach the intake manifold assembly.
15.
Install
the fuel pressure regulator.
21
16.
Install
the timing belt
22.
17.
Attach the camshaft timing pulleys and
idler.
the ignition coils and wires.
18.
Fill
.
air
connector.
air
cleaner hose.
the cooling system.
Start the engine, top off the cooling system.
belt.
TROUBLE CODES Place the gear
3.
The
ECM
contains a
built-in,
is
self-diagnosis system which
detected, the Malfunction Indicator
cated on the instrument panel,
By analyzing various
will
Once a malLamp (MIL), lo-
light.
signals, the
ECM
code associated with the detected
nosis system
is
in
Neutral. Turn
detects system mal-
The
ECM
stores the
failure until the diag-
cleared.
The MIL on the instrument panel informs the driver that a The light will go out automatically once the malfunction has been cleared. malfunction has been detected.
Data Link Connector (DLC)
The engine should be
5.
Using a jumper wire, connect terminals TE1 and El
the Data Link Connector
Turn the
6.
at
normal operating temperature.
> See Figures 85, 86 and 87
The DLC1 located
in
is
located
in
of
(DLC1).
1
ON,
ignition switch
but do not start the engine.
the diagnostic code by the counting the
number
of
flashes of the malfunction indicator lamp.
Codes
7.
will
flash in numerical order.
If
no
faults are
stored, the
lamp flashes continuously every V2 second. This
sometimes
called the
Normal or System Clear
is
signal.
After the diagnosis check, turn the ignition
8.
move
OFF and
re-
the jumper wire.
Compare
9.
code
chart.
tests
in this
If
the codes found to the applicable diagnostic
necessary, refer to the individual component
section.
If
the
component
tests are
wire harness and connectors for shorts,
is
accessories
all
4.
Read
functions related to the operating sensors. failure
lever
off.
detects troubles within the engine signal network. function
shift
(|
General Information
OK,
test the
opens and poor
connections.
The DLC3
the engine compartment.
MODELS
1996
the interior of the vehicle, under the driver’s side
l
dash.
'•'These models require the use of the Toyota’s hand held
OBD
scan tool or an equivalent
Reading Codes
1
Prepare the scan
.
II
compliant scan
tool.
according to the manufacturers
tool
instructions.
1989-95
MODELS
Connect the
2.
OBD
II
scan
tool, to
the
DLC3 under
the
instrument panel. 1.
2.
Make Make
sure the battery voltage sure the throttle valve
is
at least 11
is fully
•*When the diagnosis system is switched from the normal mode to the check mode, it erases all Diagnostic Trouble Codes (DTC) and freeze frame data recorded. Before switching modes, always check the DTC and freeze frame
volts.
closed.
data and write them down.
Turn the
3.
scan
ignition switch to the
ON
OBD
and switch the
II
tool switch on.
4.
Use
the
OBD
II
scan
tool to
check the
DTC and
freeze
frame data. Write them down. 5.
Compare
code
chart.
tests
in
If
the codes found to the applicable diagnostic
necessary, refer to the individual component
this section.
If
the component tests are OK, test the
wire harness and connectors for shorts, opens and poor
connections.
Clearing Trouble
Codes
After repair of the circuit, the diagnostic code(s)
86824g88
Fig.
85 The DLC1 terminals are protected by a
must be
removed from the ECM memory. With the ignition turned OFF, remove the 15 amp EFI fuse for 30 seconds or more. Once the time period has been observed, reinstall the fuse and
lid
check
for
normal code output.
•1
1
DRIVEABILITY
AND EMISSION CONTROLS
TOYOTA
4-47
Hand-Held Tester
86824pc4
Fig.
If
the
87 The
DLC3
is
located under the dash
the diagnostic code
ECM
is
not erased,
it
will
and appear along with a new code
be retained by in
event of future
trouble.
Cancellation of the trouble code can also be accomplished
by disconnecting the negative battery cable. However, discon-
necting the battery cable including the clock
and
will
erase the other
radio settings.
If
this
memory systems method
is
used,
always reset these components once the trouble code has
been erased.
4-48
DRIVEABILITY
AND EMISSION CONTROLS
Number of blinks
Code
Malfunction
No.
Indicator
System
Diagnosis
MIL
Trouble Area
Lamp !
-
fi/ififuuin/L
Normal
-
No
trouble code
is
recorded. i
FI1401
•Open 12
fUUL
RPM
ON
Signal
No NE signal is input to the ECM or more after STA turns ON.
for
2 secs,
_iUUUl F1
NE
RPM
signal
is
not input to
ECM
for
300
Signal
ON
msec, or more when engine speed rpm or more.
Ignition
ON
IGF signal from igniter is not input to for 4 consecutive ignition.
is
•
1,500
•
fUUUUL
Signal
ECM
Open
or short in heater circuit of main oxyfor 500 msec, or more. (HT) (2) At normal driving speed (below 60 mph and 1
)
gen sensor
Main
fUUL
Oxygen
Open or short in Distributor
NE
circuit
1
Sensor
ON
Engine Coolant
Open
or short in engine coolant sensor circuit for 500 msec, or
temp, more. (THW)
Intake
Open
or short in heater circuit
main oxygen sensor Main oxygen sensor heater
of •
•ECM
•
Open
or short in engine coolant temp, sensor circuit Engine coolant temp, sensor
•Open Open
Temp.
ON
Sensor FI161
•
•ECM
Signal
Air
24
IGT
ECM
• Igniter
•
ON
Temp. Sensor
FM 392
or short in IGF or from igniter to
circuit
•ECM
400
_juuui_
Open
engine speed is above 1,700 rpm),, amplitude of main oxygen sensor signal •Open or short in main oxygen (0X1) is reduced to between 0.35 — 0.70 sensor circuit V continuously for 60 secs, or more. • Main oxygen sensor
Signal
22
circuit
•ECM (
F1
STA
•ECM
FI1391
21
circuit
1390 •
14
NE
•ECM
FI1389
13
or short in Distributor • Open or short in
•
or short in intake air temp, sensor circuit for 500 msec, or more. (THAI
temp, •
Intake
or short in intake air circuit air
temp, sensor
•ECM
Signal
•
Engine ground bolt loose in El circuit
Open •
Air-Fuel
Ratio
25
fUUUlML
ON
Lean Malfunction
(1)
Oxygen sensor output is less than 0.45 for at least 90 secs, when oxygen sensor is warmed up (racing at 2,000 rpm). —Only for code 25.
V
(2)
FI2562
26
fULMUiniL Rich Mal-
in injector circuit
When
the air-fuel compensation value fluctuates more than 20% from the ECM set range within 60 secs, period while driving at 1 5 km/h (9 mph) or more at coolant temp, of 70‘C (158‘F) or above.
sor circuit •
ON
Oxygen sensor
system •Engine coolant temp, sensor • Volume air flow meter • Ignition
(Air intake) •
ECM
Engine ground bolt loose • Open in El circuit •Short in injector circuit •Fuel line pressure (Injector •
•
Air-Fuel Ratio
Open
•Fuel line pressure (Injector blockage, etc.) •Open or short in oxygen sen-
leakage, etc.) Open or short in cold start injector circuit start injector
•Cold •
function • • • •
Open
or short in
oxygen
sensor circuit Oxygen sensor Engine coolant temp, sensor Volume air flow meter Compression pressure
•ECM
FI2563
86824c55
Fig.
88 Diagnostic Trouble Codes
— 22R-E
DRIVEABILITY
AND EMISSION CONTROLS
Number of blinks
Code
Malfunction
No.
Indicator
System
MIL
Trouble Area
Diagnosis
Lamp (
1
)
full acceleration continued for 2 seconds, output of main oxygen sensor is 0.45 V or more (rich) and output of sub-oxygen sen-
Sub-
Oxygen Sensor
27
When sub-oxygen sensor is warmed up and
ON
sor (2)
Signal
is
0.45 V
or less (lean).
(0X2)
Open or short detected continuously for 500 msec, or more in sub-oxygen sensor heater circuit
•Short or open in sub-oxygen sensor circuit •Sub-oxygen sensor • Open or short in sub-oxygen sensor heater
•ECM
FI3294
Open or short detected continuously for 500 msec, or more in volume air flow meter
Volume Air
FI1394
41
ON
Flow Meter
31
(Ul/lfUL FIT
396
Signal
Short
— VC or E2 - VC-E2 or VS-VC
Open
•
flow meter circuit Volume air flow meter
or short in
ON
•ECM
i
RAlUlilfl Sensor
__jifmiuifL
SPD OFF
Signal
signal
is
not input to the
ECM
•Open
for at
seconds during high load driving with engine speed between 2,200 rpm and 5,000 rpm.
or short in vehicle
speed sensor circuit •Vehicle speed sensor
least 8
•ECM
Starter Signal
Starter signal (STA)
OFF
even once
is
not input to
engine reaches
until
ECM
800 rpm
or
•
more when cranking.
•
juwwjw_
Sensor-
ON
Signal
With engine speed 2,000 tpm or more signal from knock sensor is not input to ECM for 25 revolution. (KNK)
or short in IG relay circuit
SW
or
ECM Open
or short in
knock sensor
circuit •
Knock sensor (looseness, etc.)
•ECM
FM61 8
53
Open main
•
Knock
or short in starter signal
circuit
FI1398
52
air
or short in throttle position sensor circuit •Throttle position sensor
•Open 43
volume
•ECM
or short detected in throttle position sensor signal (VTA) for 500 msec, or more.
Signal
Speed FM397
Open
•
Open
Vehicle
42
•
•
•Open
Throttle Position
Sensor
circuit
Knock jinnrwjinfL Control
ON
Signal
The engine control computer control) malfunction
is
(for
knock
detected.
•
ECM
FI1619
71
iumnnno
EGR System Malfunction
ON
With the coolant temp, at 65°C (149°F) or more, 50 seconds from start of EGR operation. The EGR gas temp, is less than 70°C (158°F) and the EGR gas temp, has risen less than 3°C during the 50 seconds.
•Open
in
EGR gas temp,
•Open in VSV circuit for EGR •EGR vacuum hose disconnected, valve stuck
•Cologged
Condition
when IDL contact OFF or shift "2' or "1" ranges position in 'R D with the check terminals El and TE1 con-
Displayed
Switch
_juumjL
in
EGR gas passage
•ECM
FI2622
51
sen-
sor circuit
•Throttle position sensor IDL circuit
'
OFF
Signal
,
nected.
FI1399
,
•
PNP switch
•
Accelerator pedal, cable
•
ECM
circuit
86824c56
Fig.
89 Diagnostic Trouble Codes
— 22R-E
continued
4-49
AND EMISSION CONTROLS
DRIVEABILITY
4-50
Malfunction Indicator
DTC No.
-
Number
ol Malfunction Indicator Lamp Blinks
jimrjiTL FIT
12
Lamp
System
Normal
Trouble area
Diagnosis
Normal
Test
Mode
Mode
-
-
ON
N.A.
No malfunctions
-
detected.
604 • Distributor circuit
or "G1". "G2" signal to • Distributor within 2 seconds after cranking • Starter signal circuit the engine. •
No "NE"
nnn
RPM
Signal
ECM
ECM
FI1606
13
n nnn
RPM
Signal
ON
ON
No “NE" signal is to ECM for 0.1 sec. more when engine speed is above
• Distributor circuit
or
•
Distributor
1,000 rpm.
•
ECM
FI1607
14
n
No "IGF"
nnnn
Ignition Signal
ON
N.A.
in
• Igniter
input
• Igniter
At normal driving speed (below 100 is 'above 1 ,700 rpm), amplitude of heated oxygen sensor signal (OX 1 is reduced to )
Signal
_JUU1
ON
609
ON
No.1 Heated Oxygen Sensor Heater Signal
_jifuuL_
Temp.
between 0.35 ously for
Open
—
V
0.70
60 seconds
or
and and
ignition coil circuit ignition coil
•
ECM
• •
Heated oxygen sensor Heated oxygen sensor
•
ECM
• •
Heated oxygen sensor Heated oxygen sensor
•
ECM
continu-
or short circuit in heated oxy-
ON
Sensor Signal
ECT sensor ECT sensor
•
ECM
air
•
0.5 sec. or
•
IAT sensor IAT sensor
•
ECM
•
Engine ground bolt loose
or short circuit in engine coolant temp, sensor signal for 0.5 sec. or
circuit
•
Open
ON
circuit
more.
gen sensor heater. (HT1)
Engine Coolant
22
6 times
signal
kmfh and engine speed
No.1 Heated Oxygen Sensor
Fit
no
608
FI1
21
ECM
signal to
succession, and within 256 msec.
more. (THW)
•
circuit
FI1610 Intake
24
_fUUUUUl
Air
Temp.
Sensor Signal
Open
ON
ON
or short
circuit
temp, sensor signal more. (THA)
for
in
intake
circuit
FM611 !1)
Air-Fuel Ratio
25
nn nnnnn
Lean Malfunction
ON
3)
nn nnnnnn
Rich Malfunction
• Injector • Fuel line
When
•
the engine speed varies by more than 1 5 rpm over the preceding crank angle period during a period of 20 seconds during idling with the intake air temp. 0°C (32°F) or above.
When
the difference between the feed back compen-
ON
ON
•
•
ECM
•
•
air-fuel ration
•
sation value of the front and rear exceeds 1 5 of the two values in a period of 20 seconds while
•
%
the engine speed is 2,000 tpm or more and the engine coolant
temp, is between 70°C (158°F) and 95°C (203°F).
pressure
VAF meter PAIR system Heated oxygen sensor circuits Heated oxygen sensors Ignition system
•
F12562
Air Fuel Ratio
• Open in E 1 circuit • Injector circuit
cepting high-altitude areas.
ON 21
26
Heated oxygen sensor output at 2.000 rpm is less than 0.45 V for least at 20 seconds when warmed up. Applies only to code 25 and for California models, ex-
•
Engine ground bolt loose in El circuit
Open
•
Injector circuit Injector
•
Fuel line pressure
•
ECT sensor
•
Compression pressure
•
ECM
FI2563 86824c57
Fig.
90 Diagnostic Trouble Codes
— 3F-E
DRIVEABILITY
AND EMISSION CONTROLS
4-51
Malfunction Indicator
DTC No.
Number
of Malfunction Indicator Lamp Blinks
Lamp
System
Test
Mode
Mode At normal driving speed (below 100 km/h and engine speed is above 1,700 rpm), amplitude of heated oxy-
No. 2 Heated
Oxygen Sensor Signal
ON
28
Trouble area
Diagnosis
Normal
ON
No. 2 Heated Oxygen Sensor Heater Signal
gen sensor signal (0X2) is reduced to between 0.35 — 0.70 V continuously for 60 seconds or more.
Open
or short circuit in heated oxy-
gen sensor heater. (HT2)
•
Heated oxygen sensor Heated oxygen sensor
•
ECM
•
•
Heated oxygen sensor Heated oxygen sensor
•
ECM
•
•
circuit
circuit
FI2698
When Volume 31
-J1MJL
Air
Flow Meter
ON
ON
idle contacts are closed and engine speed is 1,500 rpm'or less, there is an open circuit in VC and VS
•
VAF meter VAF meter
between VS
•
ECM
signal or a short circuit
Signal
circuit
and E2. FI1612
Volume 32
JUUUUl
•
VAF meter VAF meter
•
ECM
•
ECM
•
Air
Flow Meter
ON
ON
Signal
Open circuit in E2 or short tween VC and VS.
circuit be-
circuit
FI1613
35
fUUUUUUUl
BARO
Sensor
Signal
or short circuit in BARO sensor signal for 60 seconds or more.
ON
ON
Open
ON
ON
Open
FI2699
41
_nnnnjL_
Throttle Position Sensor Signal
or short circuit in throttle posi-
tion sensor signal.
•
TP sensor
•
TP sensor
•
ECM
• •
Vehicle speed sensor circuit Vehicle speed sensor
•
ECM
circuit
FI1614
Vehicle Speed
42
Sensor Signal
OFF
OFF
No ''SPD" signal for 8 seconds when engine speed 2,300 rpm or more and with vehicle not moving.
FI1615
No "STA” 43
flMUlfUL
Starter Signal
N.A.
OFF
ECM
engine
• Ignition
speed reaches 800 rpm with vehicle not moving.
• Ignition
signal to
until
•
switch switch
circuit
ECM
F11616
No.
52
JlMIUUlfL
1
No No.1 knock
Knock
Sensor Signal
ON
(front sidel
N.A.
rpm.
BE3935
sensor signal to
ECM
6 crank revolutions with engine speed between 1.600 rpm and 5,200
for
•
Open or short in No.1 knock sensor circuit. No.1 knock sensor
•
ECM
•
(looseness)
86824c58
Fig. 91
Diagnostic Trouble Codes
— 3F-E
continued
AND EMISSION CONTROLS
DRIVEABILITY
4-52
Malfunction
DTC No.
53
Number
of Malfunction Indicator Lamp Blinks
juum_ML
tor
System
Knock Control Signal
Indica-
Lamp
Normal
Test
Mode
Mode
ON
N.A.
Trouble area
Diagnosis
No knock control signal to ECM for 6 crank revolutions with engine speed between 1,800 rpm and 5,200 rpm.
•
ECM
•
Open
BF3935
55
juuumjiMruL
No No.
No. 2 Knock
Sensor Signal
ON
N.A.
(rear side)
'
ECM
2 knock sensor signal to
6 crank revolutions with engine speed between 1,800 rpm and 5,200 rpm.
for
RF.iqns
60 seconds after start of EGR operaEGR gas temp, is less than 70°C (1 58°F) and the following (a)-
or short in No. 2 knock sensor circuit knock sensor
• No. 2
(looseness) •
ECM
•
•
EGR valve EGR hose EGR gas temp, sensor EGR gas temp, sensor VSV for EGR VSV circuit for EGR
•
ECM
•
ECT1
circuit
•
ESA1
circuit
•
ESA2
circuit
•
ESA3
circuit
tion,
conditions also occurs: Engine coolant (a)
•
(cl
EGR System 71
JlMMJlfUl
ON
Malfunction
ON
(1
•
temp.:
53°C
27°F) or more
(b) (c)
• •
Engine speed: 1 ,200 rpm or more Intake air temp.: 0°C (32°F) or
circuit
more FI2R22
81
TCM
juiMnwi/ui
Communication
ON
N.A.
ON
N.A.
ON
N.A.
ON
N.A
Open
in
ECT1
circuit
for
2 sec. or
more.
P093Q4
83
jwwjwuuwl
TCM Communication
Open after
in
ESA1
0.5 sec.
circuit
for
0.5 sec.,
at idle.
P09304
TCM
84
Communication
Open after
in
ESA2
0.5 sec
circuit
for
0.5 sec.,
at idle.
P 09304
85
TCM
JUlfUMUUL^
Communication
Open ter
in
ESA3
0.5 sec.
circuit
for
0 5
sec.,
at idle.
P09304
•
A/C switch circuit A/C switch A/C amplifire TP sensor IDL circuit
• •
51
nnnnn
Switch Condi-
n
tion Signal
N.A.
FI1617
OFF
No "IDL” signal, 'NSW” "A/C” signal to ECM, with
•
signal or
the DLC1 terminals El and TE1 connected
•
PNP switch
•
Acceleration pedal and cable
•
ECM 86824c59
Fig.
92 Diagnostic Trouble Codes
— 3F-E
continued
AND EMISSION CONTROLS
DRIVEABILITY
Number
DTC No.
Mal-
of
blinks
Malfunction
System
_jinnnnnjuL
Trouble Area
Diagnosis
Lamp
Indicator
Lamp
-
function Indicator
Normal
Normal
Test
Mode
Mode
-
-
ON
N.A.
Output when no other code
is
recorded.
FI1401
12
TUlfL_
RPM Signal
No G
or
more
or
NE
signal
after
STA
is
input to the
turns
ECM
2 secs,
for
ON.
FI1606
13
ruuuL_ F1
1
RPM Signal
ON
ON
NE signal is not input to ECM for 0.1 sec. when engine speed is 1,000 rpm or more.
or
more
Open
e
Open
e
ECM
•
Open
•
Distributor
•
ECM
circuit
Distributor or short in
STA
or short in
NE
circuit
circuit
607
e
14
G
or short in NE,
e e
JUUUUl
Ignition
Signal
ON
N.A.
IGF signal from igniter consecutive ignitions.
is
not input to
ECM
for
6
FI1608
Open
IGF or IGT
or short in
from igniter to
circuit
• •
Igniter
•
ECM
ECM
ECM
A/T 16
fuuuum
Control
ON
N.A.
Normal signal
is
not output from
ECU CPU
Signal FI3600 (1
)
Open
or short in heater circuit of heated
more (HT) At normal driving speed (below 60 mph and engine speed is above 1,500 rpm), amplitude of heated oxygen sensor signal (OX) is reduced to between 0.35 - 0 70 V continuously for 60 secs or more. oxygen sensor
Heated 21
Oxygen rin_n
Sensor
(2)
ON
Signal
for 0.5 sec
FI1609
Engine Coolant
22
ruuui
Temp
ON
ON
Sensor FI1610
Open
or short in
engine coolant temp sensor more. (THW)
circuit for 0.5 sec. or
Signal Intake
Temp.
ON
ON
Sensor
FM611
Open
for 0.5 sec. or
more. (THA)
Air- Fuel
^JUUUUUUL
Lean Mal-
ON
(1)
FI2562 (2)
Heated oxygen sensor output is less than 0.45 V for at least 90 secs. When heated oxygen sensor is warmed up (racing at 2.000 rpm) and drive at 50 - 100 km/h
When
the engine speed varies by more than rpm over the preceding crankshaft position period during a period of 50 seconds during idling with the engine coolant temp. 75'C 1
5
(1
Ratio Rich Mal-
oxygen sensor Heated oxygen sensor heater
ECM Open
or short in heated
oxygen
sensor circuit
e •
Heated oxygen sensor
• •
Open or short in engine coolant temp sensor circuit Engine coolant temp, sensor
•
ECM
ECM
Open
or short in intake air
temp,
circuit
• •
Intake
air
temp, sensor
ECM
•
Engine ground bolt loose
• •
Open Open
•
Fuel line pressure (Injector
• • •
in El circuit in injector circuit
Open
or short in
heated
oxygen sensor circuit Heated oxygen sensor Ignition system
Engine coolant temp, sensor air flow meter (Air intake)
•
Volume
•
ECM
• •
Open
in El circuit
•
Short
in injector circuit
•
Fuel line pressure (Injector leakage, etc.)
•
Open
67’F) or more.
Air- Fuel
mjmml
e
•
ON
function
26
or short in heater circuit
blockage, etc.)
Ratio
25
e e
or short in intake air temp, sensor circuit
Signal
Open
of heated
•
Air
24
e
or
Engine ground bolt loose
or short in cold start
injector circuit
ON
ON
function
• •
Cold
Open
start injector
or short in heated
oxygen
sensor circuit
• • • • FI2563
•
Heated oxygen sensor Engine coolant temp, sensor
Volume
air
flow meter
Compression pressure
ECM 86824c69
Fig.
93 Diagnostic Trouble Codes
— 3VZ-E and 3RZ-FE
4-53
AND EMISSION CONTROLS
DRIVEABILITY
4-54
Number
DTC No.
Mal-
of
blinks
Malfunction
System
function Indicator
Trouble Area
Diagnosis
Lamp
Indicator
Lamp
Normal
Test
Mode
Mode (1
or short in heater circuit of sub
Open
)
heated oxygen sensor (2)
Healed
Oxygen
27
ON
for 0.5 sec. or
more (HT2) When sub heated oxygen sensor is warmed up and full acceleration continued for 2 seconds, output of main heated oxygen sensor is 0.45 V or more (rich) and output of sub heated oxygen sensor is 0 45 V or less (lean). (0X2)
Sub
ON
Sensor Signal
•
Open
or short in heater circuit
of sub heated
oxygen sensor
circuit
•
Short or open
ygen sensor e •
in
sub heated ox-
circuit
Sub heated oxygen sensor
ECM
FI3294
Air
31
nnn
n
Flow
Meter
ON
ON
circuit.
Signal FI1612
Volume Flow
Air
32
Meter FI1613
_jiwuul_
ON
F 11 6
1
Sensor
_JU1IUUUL_ FI1615
Sensor
Short -
ON
ON
OFF
Signal
-
or short detected continuously for 0 5 sec
Short -
VS
-
circuit.
not input to the
is
Open
•
meter circuit Volume air flow meter
•
ECM
ECM
•
not input to ECM even once until engine reaches 800 rpm or more when cranking.
(STA)
43
Signal
N
A.
OFF
•
Open
• •
Knock
jumn/uin_
ON
N
A.
Signal FI
1
6
ECM or short in vehicle
speed
sensor circuit Vehicle speed sensor
ECM Open
or short in starter signal
•
Open
or short in IG
SW
or
main
relay circuit
With engine speed between 1,600 rpm - 5,200 rpm, signal from knock sensor is not input to ECM for 6 revolution. (KNK)
•
ECM Open
or short in
knock sensor
circuit
Knock sensor (looseness,
• •
ECM
•
ECM
etc.)
1
Knock 53
flow
circuit
•
Sensor
air
or short in throttle position
Throttle position sensor
is
FI1616
52
Open
• •
for at least
8 seconds during high load driving with engine speed between 2,750 rpm and 4,000 rpm.
Starter signal
volume
sensor circuit
• Starter
or short in
VC
or short
signal
• E2
detected in throttle position sensor signal (VTA) for 0 5 sec or more IDL contact is ON and VTA output exceeds 1.45 V
SPD
ON
VC
more in volume air flow meter • Open - E2
Open
Signal
Speed
Open - VC
•
•
Vehicle
42
or
Signal
Position
•
Open
ON
Throttle
41
i
At idling, open or short detected continuously for 0.5 sec. or more in volume air flow meter
Volume
JMWU1WL
Control
ON
N.A.
Engine speed is between 650 rpm and 5,200 rpm and engine control module (for knock control) malfunction
signal
is
detected
FI161
EGR 71
juuinniiu
System Mal-
ON
ON
With the engine coolant temp at 60'C (140*F) or more, 240 seconds Irom start of EGR operation. The EGR gas temp is less than 55*C (1 31 *F) and the EGR gas temp, has risen less than 20‘C (36”C) during the 240 seconds.
function FI2622
51
jinjiniUL_
Switch Condition Signal
F1
1
Displayed N.A.
OFF
when A/C
shift position in "R",
with the
DLC1
is
ON, IDL contact OFF
"D",
"
2
".
•
• •
EGR
gas temp, sensor
in VSV circuit for EGR EGR vacuum hose disconnected,
Open
valve stuck
Clogged
•
ECM
in
EGR
gas passage
•
A/C
•
Throttle position sensor
switch circuit
IDL
circuit
•
terminals El and TE1 connected
Park/Neutral position switch circuit
• •
61
in
•
or
or "L* positions
Open circuit
Accelerator pedal, cable
ECM 86824c70
Fig.
94 Diagnostic Trouble Codes
— 3VZ-E and
3RZ-FE continued
AND EMISSION CONTROLS
DRIVEABILITY
DTC
POIOO
Diagnostic Trouble Code Detecting Condition
Detection Item
No.
Mass
Air
4-55
Open or short in mass 4,000 rpm or less
Flow Circuit
Malfunction
air
flow meter
circuit
with engine speed
1
Conditions
POIOI
Mass
Flow Circuit Range/Performance Problem Air
P0115
P0116
P0120
Intake Air
Temp.
Circuit
Malfunction
Engine Coolant Temp. Circuit Malfunction
Engine Coolant Temp. Circuit
Range/Performance Problem
Throttle/Pedal Position Sensor/
"A”
Switch
continue with engine speed
Open
or short in intake air
Open
or short in engine coolant
20 min.
or
value
32°C (90°F)
is
Condition
more
(a)
VTA"< VTA >
Circuit Malfunction (b)
P0121
(b)
When (2 trip
temp, sensor
P0130
for
Closed Loop Fuel Control
or less
or (b) continues:
0.1 V, and closed throttle position switch
4.9
is
ON, condition
2.0
V
After the engine
is
warmed
up, heated
when
(a)
oxygen sensor output does
conditions
(a), (b)
and
(c)
con-
tinue for at least 1.5 minutes: (a)
Engine speed: 1,500 rpm or more
(b)
Vehicle speed:
(c)
Closed throttle position switch: OFF
40
~
100 km/h (25
~
62 mph)
V or more, warmed up
Voltage output of heated oxygen sensor remains at 0.4 or
Sensor
OFF
detection logic)
Malfunction 1
is
V
Heated Oxygen Sensor Circuit (Bank
P0133
circuit
after starting engine, engine coolant temp, sensor
not indicate RICH even once
P0125
circuit
temp, sensor
closed throttle position switch
VTA >
(a)
Temp,
or less:
continues:
Switch "A” Circuit Range/ Performance Problem
Insufficient Coolant
900 rpm
Closed throttle position switch: ON Mass air flow meter output > 2.2 V
(a)
(a)
Throttle/Pedal Position Sensor/
and
(2 trip detection logic)
(b)
POIIO
(a)
0.55 V
or less, during idling after the engine
is
1
Heated Oxygen Sensor Circuit Slow Response (Bank 1 Sensor 1
Response time for the heated oxygen sensor's voltage output to change from rich to lean, or from lean to rich, is 1 sec. or more during idling after the engine is warmed up
86824c60
Fig.
95 Diagnostic Trouble Codes
— 2RZ-FE and
3RZ-FE
DRIVEABILITY
4-56
DTC
AND EMISSION CONTROLS
Diagnostic Trouble Code Detecting Condition
Detection Item
No.
When
the heater operates, heater current exceeds 2
drop for the heater
A
or voltage
exceeds 5 V
circuit
Heated Oxygen Sensor Heater
P0135
Circuit Malfunction
(Bank
Sensor
1
1)
Heater current of 0.25
Heated Oxygen Sensor Circuit
P0136
Malfunction
Sensor
1
or less
when
the heater operates
Voltage output of the heated oxygen sensor (bank
mains at
(Bank
A
at
0.4
50 km/h
V
sensor 2)
1
re-
more or 0.5 V or less when the vehicle is driven mph) or more after the engine is warmed up
or
(31
2)
Heated Oxygen Sensor Heater
P0141
Circuit Malfunction
(Bank
Sensor
1
Same
as
DTC
When the
P0170
No.
P0135
2)
Fuel Trim Malfunction
air fuel ratio
the fuel trim
is
feedback
considerably
in
stable after engine
is
error
warming
up,
on the RICH side or the LEAN
side (2 trip detection logic)
After the engine
P0401
Exhaust Gas Recirculation Flow Insufficient Detected
EGR gas temp, is
air
temperature
sensor value
cold and
run at 80 km/h (50 mph) for 3 between value of EGR gas temp,
vacuum
is
is
high during
EGR
cut-off
when
applied to port E
Exhaust Gas Recirculation Flow Excessive Detected
EGR
valve
is
always open
After the engine
P0420
warmed up and
sensor and ambient
engine
P0402
is
to 5 minutes, small difference
System Efficiency Below Threshold Catalyst
~
is
warmed up and
the vehicle driven for 5 min. at
—
52 mph), the wave forms of the heated oxygen sensors, bank 1 sensor 1 and bank 1 sensor 2, have the
30
83 km/h (19
same amplitude
Evaporative Emission
P0441
Control
System
The proper response
to the
computer command does not occur
Incorrect Purge Flow
86824c61
Fig.
96 Diagnostic Trouble Codes
— 2RZ-FE and 3RZ-FE continued
DRIVEABILITY
DTC
P0500
P0505
Diagnostic Trouble
Detection Item
No.
Vehicle Speed Sensor
Malfunction
Idle
AND EMISSION CONTROLS
No
PI 300
ECM
under conditions
(a):
being driven
(a)
Vehicle
Idle
speed continues to vary greatly from the target speed
Control System
Malfunction
Closed Throttle Position Switch
Code Detecting Condition
vehicle speed sensor signal to
The closed
P0510
4-57
when
is
throttle position switch
the vehicle
is
does not turn
ON
even once
driven
Malfunction
Igniter Circuit
Malfunction
No IGF
signal to
ECM
for
4 consecutive IGT
signals during engine
running
Crankshaft Position
PI
335
Sensor Circuit Malfunction (during
No crankshaft position sensor 1 ,000 rpm or more
signal to
ECM
with engine speed
engine running)
PI
500
P1600
Starter Signal Circuit
Malfunction
ECM BATT
Malfunction
No
starter signal to
Open 2 or
in
ECM
back up power source
more switches
are
ON
circuit
simultaneously for "N",
"2" and "L"
position
PI
780
Park/Neutral Position Switch
When
Malfunction
park/neutral position switch
driving under conditions (a) is
ON
and
(b) for
30
sec. or
more the
(N position):
(2 trip detection logic) (a)
Vehicle speed:
(b)
Engine speed:
70 km/h (44 mph) or more 1,500 2,500 rpm
~
86824c62
Fig.
97 Diagnostic Trouble Codes
— 2RZ-FE and
3RZ-FE continued
DRIVEABILITY
4-58
DTC
PI
No.
300
AND EMISSION CONTROLS
Diagnostic Trouble
Detection Item
Igniter Circuit
Malfunction
No IGF
signal to
ECM
for
Code Detecting Condition
4 consecutive IGT signals during engine
running
Crankshaft Position
P1335
Sensor Circuit
No crankshaft
Malfunction (during
1
,000 rpm
or
position sensor signal to
ECM
with engine speed
more
engine running)
PI 500
P1600
Starter Signal Circuit
Malfunction
ECM BATT
Malfunction
No
starter signal to
Open 2 or
in
ECM
back up power source
more switches
are
ON
circuit
simultaneously for "N",
"2" and "L"
position (2 trip detection logic)
PI
780
Park/Neutral Position Switch
When
Malfunction
park/neutral position switch
driving under conditions is
(a)
ON
and
(b) for
30
sec. or
more the
(N position):
(2 trip detection logic) (a)
Vehicle speed:
(b)
Engine speed:
1
70 km/h (44 mph) or more ,500 ~ 2,500 rpm 86824c63
Fig.
98 Diagnostic Trouble Codes
— 2RZ-FE and
3RZ-FE continued
AND EMISSION CONTROLS
DRIVEABILITY
DTC
POIOO
Diagnostic Trouble
Detection Item
No.
Mass
Air
Flow
Open or short rpm or less
Circuit
Malfunction
Conditions
mass
in
(a)
and
air
(b)
4-59
Code Detecting Condition.
flow meter circuit with engine speed 4,000
900 rpm
continue with engine speed
or
less:
POIOI
Mass
Air Flow Circuit Range/Performance Problem
(a)
(b)
POIIO
P0115
P0116
P0120
Intake Air
Temp.
Circuit
Open
or short in intake air
Open
or short in engine coolant
temp, sensor
circuit
Malfunction
Engine Coolant Temp. Circuit Malfunction
Engine Coolant Temp. Circuit
Range/Performance Problem
Throttle/Pedal Position Sensor/
Switch
"A”
Circuit Malfunction
20 min.
or
value
35°C (95°F)
(a)
Sensor/Switch "A” Circuit Range/Performance Problem
more
0.
1
4.9
temp, sensor
circuit
after starting engine, engine coolant
(a) or (b)
VTA < VTA >
When
Throttle/Pedal Position
is
Condition
(b)
P0121
Closed throttle position switch: ON Mass air flow meter output > 2.2 V
temp, sensor
or less
continues:
V, and closed throttle position switch
is
OFF
V
closed throttle position switch
is
ON, condition
(a)
continues: (a)
VTA >
2.0
V
is warmed up, heated oxygen sensor output does not indicate RICH even once when conditions (a), (b) and
After the engine
P0125
Insufficient Coolant
Temp,
Closed Loop Fuel Control
for
(c)
continue for at least 1.5 minutes:
(a)
Engine speed:
(b)
Vehicle speed:
(c)
Closed throttle
1
,500 rpm or more
40 km/h (25 mph) or more position switch: OFF 86824c64
Fig.
99 Diagnostic Trouble Codes
— 5VZ-FE
4-60
DTC
DRIVEABILITY
No.
AND EMISSION CONTROLS
Heated Oxygen Sensor
P0130
P0133
Circuit
Malfunction
(Bank
1
V or more, warmed up
Voltage output of heated oxygen sensor remains at 0.4 or
Sensor
Code Detecting Condition
Diagnostic Trouble
Detection Item
0.55V
or less, during idling after the engine
is
1
Heated Oxygen Sensor Slow Response (Bank 1 Sensor 1)
Circuit
Response time for the heated oxygen sensor's voltage output to v change from rich to lean, or from lean to rich, is 1 sec. or more during idling after the engine is warmed up
When
the heater operates, heater current exceeds 2
drop for the heater
circuit
exceeds 5
A
or voltage
V
Heated Oxygen Sensor Heater
P0135
Circuit Malfunction
(Bank
1
Sensor
r
1)
Heater current of 0.25
Heated Oxygen Sensor
P0136
1
Sensor
or less
when
the heater operates
Voltage output of the heated oxygen sensor (bank Circuit
mains
Malfunction
(Bank
A
at
at
0.4 V or more or 0.5
50 km/h
(31
mph)
or
V
more
or less
when
1
sensor 2)
the vehicle
after the engine
is
is
re-
driven
warmed up
2)
Heated Oxygen Sensor Heater
P0141
Circuit Malfunction
(Bank
P0170
1
Sensor
Same
as
When
the
DTC
No.
P0135
2)
air fuel ratio
the fuel trim
is
feedback
considerably
is
stable after engine
in error
Fuel Trim Malfunction
warming
up,
on the RICH side or the LEAN
side
P0300
P0301 P0302 P0303
P0304 P0305 P0306
Random/Multiple Cylinder
Misfiring of
Misfire Detected
or
Cylinder
—
Cylinder 5
—
is
detected during any particular 200
For any particular 200 revolutions of the engine, which can cause catalyst overheating (This causes MIL to blink)
Misfire Detected
— — — —
random cylinders
1,000 revolutions
1
misfiring
is
detected
Cylinder 2 Cylinder 3 Cylinder 4 For any particular 1,000 revolutions of the engine, misfiring
tected which cause a deterioration
Cylinder 6
in
is
de-
emissions
86824c65
Fig.
100 Diagnostic Trouble Codes
— 5VZ-FE
continued
DRIVEABILITY
DTC
No.
P0325
P0330
Diagnostic Trouble
Detection Item
Knock Sensor
1
signal to
ECM
with engine speed 2,000 rpm or
Circuit
Malfunction
No knock sensor 2 more
signal to
ECM
with engine speed 2,000 rpm or
Crankshaft Position Sensor
position sensor signal to
Camshaft Position Sensor
position sensor signal to
ECM
with engine speed
600
more
or
No camshaft
position sensor signal to
No camshaft
position sensor signal to
ECM
during cranking
Circuit
Malfunction
After the engine
Exhaust Gas Recirculation Flow Insufficient Detected
ECM
warmed up and run at 80 km/h (50 mph) for 3 EGR gas temperature sensor value does not ex-
ceed 60°C (140°F) above the ambient
EGR gas temp, sensor is
value
is
is
air
high during
cold (Race engine at about
vacuum
during engine running
is
to 5 minutes, the
gine
P0402
during cranking
"A" No crankshaft
P0401
ECM
Circuit Malfunction
rpm
P0340
Code Detecting Condition
more
No crankshaft
P0335
4-61
1
No knock sensor
Circuit
Malfunction
Knock Sensor 2
AND EMISSION CONTROLS
temperature
EGR
cut-off
when
4,000 rpm without load so
enthat
applied to port E)
Exhaust Gas Recirculaton Flow Excessive Detected
EGR
valve
is
always open
86824c66
Fig. 101
Diagnostic Trouble Codes
— 5VZ-FE
continued
4-62
DTC
DRIVEABILITY
AND EMISSION CONTROLS
Detection item
No.
Diagnostic Trouble
After the engine
P0420
is
Code Detecting Condition
warmed up and
the vehicle driven for 17 min.
30 ~ 83 km/h (19 — 52 mph), the waveforms
Catalyst system Efficiency
at
Below Threshold
oxygen sensors, bank
1
sensor
1
and bank
1
of the heated
sensor
2,
have the
same amplitude
P0441
P0500
Evaporative Emission Control
System
The proper response to the computer command does not occur
Incorrect Purge Flow
No
Vehicle Speed Sensor
Malfunction (a)
P0505
P0510
Idle
Control System Malfunction
Closed Throttle Position Switch Malfunction
Idle
vehicle speed sensor signal to
Vehicle
is
ECM
under conditions
(a):
being driven
speed continues to vary greatly from the target speed
The closed
when
throttle position switch
the vehicle
is
does not turn
ON
even once
driven
86824c67
Fig.
102 Diagnostic Trouble Codes
— 5VZ-FE
continued
DRIVEABILITY
DTC
No.
PI 300
Diagnostic Trouble
Detection Item
No IGF
Igniter Circuit Malfunction
500
ECM
for
Code Detecting Condition
6 consecutive IGT signals during engine
No crankshaft position sensor 1 ,000 rpm or more
Circuit Malfunction
(during engine running)
PI
signal to
4-63
running
Crankshaft Position Sensor
PI 335
AND EMISSION CONTROLS
Starter Signal Circuit
No
Malfunction
PI 600
ECM BATT
P1605
Knock Control CPU Malfunction
starter signal to
Open
Malfunction
in
signal to
ECM
with engine speed
ECM
back up power source
circuit
Engine control computer malfunction (for
knock control)
Two or more switches
are
ON
simultaneously for "N",
"2" and “L"
position
P1780
Park/Neutral Position Switch
When
Malfunction
driving under conditions
park/neutral position switch (a)
Vehicle speed:
(b)
Engine speed:
is
(a)
ON
and
(b) for
30
sec. or more, the
(N position):
70 km/h (44 mph) or more 1,500 - 2,500 rpm 86824c68
\
Fig.
103 Diagnostic Trouble Codes
— 5VZ-FE
continued
4-64
AND EMISSION CONTROLS
DRIVEABILITY
DTC
Trouble Area
Detection Item
No.
•
POIOO
Mass
Air
Flow Circuit
Malfunction
POIOI
POIIO
•
Mass
•
ECM
Air Flow Circuit Range/Performance Problem
•
Intake Air
Temp.
•
Engine Coolant
air
flow meter
air
flow meter
Mass
air
flow meter
Open
or short in intake air temp,
•
Intake
•
ECM
Temp
Circuit Malfunction
or short in engine coolant temp,
Engine coolant temp, sensor
•
ECM
•
Engine coolant temp, sensor
•
Cooling system
•
Open
Throttle/Pedal Position
Sensor/Switch
temp, sensor
•
Engine Coolant Temp.
Range/ Performance Problem
Open
air
sensor circuit
Circuit
P0120
mass
sensor circuit
Circuit
•
P0116
or short in
Mass
Malfunction
P0115
Open
circuit
or short in throttle position
sensor circuit
"A" •
Throttle position sensor
•
ECM
•
Throttle position sensor
Circuit Malfunction
Throttle/Pedal Position
P0121
P0125
Sensor/Switch "A" Circuit Range/ Performance Problem Insufficient Coolant for
Temp,
Control
P0130
•
Closed Loop Fuel
Heated oxygen sensor
•
Heated oxygen sensor
•
Fuel trim malfunction
•
Heated oxygen sensor
Heated Oxygen Sensor 1
Sensor
or short in heated
•
Circuit Malfunction
(Bank
Open
oxygen
sensor circuit
1
Heated Oxygen Sensor
P0133
Circuit
Slow Response (Bank 1 Sensor
1
Heated Oxygen Sensor
P0135
Open
(Bank
1 1
Sensor Sensor
or short in heater circuit of
•
oxygen sensor Heated oxygen sensor heater
•
ECM
•
Heated oxygen sensor
Circuit Malfunction
(Bank
P0136
•
Heater
1
heated
2)
Heated Oxygen Sensor Circuit Malfunction
(Bank
1
Sensor
2) 86824cal
Fig.
104 Diagnostic Trouble Codes
— 1FZ-FE
DRIVEABILITY
DTC
No.
AND EMISSION CONTROLS
Trouble Area
Detection Item
Heated Oxygen Sensor
P0141
Heater (Bank
P0171
1
Sensor
•
Air intake (hose loose)
Fuel line pressure, leak
System too Lean
•
Injector blockage
(Fuel Trim)
•
Heated oxygen sensor malfunction Mass air flow meter Engine coolant temp, sensor
System too Rich
•
Fuel line pressure
•
Injector blockage, leak
•
•
Heated oxygen sensor malfunction Mass air flow meter Engine coolant temp, sensor
•
P0325
Random/Multiple Cylinder
•
Ignition
Misfire Detected
•
Injector
•
Fuel line pressure
Misfire Detected
•
EGR
— — — — —
1
•
Compression pressure
Cylinder 2
•
Valve clearance not to specification
Cylinder 3
•
Valve timing
Cylinder 4
•
Mass
Cylinder 5
•
Engine coolant temp, sensor
• •
Open or short Knock sensor
•
ECM
• •
Open or short in knock sensor 2 Knock sensor 2 (looseness)
•
ECM
•
Open
Cylinder
Knock Sensor
1
Circuit
Knock Sensor 2
Circuit
Malfunction
P0335
P0340
Crankshaft Position
air
flow meter
knock sensor
in 1
1
circuit
(looseness)
circuit
or short in crankshaft position sen-
sor circuit for
NE
signal
Sensor
•
Crankshaft position sensor for NE signal
"A"
•
Starter
•
ECM
•
Open
Circuit Malfunction
Camshaft Position Sensor Circuit
in
camshaft position sensor
•
Camshaft position sensor
•
ECM
•
Open
Crankshaft Position
or short in crankshaft position sen-
sor circuit for
Sensor
"B"
or short
circuit
Malfunction
P0385
system
Cylinder 6
Malfunction
P0330
No.
•
(Fuel Trim)
P0301 P0302 P0303 P0304 P0305 P0306
as
2)
•
P0300
P0135
Same
•
P0172
DTC
•
Circuit Malfunction
NE2
signal
•
Crankshaft position sensor for
•
ECM
Circuit Malfunction
NE2
signal
86824ca2
Fig.
105 Diagnostic Trouble Codes
— 1FZ-FE
continued
4-65
4-66
AND EMISSION CONTROLS
DRIVEABILITY
DTC
Trouble Area
Detection Item
No.
P0401
•
EGR
Exhaust Gas Recirculation Flow
•
Short
in
•
Open
in
Insufficient Detected
•
EGR hose disconnected
•
ECM
•
•
EGR valve stuck open EGR VSV open .malfunction Open in VSV circuit for EGR Short in EGR gas temp, sensor
•
ECM
•
Three-way
•
Open
Exhaust Gas Recirculation Flow Excessive Detected
P0402
Catalyst
P0420
System
•
•
valve stuck closed
VSV circuit for EGR EGR gas temp, sensor
circuit
circuit
catalytic converter
or short in heated
oxygen sensor
Efficiency circuit
Below Threshold • •
Heated oxygen sensor
Open
or short in vehicle speed sensor
circuit
P0500
P0505
Vehicle Speed Sensor
•
Vehicle speed sensor
Malfunction
•
Combination meter
•
ECM
Control System
Idle
Malfunction
•
IAC valve
• •
Open Open
•
Air intake (hose loose)
•
P0510
Closed Throttle Position
Switch Malfunction
Open
stuck or closed
is
or short in or short
in
IAC valve
A/C
circuit
signal circuit
closed throttle position switch
circuit •
Closed throttle position switch
•
ECM 86824ca3
Fig.
106 Diagnostic Trouble Codes
— 1FZ-FE
continued
VACUUM DIAGRAMS Following
is
a
listing of
vacuum diagrams
for
most
of the
engine from the vehicle’s
engine and emissions package combinations covered by this manual. Because vacuum circuits will vary based on various
grams below
engine and vehicle options, always refer
manufacturers
emission control information
label,
if
first
to the vehicle
present. Should the label
be missing, or should vehicle be equipped with a
different
If
for the
you wish
to obtain
make
original
same
equipment, refer
to the dia-
or similar configuration.
a replacement emissions
label,
the labels available for purchase.
bels can usually be ordered from a local dealer.
most
The
la-
DRIVEABILITY Thermo Valve
EGR EGR Vacuum
Valve
MC
AND EMISSION CONTROLS
HAI Diaphragm
Valve
Modulator
Choke Opener Outer Vent
Charcoal Canister
Check Valve (w / HAC only)
HAC
Valve
8VSV
(Fed. only
Vacuum Switch
VSV VSV
Water
Temp
Sensor
(for Al) (for
EVAP)
Charcoal Canister
86824V13
Fig.
107 Vacuum hose routing
— 1989 22R
(Federal
and Canada)
4-67
4-68
DRIVEABILITY
AND EMISSION CONTROLS
DRIVEABILITY
AND EMISSION CONTROLS
4-69
4-70
DRIVEABILITY
AND EMISSION CONTROLS
86824V26
Fig.
118
Vacuum hose
routing
— 1993-95
1FZ-FE
DRIVEABILITY
Check Valve
PCV
(A/T)
Valve
EGR Valve EGR Vacuum
AND EMISSION CONTROLS
VSV Modulator
Healed Oxygen Sensor (Bank 1 Sensor 2)
,^To Throttle
for
EVAP Vapor Pressure Sensor
Body
VSV for Ev£p~ VSV for Vapor \
\
Pressure"
Sensor
VSV for EGR Heated Oxygen Sensor (Bank 1 Sensor 1) Charcoal Canister
Fig. 121
Vacuum hose
routing
— 1996
2RZ-FE
4-71
4-72
DRIVEABILITY
AND EMISSION CONTROLS Heated Oxygen Sensor
Vapor Pressure Sensor
86824V30
Fig.
122
Vacuum hose
routing
— 1996
3RZ-FE
BASIC FUEL SYSTEM DIAGNOSIS CARBURETED FUEL SYSTEM CARBURETOR 5-3 MECHANICAL FUEL PUMP 5-2
PRECAUTIONS 5-2 UNDERSTANDING THE FUEL SYSTEM 5-2 FUEL TANK TANK ASSEMBLY 5-60 MULTI-PORT FUEL INJECTION COLD START INJECTOR 5-33 ELECTRIC FUEL PUMP 5-21 FUEL INJECTORS 5-31 FUEL PRESSURE REGULATOR GENERAL INFORMATION 5-21 RELIEVING FUEL SYSTEM PRESSURE 5-21 SAFETY PRECAUTIONS 5-21 THROTTLE BODY 5-24 SEQUENTIAL FUEL INJECTION ELECTRIC FUEL PUMP 5-41 FUEL INJECTORS 5-50 FUEL PRESSURE REGULATOR GENERAL INFORMATION 5-41 RELIEVING FUEL SYSTEM PRESSURE 5-41 THROTTLE BODY 5-47 SPECIFICATIONS CHARTS
CARBURETOR SPECIFICATIONS 5-20
5-2
5-35
5-57
SYSTEM BASIC FUEL SYSTEM DIAGNOSIS
5-2
CARBURETED FUEL SYSTEM FUEL TANK
5-2
MULTI-PORT FUEL INJECTION SEQUENTIAL FUEL INJECTION
5-60 5-21 5-41
SPECIFICATIONS CHARTS 5-20
FUEL SYSTEM
5-2
BASIC FUEL SYSTEM DIAGNOSIS When
there
is
a problem starting or driving a vehicle, two of
testing,
please refer to the information on engine electrical
the most important checks involve the ignition and the fuel
components and
systems. The questions most mechanics attempt to answer
If
there spark?” and
“is
first,
“is
there fuel?”
most basic problems. For
solving
will
must determine
often lead to
system diagnosis and
ignition
ignition
systems found
the ignition system checks out (there if
the fuel system
manual.
earlier in this
you
spark), then
is
operating properly
is
(is
there fuel?)..
CARBURETED FUEL SYSTEM quantity.
Understanding the Fuel System
Always drain coolant
into a sealable container.
Coolant may be reused unless
it
is
contaminated or
several years old.
An automotive
system consists
fuel
of everything
between
the fuel tank and the carburetor. This includes the tank
itself,
Disconnect the upper radiator hose and wire
3.
the fuel lines, one fuel
a mechanical fuel pump, and the
filter,
carburetor. 4.
With the exception simple
in
of the carburetor, the fuel
system
quite
is
drawn from the tank through the
is
5.
fuel
pump, which forces
it
through the fuel
filter
where
it
is
Unscrew the two
distributed to the cylinders.
Precautions
from the
fuel lines
pump
retaining bolts.
Remove
the
insulator.
Inspect the insulator for any cracks or
6. if
and plug the three fuel
pump, gaskets and
fuel
to the carburetor,
Label, disconnect
pump.
fuel
operation. Fuel
by the
fuel line
out of the
it
way.
damage. Replace
necessary.
To
install:
Place new gaskets on either side of the insulator. Insert pump arm through the hole of the insulator/gaskets and
7.
Before working on the fuel system, disconnect the
•
the
mount on the engine. Tighten the two mounting screws.
negative battery cable. •
Keep gasoline
•
When
off
rubber or leather parts.
working around
keep away from possible
fuel,
^•Always use new gaskets when
DO NOT SMOKE.
hazards;
Keep your work area clean to avoid contamination of the carburetor and its components. • Work on only one component group at a time to avoid •
any confusion between
Be
•
similar looking parts.
careful not to mix-up or loose
any
clips or springs.
8.
Reconnect the
9.
Attach the upper radiator hose, then
fuel lines. fill
the system with
a coolant/water mixture. 10.
Connect the negative battery cable.
11.
Start the engine
and check
for
any
leaks.
Top
off
the
cooling system.
Pump
Mechanical Fuel
pump.
installing the fuel
fire
TESTING
22R carbureted engines are equipped with a pump of diaphragm construction (some models use two different types of pump). A separate All
fuel filter
is
incorporated into the fuel line (see Section
required service).
The
fuel
pump
is
1
for
pumps should always be tested on the vehicle. The between the pump and tank is the suction side of the system and the smaller line, between the pump and carburetor is the pressure side. A leak in the pressure side would be apparent because of dripping fuel. A leak in the suction Fuel
mechanically operated fuel
larger line
its
located on the right side of
the cylinder head.
side
REMOVAL & INSTALLATION
is
usually only apparent
fuel delivered to the
because
of a
reduced volume
of
pressure side.
•'^CAUTION >
See Figure
1
Gasoline, both liquid and vapor, 1
.
2.
extremely explosive.
Extinguish
Drain the radiator coolant.
materials, heaters, welders, etc. Contain
‘'CAUTION When
is
Disconnect the negative battery cable.
draining coolant, keep
in
mind
that cats
and dogs
all
open flames
in
the area including smoking
all spillage and keep away from sources of high temperature. Have a dry powder (Type B-C) fire extinguisher within arm’s reach and know how to use it.
are attracted by ethylene glycol antifreeze, and are quite
in
any that
an uncovered container or puddles on the ground. This will prove fatal in sufficient
likely to drink
1
.
is left in
Tighten any loose
line
connections and look
for
any
kinks or restrictions. 2.
Disconnect the
Disconnect the
fuel line at the carburetor or fuel
distributor-to-coil
pump.
primary wire. Place a
container at the end of the fuel line and crank the engine a
FUEL SYSTEM TYPE
TYPE
I
5-3
II
Gasket
Gasket Gasket
Non
reusable part 86825g01
Fig.
few revolutions.
pump
fuel
nect the
If
no
or
little
types with their insulators and gaskets
compressed
air
from the
fuel flows
inoperative or the line
is
the lines with
3.
pump
Mechanical fuel
1
and
is
line,
either the
plugged. Blow through the test again. Recon-
try
line.
fuel flows in
If
good volume, check the
fuel
pump
pres-
CARBURETOR
sure to be sure. Attach a pressure gauge to the pressure side of the fuel
4.
On
line.
trucks equipped with a vapor return system,
squeeze
the return hose.
off
5.
Run
the engine at idle and note the reading on the
gauge. Stop the engine and compare the reading with the specifications listed
pump
the fied
and
in
the “Tune-Up Specifications” chart.
operating properly, the pressure
is
be constant
will
sporadically or
at idle
speed.
If
If
be as speci-
pressure varies
pump
too high or low, the
is
will
should be
replaced. 6.
Remove
the pressure gauge.
Carburetor I
See Figure 2 The carburetor
is
the most complex part of the fuel system.
Carburetors vary greatly basically the
ture of fuel
same way;
and
air to
construction, but they
in
all
operate
GASKET KIT
supply the correct mix-
their job
is
to
the engine
in
response
to varying
conditions.
Despite their complexity
cause
of
drawn
into the
operation, carburetors function be-
in
a simple physical principle; the venturi principle. Air
the air enters the top of the carburetor,
which
venturi,
bore.
The
causing a
air
is
nothing
more than a
speeds up as
slight
drop
in
from the
float
where
mixes with the
it
is
engine by the pumping action of the pistons. As
it
it
passes through a
restriction in the throttle
passes through the
venturi,
pressure. This pressure drop pulls fuel
bowl through a nozzle air
into the throttle bore,
and forms a
fine mist,
which
is
distributed to the cylinders through the intake manifold.
Fig. 2
The carburetor
heater unit
sits
atop an insulator, gasket and
FUEL SYSTEM
5-4
There are multiple systems
make
that
it
(air/fuel circuits) in
a carburetor
work; the
• Float
Main Metering
• •
Idle
•
Low-Speed
Pump
• Accelerator
Power • Choke system The way these systems are arranged mines the carburetor’s size and shape. •
Carburetors
have
function
all
principle
the carburetor deter-
fashion; larger engines air
and
fuel,
but the
many manage emissions and
the same. Older units don’t have as
is still
and controls
external linkages
the principle
driveability, but It’s
the same move more
in
larger carburetors to
in
the same.
is still
remember
important to
to
that carburetors
seldom give
trouble during normal operation. Other than changing the fuel
and
and making sure the
air filters
tune-up, there’s not
OK
at
of
Fig.
every
water
3 Set the throttle shaft lever to the
fast idle
first
step of the
cam
the
in
affect the carburetor; dirt particles in the fuel
will
and water causes
jets
vehicle
be parked or stored
to
and presence
of fuel
can clog the is
is
much maintenance you can perform on
average carburetor. Quality the system
speed
idle
and corrosion.
rust
for
If
the
a long period of time,
drain the carburetor to prevent the evaporating fuel from
gum-
ming up the system.
The carburetors used on Toyota bbl,
trucks are conventional 2
downdraft types similar to domestic carburetors. The main
circuits are:
•
Primary
—
for
•
Secondary
—
•
Float
—
normal operational requirements supply high speed/high load fuel needs
to
supply fuel to the primary and secondary
to
circuits
• Accelerator
—
to
supply fuel
for
quick and safe
acceleration
—
Choke for Power valve
• •
reliable starting in cold
—
for fuel
weather
economy
ADJUSTMENTS ON THE TRUCK Fast Idle I
See Figures
5, 6,
7 and 8
OFF THE TRUCK 1
t See Figures 3 and 4
'An
angle gauge tool
is
used
make
to properly
this
2. idle
Remove Set the
the carburetor. throttle shaft lever to
cam. Make certain the choke
the
first
step of the fast
plate (blade)
is
completely
closed. 3.
Attach the blade angle tool to the primary throttle blade.
Adjust the primary throttle blade angle to 23°
(Calif.)
or 24.5°
(Federal and Canada) from horizontal by turning the fast idle
2.
it
to
reach normal operating
Stop the engine and connect a tachometer
Remove
4.
Disconnect and plug the vacuum hoses
Intake (HAI)
to the
the angle tool from the carburetor and
the carburetor as previously outlined.
install
the air cleaner assembly. for the
and Mixture Control (MC) systems
if
Hot Air
so equipped.
Disconnect and plug the vacuum hose from the choke opener diaphragm and Exhaust Gas Recirculation (EGR) valve; plug the ends. 5. 6. fully
Remove
and allow
3.
screw. 4.
Start the engine
engine.
adjustment. 1.
.
temperature.
Make Open
certain that
all
accessories are switched OFF.
the throttle valve slightly, push the choke plate
closed and release the
throttle.
This sets the carburetor
the fast idle position. 7.
Without touching the accelerator pedal,
and read the tachometer.
If
start the
necessary, adjust the fast
engine idle
in
FUEL SYSTEM
Fig. 5 coil
5-5
Attach the tachometer test probe to the ignition
negative terminal
speed
by turning the fast
to
idle
screw. Correct fast
idle
speed:
2600 rpm. 8. Stop the engine. Reconnect the vacuum hoses, disconnect the tachometer and reinstall the air cleaner. 3000 rpm;
Federal,
Float >
California,
and Fuel Level
See Figures
9,
10 and 11
Float level adjustments are within the lines
The
on the
sight glass
is
when
if
the fuel level
the engine
is
falls
running.
located on the side of the carburetor and
usually required for
is
Removing the air cleaner access, although can be done with an
a window to the
literally
unnecessary
sight glass
float bowl.
is
it
extension or dental mirror.
With the carburetor
adjustments which
the engine, there are two float level
off
may be made. One
horn inverted, so that the other
with the air horn
is
bottom
float falls to the
The
float level is
float is in
is
done
fully
with the air
raised position; the
an upright position, so that the
in
of
a
its
travel.
measured
either with a special carburetor
gauge, which comes with a rebuilding
float level
kit,
or with a
standard wire gauge. 1.
Turn the
down by 2.
its
air
own
horn upside
down and
let
the float
hang
weight.
Using a special
gauge SST 09240-00014 or between the tip of the float the air horn. The clearance should be
float
equivalent, check the clearance
and the 0.386
flat
in.
surface of
(9.8mm).
'•This measurement should be
on the 3.
If
air
the float clearance
by bending the upper (A) 4.
Lift
made
up the
horn and the
float
float
is
not within specifications, adjust
If
and check the clearance between the
bottom.
the clearance
bending the lower
is
it
float tab.
A
air
Vernier caliper works well for this
measurement. The clearance should be 5.
without the gasket
horn.
48mm
(1.89 inches)
not within specifications, adjust
float tab (B).
it
by
5-6
FUEL SYSTEM Choke Unloader I
See Figure 12
(You
need the use of SST 09240-00014 or its make any adjustments.
will
equivalent angle gauge to
The unloader adjustment valve
fully
is
made
angle with a special gauge supplied
a gauge
with the primary throttle
open. With the valve open, check the choke valve
of the
in
the rebuilding
or with
kit
proper angle fabricated out of cardboard. The
angle of the choke valve opening should be 45°.
To adjust the angle, bend the measurement is achieved. Throttle Valve
fast idle lever until the
proper
Opening
I See Figure 13
You Fig. 9
The sight glass
carburetor
is
located on the side of the
will
need the use of SST 09240-00014 or its make any adjustments.
equivalent angle gauge to 1
.
Check
the
full
opening
of the primary
and secondary
throttle valves.
Fig.
12 Bend the primary throttle arm 45° from the
horizontal plane
FUEL SYSTEM
5-7
2.
Adjust by bending the respective the primary (1) and secondary
for
should read:
(2).
first throttle arm levers The standard angle
— 90° from the horizontal plane — 90° from the horizontal plane
Primary
Secondary
Secondary Touch Angle I
See Figure 14
**You
need the use
will
1.
Check the primary
SST 09240-00014 or its make any adjustments.
of
equivalent angle gauge to
throttle
valve opening at the
same
time the second throttle valve just starts to open. 2.
Standard angle
3.
It
is
is
59° from the horizontal plane.
not necessary to adjust the secondary touch angle.
Choke Opener I
See Figures 15 and 16 1.
Apply vacuum
2.
Check
step. Adjust
to the
choke opener diaphragm.
that the fast idle
cam
is
releasing to the fourth
by bending the choke opener lever A.
it
3.
Disconnect the vacuum hose.
4.
Close the choke valve, then set the fast
idle lever to
the
step.
first
5.
lever
Check
that there
and the
fast idle
is
clearance between the choke opener
cam.
Choke Breaker 1.
With the engine
vacuum 2.
to the
OFF and
the air cleaner removed, apply
choke breaker diaphragm.
Close the choke by hand, and remove your hand. With of the choke plate is 42°
an angle gauge, check that the angle from horizontal. 3.
If
the angle
is
breaker
link.
Idle-Up
Diaphragm
1.
incorrect, adjust
it
by bending the choke
Apply vacuum to the idle-up diaphragm.
2.
Check the
throttle
valve opening angle. Adjust by turning
the adjusting screw. With an angle gauge, check that the stan-
dard angle Air Valve
>
16.5° from the horizontal plane.
is
and Metering Needle
See Figure 17 1
.
Check
that the air valve
and metering needle move
smoothly together. 2.
While the primary
check the 3.
gle,
air
throttle
valve angle
is
in
idle position,
valve opening angle.
While the primary
check that there
is
throttle
valve
is
at
a
full
opening an-
clearance between the connecting rod
and the stopper. Idle
Mixture Screw
I See Figures 18, 19, 20, 21, 22, 23, 24, 25 and 26
As
stated
in
section 2, the mixture adjusting screw
should be the very troubleshooting.
last
The
item you
MAS
is
try to
(MAS)
adjust during tune-up or
concealed behind a plug; the plug
FUEL SYSTEM
5-8
cannot be removed with the carburetor on the
ment
is
to
truck.
If
adjust-
be done, great care must be taken during removal clearances are very
of the plug;
tight
and damage
to the
5.
carburetor can occur.
Tag and disconnect
1.
all
hoses and linkages attached
to
the carburetor. 2.
Remove
3.
Plug each carburetor
the carburetor.
vacuum
port to prevent entry of
metal particles.
Mark the center
4.
0.256
in.
of the
(6.5mm) hole
in
MAS
plug with a punch.
Drill
a
the center of the plug.
WARNING The head plug
—
of the
drill
screw is only 0.04 in. (1mm) below the and slowly to avoid damage.
carefully
The plug may come out use a small screwdriver turn the adjusting
screw
the screw; just tighten
it
to all
with the
drill
at this time.
If
not,
reach through the hole and gently the
until
it
way
in.
Do NOT
touches bottom.
overtighten
FUEL SYSTEM
5-9
86825g28 86825g31
Fig.
22 To remove the
(7.5mm)
drill bit
MAS
plug, use a 0.295
in.
25 Location of the
Fig.
26 The
idle
mixture adjusting screw
Speed Adjusting Screw
Idle
Fig.
idle
speed adjusting screw protrudes from
the carburetor
6.
Use a 0.295
7.
Remove
(7.5mm)
in.
drill
to force the plug
the adjusting screw. Inspect the
damage; remove any
steel particles.
the top of the screw,
it
the
drill
any
has damaged
must be replaced.
Reinstall the adjusting screw.
8.
If
off.
tip for
Turn
all
it
the
way
in,
just
touching bottom.
Once
9.
the screw has bottomed, turn
10.
Reinstall the carburetor
11.
Before adjusting
ing conditions a.
air
it
out 372 turns.
cleaner.
speed and mixture, ALL the
idle
Air cleaner properly installed.
Engine running
c.
Choke
d.
All
accessories OFF.
e.
All
vacuum
fully
at
normal operating temperature.
opened.
lines
connected.
Ignition timing correctly set.
g.
Transmission
h.
Fuel level should be approximately centered
in
neutral.
glass. i.
follow-
must be met:
b.
f.
and
For
Calif, vehicles,
EBCV
off.
in float
FUEL SYSTEM
5-10 12.
Connect a tachometer.
13.
Start the engine.
MAS
To
rpm is achieved. 15. Turn the idle speed adjusting screw until 740 rpm is achieved. The idle speed adjusting screw is located above and 14.
to the 16.
Turn the
the highest possible
until
When
Repeat Steps 13 and 14 several times.
does not
rise
no matter how much the
MAS
is
MAS
screw IN
Turn the
18.
Turn the engine OFF.
19.
Gently tap a
Check and
new
Remove
the
Install
cleaner assembly, making sure
air
it
cor-
is
the coolant. Connect the negative battery cable.
10.
Refill
11.
Start the engine
and check
for
any
leaks.
Check the
float level.
the air cleaner.
plug into place over the
adjust the fast idle
700 rpm.
connect the wiring
seated on the carburetor.
rectly
turned, proceed
to set the idle to
fuel lines;
harness.
to the next Step.
17.
linkages.
all
Connect the vacuum and
8.
9.
the idle
the carburetor, tighten the mounting bolts and
Install
reconnect
(10 o’clock) of the mixture' adjusting screw.
left
install:
7.
MAS
speed as described
OVERHAUL
plug.
in this
section.
I
^The method
used to set the idle mixture and speed also known as the Lean Drop Method.
See Figures 27 and 28
is
Efficient carburetion
depends on
tion during overhaul, since
Automatic Choke Inspection
dirt,
and opens completely au-
sets
no input from the accelerator pedal. The driver no longer sets the choke; it is set by the expansion or contraction of the bimetal coil. Refer to section 4, Emission Controls,
Overhaul your carburetor
in
disassemble the carburetor,
Keep
views.
similar
all
and
disassembly and cleaning
complete inspection procedures.
Carburetor overhaul
REMOVAL & INSTALLATION
These
haul.
kits
Loosen the
radiator drain plug
are
all
kit
recommended new
for
gaskets and
each over-
parts to replace
rapidly. Failure to replace
(especially gaskets)
can
result in
all
parts
poor
performance and a leaks.
and drain the coolant
into
The
following procedure is organized so that only one group of components is worked on at a time. This will help eliminate confusion of parts or sub-assemblies on the
a suitable container.
I-CAUTION When
exploded
to avoid accidental interchange dur-
kits
contain
supplied with the
Disconnect the negative battery cable.
a clean, dust-free area. Carefully
referring often to the
look-alike parts segregated during
those that deteriorate most .
or on
assembly.
ing
1
in
performance.
tomatically, with
2.
and inspec-
the carburetor parts are often responsible for poor
The automatic choke system
for
careful cleaning
gum, water, or varnish
bench. Always keep parts
dogs
draining coolant, keep in mind that cats and
in
order; take great care not to
lose small parts or clips.
are attracted by ethylene glycol antifreeze, and are quite likely to in
drink any that
an uncovered container or prove fatal in sufficient
is left in
puddles on the ground. This
Always drain coolant Coolant may be reused unless quantity.
Disassembly
will
into a sealable container. it
is
contaminated or sev-
HORN
AIR
> See Figures 29, 30, 31, 32 and 33
eral years old. 1
.
2. 3.
Unscrew the mounting screws and remove the
housing. Disconnect
all
hoses and
lines leading
air filter
from the
all
fuel,
terminals.
vacuum, coolant and
electri4.
cal lines or
the terminal from the connector, pry up on
air 3.
Tag and disconnect
the carburetor.
the locking lugs with a flat-bladed tool, then pull out the
cleaner. 4.
Remove
To release
Loosen the screw and remove the metering needle. Disconnect the fast idle linkage and air valve connecting
hoses leading from the carburetor. rod.
5.
On
Disconnect the accelerator linkage from the carburetor. 5.
trucks equipped with an automatic transmission, disconnect
Remove the Remove Remove the
the body.
the throttle cable linkage running from the transmission. 6. 6.
Remove
the four carburetor mounting bolts and
lift
5
air
horn screws and
the gasket and discard pivot pin
and the
lift
the air horn from
it.
float with
the needle
off
valve.
the carburetor and
its
gasket. 7.
(Cover
the manifold opening with a clean rag to prevent
objects from falling into the engine.
Loosen the
retainer
8.
Remove
for the power piston. Hold the remove the piston and spring.
screw
piston, rotate the retainer, then
the 3 screws holding the outer vent control
valve and remove the valve.
FUEL SYSTEM
5-11
I
86825g70
Fig.
27 Exploded view of the carburetor
— USA (including
California)
5-12
FUEL SYSTEM
i
86825g71
Fig.
28 Exploded view of the carburetor
— Canada
FUEL SYSTEM
5-13
86825g34
Fig.
30 Loosen the screw, then remove the metering
needle
Fig. 32 Loosen the retainer screw for the power piston. Hold the piston and rotate the retainer, then remove the
piston and spring
FUEL SYSTEM
5-14
CARBURETOR BODY t
See Figures 1
.
34, 35, 36, 37, 38,
Using a set
39 and 40
wrenches or special
of carburetor
tool
09922-00010, remove the following: •
slow
•
power valve
•
metering needle guide
•
secondary main
•
Plug (5)
•
primary main
Use the
the
jet (1)
(2) (3)
jet (4)
jet (6)
help you.
illustration to
2.
Remove
3.
At the accelerator
A
the fuel cut solenoid from the carburetor body.
pump, remove the 4 screws. Remove
pump housing, diaphragm and spring. 4. Remove the auxiliary acceleration pump. 5.
Disconnect the linkage and remove the idle-up
diaphragm. 6.
Disconnect the choke opener
link;
remove the choke
opener.
Fig.
34 Note the positions of the various items:
power valve, secondary main jet,
jet, (2)
Fig.
(3)
metering needle guide,
(5) plug,
35 The fuel cut solenoid
the carburetor
and
is
(6)
(1)
slow
(4)
primary main
jet
located on the side of
FUEL SYSTEM
Remove
7.
5-15
and separate the body from
the three screws
the flange (lowest portion).
Cleaning and Testing >
See Figures 1.
Clean
all
41, 42, 43, 44, 45,
46 and 47
the cast metal parts with a soft brush
and
carburetor solvent. Clean any carbon from around the throttle
Blow out
plates. 2.
jets
all
and passages with compressed
air.
Inspect the following: •
and excessive wear
pivot pin for scratches
• float for a broken
or
lip
any breaks
• spring for
wear
plunger
•
strainer for breaks or rust (6)
3.
Inspect the
4.
Check
for
power
any
piston.
faulty
(1)
the pivot pin holes (2)
or deformation (3)
and needle valve
•
(5)
in
(4) for
Make sure
it
wear
or
damages
moves smoothly.
opening and closing action
of the
power valve. 5.
Test the fuel cut solenoid. Connect the wire leads to the
battery terminals;
solenoid as
Fig.
40
you should
power
Remove
is
feel
a
distinct click inside the
connected and disconnected
at the bat-
the three screws, then separate the
body from the flange (lowest portion)
42 Using your finger, gently push the power piston check for binding
Fig.
to
FUEL SYSTEM
5-16 tery.
If
this click is not felt,
replace the solenoid. Replace the
O-ring. 6.
Inspect the outer vent control valve for
or valve seat.
Check the valve
for
damaged
smoothness
valve
of motion.
Con-
nect the wire leads to the battery terminals; you should feel a distinct click inside the valve
connected
at the battery.
If
as power
is
connected and
dis-
this click is not felt, replace the
solenoid. 7.
uum
Inspect the choke breaker diaphragm by applying vacto the
diaphragm. The vacuum should not drop immedi-
and the choke should open slightly as vacuum is applied. 8. Use an ohmmeter to check choke heater resistance. Resistance should be 20-22 ohms at 68°F (20°C). Resistance will ately
vary with temperature; use good judgment
when
interpreting
test results. 9.
Inspect the choke opener and idle-up diaphragms. Apply
vacuum ately
to the
diaphragm; vacuum should not drop immedi-
and the linkages should move when vacuum
is
applied.
Fig.
46 Attach a vacuum gauge to the choke breaker
diaphragm
Assembly
BODY >
See Figures 1.
Place a
body and 2.
48, 49, 50, 51, 52, 53
new gasket
in
position
and 54 on the flange;
install
the
tighten the 3 screws.
Install
the auxiliary accelerator pump.
First,
install
the
diaphragm with outer gasket, then the spring, cover and screws. 3.
Install
the acceleration
pump
beginning with the spring,
then the diaphragm, cover, boot and screws. 4.
Install
the choke opener and connect the linkage.
5.
Install
the idle up diaphragm and connect the linkage.
6.
Install
the fuel cut solenoid. Always use a
and new
O-ring.
new gasket
FUEL SYSTEM
Fig.
48 After placing a
tighten the three
new gasket on
screws
the flange,
5-17
FUEL SYSTEM
5-18
86825g58
Fig.
54 Location of the primary main
secondary main jet valve (5), and slow under the wire it
of the
(3),
plug
jet (1),
metering needle guide
(4),
(2),
power
jet (6)
needle valve.
Install
the float and secure
with the pivot pin.
Adjust the float level, using the procedure listed sepa-
4.
rately in this section.
new gasket on
Put a
5.
When
the body and
make
screws,
installing the
install
components held by the screws such as the number plate and wire clamps. 6.
Connect the
7.
Install
end
into the hole. Insert the
8.
9.
Push
in
53 The solenoid valve screws into the carburetor;
the terminal
Install
Pull
washer and
until
on the wire
it
is
Hook
the spring
tighten the screw.
securely locked
to confirm that
it
is
in
the
secure.
Install
1 1
Attach
the carburetor. all
tagged hoses to the
Start the engine, then
make
unit.
final
adjustments as
necessary.
be sure to use a new O-ring 7.
valve connecting rods.
listed in this section.
10.
12.
air
bracket,
Adjust the carburetor on the bench, using the various
procedures
.
and
inlet
the metering needle with a collar.
connector plug.
Fig.
fast idle link
the air horn.
certain to install the external
the following:
• primary
main
jet (1)
over a
new gasket
new gasket
•
plug (2) over a
•
secondary main
•
metering needle guide
•
power valve
jet (3)
(4)
(5)
8. Place a new O-ring on the slow jet, then using SST 09922-00010 or equivalent, install the slow jet (6).
HORN
AIR
I See Figures 55, 56, 57, 58, 59, 60, 61 and 62 1
a
.
new 2.
On
the
air
horn, install the outer vent control valve with
gasket.
Place the power piston spring and piston
into the bore.
While pushing the piston, rotate the retainer over the piston
and
tighten the retaining screw.
3.
Install
In
the fuel
inlet,
install
a
new gasket and
the needle valve onto the seat. Insert the
the valve seat. lip
of the float
Fig.
55 Tighten the three mounting screws on the outer
vent control valve
FUEL SYSTEM
Fig.
59 Bend portion (B) of the
float to 1.89 in.
5-19
(48mm)
FUEL SYSTEM
5-20
CARBURETOR SPECIFICATIONS Component
Metric
U.S.
Float level
Raised position
Lowered Float
lip
position
clearance
0.386
in.
9.8mm
1.89
in.
48mm
0.04
in.
1mm
Throttle valve closed angle
Primary
Secondary Throttle valve
full
idle
20 degrees from horizontal plane
Primary
90 degrees from horizontal plane
90 degrees from horizontal plane
Secondary
90 degrees from horizontal plane
90 degrees from horizontal plane
59 degrees from horizontal plane
59 degrees from horizontal plane
24.5 degrees from horizontal plane
24.5 degrees from horizontal plane
open angle
angle Federal and
Canada
California
Fast
idle
9 degrees from horizontal plane
horizontal plane
Secondary touch angle Fast
9 degrees from horizontal plane
20 degrees from
23 degrees from
horizontal plane
23 degrees from
horizontal plane
speed Federal and
Canada
California
3000 rpm
3000 rpm
2600 rpm
2600 rpm
Unloader angle
45 degrees from
horizontal plane
45 degrees from
Choke breaker opening angle
42 degrees from
horizontal plane
42 degrees from horizontal plane
Choke heater resistance
at
68 deg F (20 deg C)
Idle-up angle
Dashpot touch angle Dashpot
setting
speed
Idle
speed
Idle
mixture adjusting screw presetting
Idle
mixture speed
horizontal plane
20-22 ohms
20-22 ohms
16.5 degrees from horizontal plane
16.5 degrees from horizontal plane
24.5 degrees from horizontal plane
24.5 degrees from horizontal plane
3000 rpm
3000 rpm
700 rpm
700 rpm
screw-out 3 1/2 turns
screw-out 3 1/2 turns
740 rpm
740 rpm 86825c55
FUEL SYSTEM
5-21
MULTI-PORT FUEL INJECTION make a few
however,
General Information Most
you adhere
Toyota trucks that are covered by
of the
manual
this
FUEL DELIVERY
are equipped with Multi-Port Electronic Fuel Injection system.
The
Electronic Fuel Injection
cause
System
is
for total
since air flows through
means
that
has
it
The MFI system supplies the optimum
power than an equivalent carburetor
more
it
good be-
particularly
requires no venturi restriction. That
it
a greater capacity
simple checks and adjustments, provided
to the safety precautions in this section.
engine under
Also, carburetors are limited airflow
in their ability to
accurately
because they do not compensate
for
changes
and quickly respond
comes those
to throttle
amount
of fuel injected
opens only
changes. This system over-
amount
kPa) pressure
by injecting the right at
40
fuel with nearly
psi
of air required for
amount
the intake ports, the engine
is
an
fed a
All
heart of the system
a fuel supply loop which consists
is
pump and damper which
of
which permits precise
fuel.
system,
such as improved adaptability and easier addition
compen-
cylinder).
throttle
The loop returns to the measures the pressure
opening) that exists
the
in
the tank, maintains pressure
in
Fuel
filter.
Each
fuel injector consists of
solenoid valve.
fuel tank via
•
Reduced emission
•
Reduction
a pressure
vacuum (depending intake manifold. The
in
airflow to the engine, the injectors
it
amount
if
of
cleaner,
and then enters the
air
change
in
a change
appropriate changes
in fuel/air
is
engine
idle is
in airflow,
it
is
running.
the system.
in
•
Keep
•
If
To
all
connectors dry.
handling electronic parts, do not drop them or permit
be banged against another part while removing or
to
them.
is
relieve the fuel pressure,
at
mix-
wrap a clean towel or rag
start injector fitting or the
(banjo bolt) at the fuel delivery
rail.
union bolt
Slowly loosen the bolt
holding the fuel line and allow pressurized fuel to escape into the rag.
wrap
it
Do NOT in
allow fuel to spray from the
fitting;
always
a rag.
routed
valve to the engine.
a change
is
the ignition switch before disengaging any con-
around either the cold
the driver releases the throttle pedal, the throttle air for
OFF
• Turn
Relieving Fuel System Pressure
microprocessor which controls the system when the truck
there
air
part
demands, much the same as in an ordinary carburesystem. There are switches which tell the electronic
Whenever
cold
and intake
de-
driver’s
and
in
not connect the battery, or jumper cables, with reverse
installing
contains the throttle which controls airflow according to the
air
for coolant
• Never disconnect the battery while the engine
them
measures the flow of air through a opens or closes with airflow
A temperature measuring
Do
•
nector
would stay open twice as
compensates for the increased density of cold air. From here, the air passes into the throttle body. This
off entirely,
made
polarity.
vice
body closes
is
inputs fuel.
precisely designed flap, which
through the auxiliary
Superior starting and warm-up performance
Safety Precautions
electronics to determine
long as before the driver accelerated. Air entering into the
When
•
the intake manifold.
supply the amount of fuel the engine requires. For example,
throttle or at idle, for
Superior acceleration and deceleration
a nozzle and a tiny electric
the driver should open the throttle and double the
against the tension of a spring.
Increased engine output
•
weather since compensation
electric pulse sent to the injector and, therefore,
flow meter. This device
•
of fuel to
the time each injector stays open, the system can precisely
air
exhaust gases
temperature
The system employs
system flows through the
of
consumption
in fuel
or
long the solenoid should be open each time
By varying the
also incorporates the following
is
the fuel line at 38-44 psi
(265-304 kPa) above the pressure
The MFI system
of
features:
pressure regulator, by precisely controlling the return
ture.
determined by the duration
the operating conditions of the engine are converted into
sating element.
supply fuel under a rela-
smooth and constant pressure through a
regulator which
full
is
electric signals, resulting in additional features of the
supplied to a loop which passes by each fuel injector (one for
tion
cycle of operation. During system
engine operation.
a fuel
how
1
injected
electric pulse sent to the fuel injector,
metering of the
The
upon
injection valve (fuel injector)
consistently atomized mixture with the injection system.
ing cold
each
controlled by the intermittent injection
(275
This improves performance and fuel economy, especially dur-
tively
is
head. The
limitations.
Additionally,
of
of the cylinder
a short period of time, depending on the
for
operation, the
more
is
passage
system where the electromagnetic
barometric pressure or temperature, and cannot accurately
in
mixture to the
freely.
injected into the intake air
measure
air/fuel
various operating conditions. System fuel,
all
reflected as
a
^Pressure may also be
relieved at the fuel
sired. Tighten the
bolt.
union
filter
if
de-
the air flow meter’s signal to the microprocessor and in
the width (or time) of the pulse the microproces-
Electric Fuel
Pump
sor sends to the injectors.
The system is extremely complex and requires specialized and equipment to fully service and repair. You can,
training
All
fuel
Toyota fuel-injected vehicles are equipped with an
pump. The pump
injection
system
to
is
electric
located inside the fuel tank. For a fuel
work properly, the pump must develop
FUEL SYSTEM
5-22
pressures well above those of a mechanical fuel pump. This high pressure
engine
is
is
maintained within the lines even
not running. Extreme caution
when
must be used
release the pressurized fuel before any work
is
check
Start the engine, then
15.
any loose connections
for
or leaks.
the
to safely
begun.
TESTING
^CAUTION I
Always relieve the fuel pressure within the system before any work is begun on any fuel component. Failure to
may
safely relive the pressure
See Figure 69
1989-95 Models
result in fire and/or serious
Turn the
1.
injury.
Data Link Connector (DLC1). This should cause the
REMOVAL & INSTALLATION
to run;
check
that there
Turn the
3.
Disconnect the negative battery cable. Safely relieve the fuel pressure within the system. Drain -
the fuel from the tank, then 3.
pump 4. 5.
Remove
the
pump
remove the
fuel tank.
2RZ-FE
the two nuts and then disconnect the wires at
lower side of the bracket. hose.
of the fuel
pump
scan
pump bracket. Using a new gasket, position
^•Do not
install
and
lbs. (3-4
the fuel tank.
Install
14.
Add gas
pump
operation;
equivalent
its
start the engine.
Turn the
c.
tester or
Data Link Connector (DLC3).
ON
ignition switch
and push the
tester
main
d.
On
e.
Refer to the tester instructions If
the Toyota tester select the active test mode. for further details.
you do not have a Toyota hand-held
tester,
connect
the positive and negative leads from the battery to the fuel
the bracket on the fuel
tighten the
Nm).
fuel
switch on.
seven mounting
pump
bolts to
connector.
Check
g.
13.
was no
EFI main relay,
the fuse cover on the instrument panel.
tool to the
(and the rubber
cushion) into the
30-35 inch
links,
Connect the Toyota hand-held
b.
the rubber cushion to the lower side of the fuel
Push the lower side
Remove
a.
f.
12.
the jumper
there
AND 3RZ-FE ENGINE
To check the
1.
pump out of the pump from the fuel
Pull the fuel
tank and then
check the fuses,
line,
if
and wiring connections.
1996 Models
pump. .
OFF and remove
did not function or
the gasket from the bracket.
Remove the rubber cushion and the clip. Disconnect the fuel pump filter from the pump. To install: 8. Install the fuel pump filter to the pump. 9. Insert the outlet port of the fuel pump into the fuel hose.
1 1
pump
the
in
bracket up and out of the fuel tank.
Install
ignition switch
the fuel
pressure
ECM
7.
10.
If
Remove Remove
Disconnect the
also hear fuel return
retaining bolts, then pull the fuel
the fuel pump. 6.
pump
fuel
the fuel return line from
in
noises.
wire. 2.
pressure
is
You should
the pressure regulator.
> See Figures 63, 64, 65, 66, 67 and 68
.
position, but don’t
With a jumper wire, connect terminals B+ and FP of the
2.
1
ON
ignition switch to the
start the engine.
the fuel
that there
filter.
If
there
pressure
is is
in
the fuel
pressure, you
will
inlet
hose from
hear the sound
of
fuel flowing.
to the fuel tank. h.
If
there
no pressure, check the following:
is
•
M-fuse (AM2 30A)
•
Fuses (EFI 15A, IGN 7.5A)
•
EFI main relay
•
Fuel
•
ECM
pump
• Wiring connections
LOCK.
i.
Turn the
j.
Disconnect the Toyota hand-held tester from the DLC3.
Check the
2.
ignition switch to
fuel pressure.
a.
Disconnect the negative cable from the battery.
b.
Wrap a shop
towel around the delivery pipe, then
slowly loosen the union bolt holding the fuel pipe to the delivery pipe c.
Install
and gasket.
the
SST 09268-45012
(pressure gauge) or
its
equivalent to the delivery pipe with the two gaskets and the
SST
(union and union
bolt).
Tighten to 22
ft.
lbs.
(29 Nm).
d.
Be sure
e.
Attach the Toyota hand-held tester or equivalent scan
tool to the
^DO NOT
to
wipe
off
any
DLC3. start the engine!
spilled fuel.
FUEL SYSTEM
Fuel
Pump
5-23
Bracket
Fuel
Pump
Filter
Non-reusable part 86825g73
Fig.
64 The electric fuel
pump has
a
filter;
check
it
for
any clogging or tears
FUEL SYSTEM
5-24
p.
Start the engine.
q.
Measure the
pressure at
fuel
(206-255 kPa).
psi
idle.
the pressure
If
is
It
should read 31-37
not as specified, check
the sensing hose and pressure regulator.
Stop the engine.
r.
Check
s.
kPa)
pressure
that the fuel pressure
remains
at 21
psi
minutes after the engine has stopped.
for 5 is
not as specified, check the
If
pump, pressure regu-
and/or injectors.
lator
After checking the fuel pressure, disconnect the nega-
t.
cable from the battery, then carefully remove the
tive
(147
the
09268-45012 or equivalent, Reconnect the
u.
new gaskets and
to prevent
SST
gas from splashing.
fuel inlet pipe to the delivery pipe with
the union
Tighten to 22
bolt.
lbs.
ft.
(29
Nm).
Reconnect the negative cable
v.
Check
w.
to the battery.
for fuel leaks.
Body
Throttle
REMOVAL & INSTALLATION >
See Figure 70 1
.
Disconnect the negative battery cable.
2.
Drain the engine coolant.
3.
Tag and disconnect
from the
throttle
body.
all
hoses or wires
lines,
On models equipped
with
that lead
an automatic
transmission, disconnect the throttle control cable. 4.
Remove
the air intake connector and the air cleaner
hose with resonator. 5.
Unscrew the mounting
bolts
and remove the
throttle
body and gasket. The cast metal parts may be cleaned brush and carburetor solvent.
soft
compressed
To 6.
air to
f.
Turn the
ignition switch
ON
and push the
tester
main
blow out the passages and tubing.
Install
the throttle body using a
On
h.
Refer to the tester instructions for further details.
i.
If
the Toyota tester select the active test
you do not have a Toyota hand-held
mode.
tester,
j.
k. l.
air
new
gasket, then tighten
(12-18 Nm).
cleaner hose with resonator and the
air
8.
Reconnect
9.
Fill
all
hoses and wires.
lines,
the engine with coolant and connect the battery
cable.
connect
the positive and negative leads from the battery to the fuel
pump
Connect the
lbs.
ft.
intake connector.
switch on. g.
with a
possible, use low pressure
install:
the mounting bolts 9-13 7.
If
TESTING & ADJUSTMENT
connector.
Reconnect the negative battery cable. Turn the
ignition switch
Measure the
22R-E Engine
ON.
fuel pressure,
it
should read 38-44 psi
I
See Figures
71, 72, 73, 74, 75
and 76
(265-304 kPa). m.
If
the pressure
is
too high, replace the pressure
o.
If
.
With the
spection.
regulator. n.
1
the pressure
is
too low, check the following:
Wash and
body
off
the vehicle, clean prior to
clean the cast parts with a soft brush
carburetor cleaner. Using compressed
passages and apertures
•
Fuel connections and hoses
•
Fuel
pump
'To
•
Fuel
filter
tion sensor.
•
Pressure regulator
•
Injectors
Disconnect the tester from the DLC3.
throttle
2.
in
air,
clean
all
'
inin
of the
the throttle body.
prevent any damage, do not clean the throttle posi-
Check
that there
is
no clearance between the
stop screw and the throttle lever closed.
when
throttle
the throttle valve
is fully
FUEL SYSTEM
5-25
SST (SPECIAL SERVICE TOOLS)
RECOMMENDED TOOLS 09082 -00050
TOYOTA
09200 - 00010
Engine Adjuat Kit
09258-00030
Hose Plug Set.
Electrical
Tester Set.
Plug for the fuel
hose
vacuum
hose,
etc.
86825gb3
Fig.
69 Toyota special service tools for most fuel injected engines
5-26
FUEL SYSTEM
Engine Wire
PCV Hose
Air
Hose
Non-reusable part 86825g72
Fig.
70 Exploded view of the throttle body and related components
— 3RZ-FE shown
FUEL SYSTEM 3.
Check the
4.
If
5-27
position sensor.
necessary, adjust the throttle position sensor by loos-
ening the 2 screws of the sensor. Insert a 0.0276
in.
(0.70mm)
gauge between the throttle stop screw and the lever. Connect the ohmmeter to the terminals IDL and E2 of the sensor. 5. Slowly turn the sensor clockwise until the ohmmeter dethen secure the sensor with the screws. Using the thick-
flects,
ness gauge, recheck the continuity between the two terminals.
3VZ-E Engine
ON VEHICLE > See Figures 77, 78, 79, 80, 81, 82, 83 and 84 1
Check the the throttle linkage moves smoothly. Check the vacuum at each port:
.
2. a.
Start the engine.
b.
Pull
each
line off
one
at
a time and check the
vacuum
with your finger.
Clearance between Continuity (IDLE lever
0.57 0.85
—
E,)
and stop screw
mm mm
(0.0224
in.)
(0.0335
in.)
Continuity
No
continuity 86825g85
Fig.
73 Loosen the throttle positioner screws
76 Insert the appropriate gauge to check for proper
Fig.
adjustment Inspect the throttle position sensor by applying
3.
to the throttle opener.
a 0.0244
sert
tween the of
(0.62mm) gauge or
in.
vacuum
Unplug the sensor connection, then
SST 09240-00020,
in-
be-
stop screw and the stop lever. With the aid
throttle
an ohmmeter, measure the resistance between each
terminal. 4.
Reconnect the sensor.
5.
Inspect the dashpot,
warm-up the engine
to
normal oper-
ating temperature. 6.
Check the
7.
Remove
Check and
8. a. b.
your Fig.
c.
74 Insert a 0.70mm gauge between the throttle stop
screw and the lever. Connect the ohmmeter to terminals IDL and E2 of the sensor
is
speed and filter
adjust,
if
necessary.
and separator from the dashpot.
adjust the dashpot setting speed:
Maintain engine speed of 2500 rpm or more.
Plug the
Vacuum
Transmitting Valve (VTV) hole with
finger.
Release the
set to d.
idle
the cap,
If
it
throttle valve,
then check that the dashpot
1800-2200 rpm. is
ing screw.
not as specified, adjust with the dashpot adjust-
5-28
FUEL SYSTEM
86825g86
Fig. Fig.
77 Check the smoothness of the throttle linkage
80 Measure the resistance between each of the
terminals on the throttle position sensor
Clearance between
Resistance
Between terminals lever
and stop ecrew
mm (0 mm 0.80 mm 0
0.50
in.)
(0.020
in.)
(0.031
in.)
Throttle valve fully
VTA IDL IDL
E2
0.47
-
E2
2.3
kO
- E2
6.1
kO
or less
Infinity
VTA - E2
3.1
-
12.1
kO
open
-
VC - E2
3.9
-
9.0
kO 86825g90
Fig.
78 With the engine running,
vacuum
lines off
one
pull
at a time, then
each of these check for vacuum
Fig. 81
Insert the appropriate
gauge
to
check
for proper
adjustment
with your finger
X Vacuum
86825g88
79 As you apply vacuum to the throttle opener, gauge or SST 09240-00020 between the throttle stop and the stop lever
86825g91
Fig.
insert a
Fig.
82 Exploded view of the dashpot assembly
FUEL SYSTEM 15.
Reconnect the vacuum hose
16.
Inspect the air valve operation by
idle
to the
5-29
opener.
screwing
fully
the
in
speed adjusting screw. At low temperature, while the screw
a.
speed should drop. b. After warm-up, while the screw should drop below
speed
idle
is
is
in,
in,
the engine
the engine
speed
stop.
OFF VEHICLE 1.
With the
spection.
throttle
Wash and
body
off
the vehicle, clean prior to
clean the cast parts with a soft brush
carburetor cleaner. Using compressed
passages and apertures
in
air,
clean
all
inin
of the
the throttle body.
»^To prevent any damage, do not clean the
throttle posi-
tion sensor. 2.
Apply vacuum
3.
Check
to the throttle
that there
is
opener.
no clearance between the
stop screw and the throttle lever
when
throttle
the throttle valve
is fully
closed. 4.
Check
5.
Apply vacuum
the position sensor. to the throttle
opener.
gauge between the throttle stop screw and the lever. Connect the ohmmeter to measure the resistance between each terminal. 7. Reconnect the sensor harness.
9.
6.
Insert a
8.
If
necessary, adjust the
throttle position
sensor by loos-
ening the 2 screws of the sensor. 9.
10.
Apply vacuum Insert
to the throttle
a gauge 0.024
opener.
(0.60mm) between the
in.
throttle
ohmmeter to measure the resistance between terminals IDL and E2 of the sensor. 1 1 Slowly turn the sensor clockwise until the ohmmeter destop screw and the lever. Connect the
.
flects,
then secure the sensor with the screws. Using the
gauge, recheck the continuity between the two terminals.
2RZ-FE and 3RZ-FE Engine I
See Figures 1
.
With the
spection.
Check the operation
Vacuum
of the
(VTV) by setting the dashpot speed
in
Transmitting Valve
the
same procedure as
Maintain engine speed of 2500 rpm or more.
b.
Plug the
Vacuum
Release the
c.
set to
then check that the dashpot
throttle valve,
the vehicle, clean prior to
in
air,
clean
all
inin
of the
the throttle body.
your finger from the hole and check that the
engine returns to
idle
speed
in
approximately
the dashpot separator,
1
second.
1 1
Inspect the throttle opener by allowing the engine to
filter
warm
up. Check the idle speed. Check the throttle opener seating speed by disconnecting the vacuum hose from the opener, then plug the hose 12.
end. Maintain the idle speed at 2500 rpm.
Release the
900-1800 rpm.
throttle
throttle valve, If
the speed
body assembly.
then check that the opener is
throttle
2.
Apply vacuum to the
3.
Check
that there
is
throttle
opener.
no clearance between the
when
throttle
the throttle valve
is fully
closed.
and cap.
Install
do not clean the
deterioration,
stop screw and the throttle lever
10.
14.
off
position sensor.
1800-2200 rpm.
Remove
d.
set,
passages and apertures
f^To prevent any
Transmitting Valve (VTV) hole with
your finger.
13.
body
clean the cast parts with a soft brush
10.
a.
.
throttle
Wash and
87 and 88
carburetor cleaner. Using compressed
above:
is
85, 86,
4.
Check
5.
Apply vacuum
the position sensor. to the throttle opener.
gauge between the throttle stop screw and the lever. Connect the ohmmeter to measure the resistance between each terminal. 7. Reconnect the sensor harness. 6.
Insert a
8.
If
necessary, adjust the
throttle position
sensor by loos-
ening the 2 screws of the sensor. is
not as specified, replace the
9.
Apply vacuum
to the throttle opener.
gauge 0.026 in. (0.65mm) between the throttle stop screw and the lever. Connect the test probe of the ohmInsert a
FUEL SYSTEM
5-30
meter
E2
1 1
Throttle
measure the resistance between terminals IDL and
Slowly turn the sensor clockwise
.
flects,
Lever
to
of the sensor.
the
until
ohmmeter
de-
then secure the sensor with the screws. Using the
gauge, recheck the continuity between the terminals.
3F-E Engine
ON VEHICLE > See Figures 89, 90, 91 and 92 1
Check
.
that the throttle linkage
from the vacuum 86825gal
3.
and
4.
Fig.
85
When
applying
ensure that there
is
vacuum
to the throttle opener,
no clearance between the
throttle
With your
that there
at
a time
no vacuum
at idle
port.
finger,
check
vacuum
is
Unplug the
that there
is
than
at anything other
electrical
connector from the
idle.
throttle position
sensor. 5.
Insert
a
and the stop
stop and throttle lever
moves smoothly.
engine and remove the hose(s) one
Start the
2.
flat
feeler
gauge between the
Clearance between lever
0.57 0.74
stop screw
throttle
lever.
and stop screw
mm mm
(0.022
in.)
(0.029
in.)
Continuity (IDL
—
E2)
Continuity
No
continuity 86825gj9
Fig. 88 Insert the appropriate gauge to check adjustment of the lever and stop screw
for
proper
Clearance between
Between terminele lever
0 0.57
0.74
Resistance
and stop screw
mm (0 in.) mm (0.022 mm (0.029
in.)
in.)
Throttle valve fully
VTA IDL -
E2
0.2
-
E2
2.3
kO
-
E2
VTA -
E2
IDL
5.7
kO
or less
Infinity
2.0
-
10.2
kQ
open
-
VC - E2
2.5
-
5.9
kO 86825ga3
Fig. 87 Insert the appropriate gauge to check for proper adjustment of the throttle position sensor on the 2RZFE and 3RZ-FE engines
Fig.
89 Using your finger, slide the linkage back and
forth to
check movement
FUEL SYSTEM
Clearance between lever
mm (O 0.77 mm .09 mm 0
Other than idling
At idling
Port No.
EGR
No vacuum
Vacuum
R
No vacuum
Vacuum
Between terminals
and stop screw
VTA
in.)
1
5-31
Resistance
- E2
-6.3 kO
0.3
(0.0303
in.)
IDL - E2
Less than 2.3 kfi
(0.0429
in.)
IDL - E2
Infinity
Throttle valve fully
opened position
VTA
- E2
VC
- E2
—
86825ga5
3.5 - 10.3
kQ
4.25 -8.25 kQ 86825ga7
92 Clearance and resistance specifications for the
Fig. Fig.
90 The results of the vacuum testing at the
EGR
3F-E
stop and lever
idle
and R ports should be as indicated Insert a
6.
gauge 0.0366
(0.93mm) between the
in.
throttle
ohmmeasure the resistance between terminals IDL and
stop screw and the lever. Connect the test probe of the
meter
E2
to
of the sensor.
Slowly turn the sensor clockwise
7.
until
ohmmeter de-
the
then secure the sensor with the screws. Using the thick-
flects,
ness gauge, recheck the continuity between the two terminals. Inspect the dashpot,
8.
warm-up the engine
normal oper-
to
ating temperature.
Check the
9.
1 1
Remove
.
your
Attach an ohmmeter to the terminals and check
Release the
set to d.
Reconnect the sensor harness.
off
the vehicle, clean prior to
clean the cast parts with a soft brush
carburetor cleaner. Using compressed
passages and apertures
See Figures 124, 125 and 126 1
.
2.
Depressurize the fuel system. Drain the cooling system.
lbs.
the union
(29-34 Nm).
to the battery.
new gasket on
the
air intake ft.
lbs.
chamber
facing the
(18 Nm).
coil wiring.
EGR
idle air control valve:
vehicles, to the
•
Water bypass; without EGR,
•
Water hose from the intake manifold
to the
EGR
valve
bypass pipe
• Air assist
Connect the vacuum hoses
to the throttle body:
• Throttle opener
EGR vacuum
•
Secure the
modulator
Idle Air Control (IAC)
and
throttle position
sensor connectors. cleaner hose.
16.
Attach the
17.
Connect the following cables:
air
Accelerator
—
• Throttle cable • 18.
1
on
AT — 2
Fill
Cruise control actuator
—3
the cooling system with a mixture of water and
antifreeze.
After checking the fuel pressure, disconnect the nega-
bolts, tighten the bolts to
Place a
• Water bypass; on
the
and/or injectors.
Remove
ignition coil wiring.
Attach the following hoses to the
psi (147
at 21
from the delivery pipes. w.
valve
install:
•
that the fuel pressure
09268-45012 or equivalent, v.
Water hose from the intake manifold
Attach the ignition
Stop the engine.
for
•
13.
15.
Measure the pressure
the pressure
t.
EGR
Water bypass; without EGR, from the bypass pipe
12.
14.
pressure regulator and/or injectors. s.
vehicles, from the
Water bypass; on
•
protrusion upwards, tighten to 13
Measure the pressure at idle, 38-44 psi (265-304 kPa). Reconnect the vacuum, sensing hose to the fuel pres-
sure regulator.
If
.
fuel
pressure regulator, then plug the hose end.
r.
EGR
•
Disconnect the
Nm).
n.
q.
the
idle air
Unbolt the throttle body, remove and discard of the
the No. 2 timing belt cover, tighten
o.
p.
• EGR vacuum modulator Tag and disconnect the following hoses from the
0.
To
Switching Valve (VSV) for fuel pressure
removed,
80 inch
to
vacuum hoses from
9.
1 1
Disconnect the tester from the DLC3. If
following
body:
gasket.
control l.
(IAC) connector.
• Air assist
regulator. k.
sensor harness.
throttle position
idle air control
control valve:
Start the engine.
(265-304 kPa). j.
the air cleaner hose.
• Throttle opener
Attach the Toyota hand-held tester or equivalent scan
Measure the
—2 —3
5.
throttle
spilled fuel.
battery.
i.
1
4.
tool to the DLC3. Reconnect the negative cable to the
h.
—
• Cruise control actuator
and gasket.
delivery pipe
SST
Disconnect the cables:
• Throttle cable on A/T
towel around the delivery pipe, then
slowly loosen the union bolt holding the fuel pipe to the
e.
3.
• Accelerator
belt cover.
5-47
FUEL SYSTEM
5-48
12.
Install all of
the previously tagged
vacuum and water
hoses. Attach the throttle position sensor and
13.
idle air control
wiring.
the control cables to the throttle body.
14.
Install
15.
Connect the
16.
Fill
PCV and
air
cleaner hoses.
the cooling system, start the engine and top
off.
INSPECTION
Always clean the
Wash and
cle.
retor cleaner.
body once removed from the
Using compressed
and apertures
^To
throttle
clean the cast parts with a soft brush
in
clean
air,
of the
all
in
vehi-
carbu-
passages
the throttle body.
prevent any damage, do not clean the throttle posi-
tion sensor.
ADJUSTMENTS Throttle Position Sensor
5VZ-FE ENGINE I
See Figures 1
127, 128
and 129
Inspect the sensor with the throttle body
.
vacuum
apply
Insert a thickness
a.
the vehicle,
off
to the throttle opener.
(0.54mm) between the
gauge 0.13 throttle
in.
(0.32mm) or 0.021
in.
stop screw and the stop lever.
Using a ohmmeter, measure the resistance between
b.
each terminal. 2.
To
adjust the sensor, loosen the 2 setscrews of the
sensor. 3. in.
Apply vacuum
4.
Connect a
and E2 5.
6.
1.
Depressurize the
Drain the engine cooling system.
3.
Disconnect the
4.
Remove
5.
Disconnect the
fuel
system.
PCV and
air
cleaner hoses.
the control cables from the throttle body. throttle position
sensor and
idle air
con-
trol wiring.
6.
Tag and disconnect
to the throttle 7.
the
Remove
air
leading
the bolts, and disconnect the throttle body from
8.
Remove
9.
Disconnect the both of the water bypass hoses from the
To 0.
11. to
vacuum and water hoses
intake chamber.
throttle
1
all
body.
15
the throttle body gasket and discard.
body, then remove the
unit.
install:
Attach the water bypass hoses to the throttle body. Install ft.
the throttle body with a
lbs. (21
Nm).
new
gasket, then tighten
probe of the ohmmeter
test
a 0.017
lever.
to terminals
IDL
of the sensor.
Gradually turn the sensor clockwise
deflects, then
2.
to the throttle opener, then insert
(0.43mm) gauge between the stop screw and
secure
Recheck the
it
until
the
ohmmeter
with the 2 setscrews.
continuity of the terminals IDL
and E2.
FUEL SYSTEM
5-49
Between
Clearance between
Resistance
and stop screw
lever
O 0.32
0.54
mm (0 in.) mm (0.013 mm (0.021
terminals
VTA IDL -
in.)
IDL
in.)
Throttle valve fully
E2
0.28
-
E2
0.5
kO
- E2
kO
6.4
or less
Infinity
VTA - E2
2.0
-
kO
11.6
open
-
VC - E2
2.7
-
7.7
kO
VC VTA
86825gh5
IDL
E2 86825gh8
128 Insert the appropriate thickness gauge and
Fig.
check for proper resistance of the sensor 5VZ-FE engine
130 Using an ohmmeter, measure the resistance between each terminal of the throttle position sensor
throttle position
Fig.
—
Clearance between
Between terminals lever
0 Clearance between
—
Continuity (IDL lever
and stop screw
0.32
mm mm
0.54
(0.013
0.75 Continuity
in.)
(0.021
0.50
E2)
No
in.)
Resistance
and stop screw
mm (0 in.) mm (0.020 mm (0.030
in.)
in.)
Throttle valve fully
continuity
VTA IDL IDL
E2
0.2
-
E2
2.3
kQ
2.0
-
- E2
VTA -
5.7
kO
or less
Infinity
E2
10.2
kO
open 86825gh7
-
VC - E2
2.5
-
5.9
kO 86825gh9
Fig. 131
129 Insert the appropriate gauge and check for
Fig.
proper resistance to recheck the continuity of the IDL
and E2 terminals
— 5VZ-FE
engine
1FZ-FE ENGINE >
See Figures
130, 131
and 132
Inspect the sensor with the throttle body
1.
vacuum
apply
Insert
a. in.
the vehicle,
off
to the throttle opener.
a thickness gauge 0.020
(0.75mm) between the
in.
throttle stop
(0.50mm) or 0.030
screw and the stop
lever.
Using a ohmmeter, measure the resistance between
b.
each terminal. Check the chart 2.
To
for specifications.
adjust the sensor, loosen the 2 setscrews of the
sensor. 3. in.
Apply vacuum to the
throttle
opener, then insert a 0.024
(0.62mm) gauge between the stop screw and 4.
Connect a
and E2 5.
of the
ohmmeter
lever.
to terminals
IDL
of the sensor.
Gradually turn the sensor clockwise
deflects, then 6.
probe
test
secure
Recheck the
it
until
the
ohmmeter
with the 2 setscrews.
continuity of the terminals IDL
and E2.
Insert the appropriate thickness
check for proper resistance of the sensor 1FZ-FE engine
—
gauge and
throttle position
5-50
FUEL SYSTEM
Throttle Valve 1
.
Apply vacuum
to the throttle
opener.
Check that there is no clearance between the throttle stop screw and the throttle lever when the valve is fully closed. The fully closed angle should be 10°. 2.
Fuel Injectors
REMOVAL & INSTALLATION 1FZ-FE Engine I See Figures 133, 134, 135, 136, 137, 138, 139, 140, 141,
and 148
142, 143, 144, 145, 146, 147
tle
1.
Depressurize the
2.
Drain the engine cooling system.
3.
Disconnect the cruise control accelerator cable and
system.
fuel
throt-
cable.
PCV
4.
Detach the No. 2
5.
6.
Remove Remove
7.
Unbolt the heater
8.
Disconnect the
9.
10.
Remove Remove
11.
Disconnect the brake booster hose.
12.
Disconnect the
hose.
the air cleaner hose. the
the
EGR vacuum inlet
PCV
modulator and valve.
pipe and
air intake
chamber.
hose.
vacuum sensing hose.
the water bypass and the
throttle position
valve, emission control valve set
EVAP
hoses.
sensor, idle
assembly and
air control
EGR
gas tem-
perature sensor wiring.
Remove
the bolts retaining the power steering reservoir
14.
Remove
the engine
15.
Unbolt the ground strap.
16.
Remove
17.
Disconnect the vacuum hoses to the Thermal
13.
tank. oil
dipstick.
the intake manifold stay.
Vacuum
Valve (TVV). 18. 19.
Remove Remove
gaskets.
the water bypass hose from the cylinder head. the
air
intake
chamber and discard
of the
FUEL SYSTEM
137 The intake manifold stay
Fig.
is
simply a brace
Fig.
secured by two bolts
Remove Remove
20. 21.
the 2 union bolts, gaskets and fuel
Unsecure the 6
b.
Remove
injectors.
Be
inlet pipe.
the delivery pipe and injectors as follows:
a.
injector connectors.
the bolts and delivery pipe together with the 6
careful not to drop the injectors
when removing
the pipe.
Remove
c.
the insulators and spacers on the intake
manifold. Pull the injectors out of the delivery pipe.
d.
Remove
the
O-rings and grommets from each injector. 22.
Inspect the injectors.
To
install:
23.
Install
new grommets on each injector, then apply a new O-rings and install them.
light
coat of gasoline to the 24.
While turning the injector
delivery pipe. Install 25.
all
6
left
and
right,
install
and spacers
26. Temporarily
in
install
the intake manifold.
it
to the
injectors.
Position the injector connector upwards. Place
sulators
139
fuel filter
position
new
in-
on the intake manifold.
the bolts holding the delivery pipe to
Remove
the fuel inlet pipe;
it
runs
down
5-51
to the
5-52
FUEL SYSTEM 27.
Check the the
recheck the position 28.
injectors rotate smoothly. of the O-rings, or replace
If
they do not,
them.
Position the injector connector upward, then tighten the
bolts holding the delivery pipe to the intake manifold to lbs. (21
15
ft.
Nm).
29.
Attach the injector connectors.
Fig.
145 Rotate the injectors to ensure their smooth
movement. An injector installed and may leak
that binds
has been improperly
86825gg5
Fig.
146 Attach the colored connectors to their correct
locations
FUEL SYSTEM
EGR
Valve and
5-53
Vacuum Modulator
Stud Bolt-
Vacuum Hose
EQR
Air
Pipe
Ti
Gasket,
Cleaner Hose
Cruise Control Actuator Cable Accelerator Cable
Engine Wire
IAC Valve Connectof-
\
v
Emission Control Valve Set Connector
Sensor''' Connector
Brake Booster Hose
Air Intake
Chamber Ground Strap No.1 Water Bypass
Hose
PS
Reservoir
Tank No. 2
PCV
Intake
Hose
Manifold Stay
86825ge3
Fig.
147 Exploded view of the components for injector removal
— 1FZ-FE engine
FUEL SYSTEM
5-54
30.
Install
the fuel
union bolt to 22
inlet
new gaskets, tighten the Nm) and the bolt to 14 ft. lbs. (20
pipe with
(29
lbs.
ft.
41.
Nm).
42.
31.
14
Install lbs.
ft.
32.
15
(20 Nm).
Install ft.
the air intake
lbs. (21
chamber
with
new
gaskets, tighten
Connect the water bypass hose
35.
Attach the
vacuum hose
to the cylinder
to the thermal
vacuum
PCV
hoses.
the bolt that holds the heater
the
EGR
43.
Install
44.
Connect the
head.
valve and
throttle,
45.
Attach the
46.
Fill
lbs.
inlet
pipe and
vacuum modulators.
accelerator and cruise control actu-
air
cleaner and
PCV
hoses.
off.
Look
for leaks.
(TVV). 36.
Install
the intake manifold stay, tighten to 26
ft.
lbs.
(36
Nm). Attach the ground strap.
38.
Install
39. lbs.
Install
the engine the
4.
Remove Remove Remove
5.
Disconnect the
6.
Unsecure the
2.
reservoir tank, tighten to 13
ft.
3.
EGR
Depressurize the
fuel
system.
dipstick.
power steering
valve set, idle
connectors.
See Figures 149, 150, 151, 152, 153 and 154 1.
oil
(18 Nm).
40. Attach the trol
5VZ-FE Engine >
37.
gas temperature sensor, emission con-
air control
valve and throttle position sensor
air
(20 Nm).
the cooling system with a water/coolant mixture. Start
the engine and top
valve
ft.
ator cables.
Nm).
34.
Install
intake chamber, tighten to 14
Attach the fuel hose to the pressure regulator.
33. to
the fuel return pipe with the bolts and tighten to
Secure the brake booster, EVAP, water bypass, vacuum
sensing and
the air cleaner hose. the air intake chamber. the fuel pressure regulator. fuel inlet pipe.
injector connections.
FUEL SYSTEM
5-55
Engine Wire
10.
Fig.
149 Exploded view of the 5VZ-FE injector components Unbolt and remove the delivery pipes together with the
7.
injectors. 8.
Remove
9.
Pull the injectors out of the delivery pipes,
the O-rings
To
the spacers from the intake manifold.
and grommets from each
install: Install
new grommets and
ply a light coat of gasoline a.
O-rings on each injector. Ap-
on the O-rings.
While turning the injector clockwise and counterclock-
wise, push
it
into the delivery pipe. Install
all
of the injectors.
b.
Position the injector connector outward.
c.
Place the spacers into position on the intake manifold.
Temporarily 86825gg7
then remove
injector.
install
the bolts to hold the delivery pipes to the
intake manifold. d.
Check
that the injectors rotate smoothly.
If
they do not,
the O-rings have probably been installed incorrectly.
If
this
has occurred, replace the O-rings with new ones. Fig.
150
Remove
delivery pipes
the six mounting bolts from the
e.
Position the injector outward, then attach the injector
connectors.
5-56
FUEL SYSTEM 11.
the fuel pipe with
Install
tighten to
25
new gaskets and
delivery pipes to the intake manifold to 10 12.
Temporarily
(8
the clamp
Install
lbs.
ft.
new
the union with
install
nect the fuel pipe.
union bolts,
(34 Nm). Tighten the bolts retaining the
lbs.
ft.
(13 Nm).
gaskets, then con-
bolt, tighten to
71 inch lbs.
Nm). the fuel pressure regulator.
13.
Install
14.
Inspect the air assist lines and connections. Look for any
loose connections, sharp bends or damage. the intake air cleaner.
15.
Install
16.
Attach the
17.
Start the
cleaner hose.
air
engine and check
for fuel leaks.
TESTING >
See Figures 155, 156 and 157 Correct testing of the fuel injectors requires specific equip-
ment not usually available outside a dealership or a is recommended that any checking or testing of the other than that included below, be service
the engine.
like
to
It
a properly equipped
facility.
can be checked with the
Injector operation in
left
fuel lab.
injectors,
A sound scope
is
needed
injectors installed
here, a stethoscope-
device available from most auto tool and parts jobbers.
With the engine running or cranking, check each injector
normal operating noise
changes
in
(a
for
buzzing or humming), which
proportion to engine rpm.
If
a sound scope
is
not
available to you, check injector operation by touching each injector with your finger.
an unusual sound
have the
injector
is
It
should be buzzing.
If
no sound or
heard, check the wiring connector, or
checked professionally.
With the engine OFF, measure injector resistance by unplugging the wiring connector from the injector, and connecting an
ohmmeter across
the injector terminals.
Check the
continuity at
both terminals; resistance should be: cold 12-16 ohms. Resis-
tance
Fig.
153 Check that the injectors rotate smoothly.
If
they do not, the O-rings have probably been installed incorrectly
will
vary with injector temperature.
FUEL SYSTEM
5-57
Fuel Pressure Regulator
REMOVAL & INSTALLATION 1FZ-FE Engine
See Figures
158, 159
and 160
1.
Depressurize the fuel system.
2.
Disconnect the vacuum sensing hose from the pressure
regulator.
Wrap a
3.
fuel return
towel around the regulator then disconnect the
hose.
Loosen the
4.
remove the
locknut, then
regulator. Discard
of the O-ring.
To Fig.
155
A sound scope
is
usually used to inspect
injector operation
install:
5.
Fully loosen the locknut
6.
Apply a
install
it
light
on the
regulator.
new
coat of gasoline to a
O-ring, then
onto the regulator.
Insert the regulator into the delivery pipe
7.
the regulator counterclockwise
by hand. Turn
the fuel outlet port faces
until
in
the direction indicated. 8.
Tighten the locknut to 18
9.
Using
new
gaskets,
ft.
install
lbs.
(25 Nm).
the return pipe to the
regulator. 10.
Connect the vacuum sensing hose.
11.
Start the engine
and check
for
any
fuel leakage.
5VZ-FE Engine I See Figures 161 and 162 1.
Depressurize the
2. 3.
Remove Remove
4.
Disconnect the
fuel
system.
the air cleaner hose.
the intake
air
connector.
fuel return
hose from the pressure regu-
Place a shop rag under the regulator to catch any
lator.
leakage. Fig.
156
If
a
sound scope
operation with your finger
is
not available, check the
Remove
5.
the bolt holding the engine wire to the left-hand
valve cover.
Disconnect the protector from the bracket on the
6.
side valve cover, then
Remove
7.
lift
the 2 bolts, then pull out the regulator.
and discard the O-ring from the
To install 9.
10.
does
and
Remove
unit.
install:
Apply a
8.
right
up the engine wire.
it
light
on the
coat of gasoline to the
Attach the regulator to the
Check a
O-ring, then
left
side delivery pipe.
that the pressure regulator rotates smoothly.
not, the O-ring install
new
regulator.
new
may be
the cause.
Remove
If
it
the regulator
O-ring.
Nm).
11.
Attach the regulator, then tighten to 71 inch
12.
Install
13.
Attach the fuel return hose to the pressure regulator. Be
the engine wire with the
sure not to insert the hose up to the stopper and Install
the intake
15.
Install
the
16.
Start the engine
14.
air
air
connector.
cleaner hose.
and check
lbs. (8
bolt.
for leaks.
clip
it.
5-58
Fig.
159
FUEL SYSTEM
Install
gasoline on
it
the
new
O-ring with a light coat of
Fig.
160 The regulator must be properly aligned on the
delivery pipe
FUEL SYSTEM
5-59
Cruise Control Actuator
Cable
Throttle
Throttle Position
Sensor Connector I
5-
EGRGasT
Accelerator Cable
Sensor Connector
VSV
jp
Connector for Fuel Pressure Control
VSV
IAC Valve Connector Air Cleaner Hose
PS
Air
Cable
Connector
EGR
EVAP Hose
Hose
Air Intake Air Assist
for
Chamber Assembly
Hose Gasket
Water Bypass Hose
DLC1 A/C
Connector A/C Air Hose
Idle-up Valve
-Vacuum Hose -Intake Air
Connector
Brake Booster Hose -Water Hose -Fuel Return Pipe
Vacuum Sensing Hose
Non-reusable part 86825gi2
Fig. 161
Exploded view of the components which must be removed to access the
fuel
pressure regulator
FUEL SYSTEM
5-60
Non-reusable part 86825gi3
Fig.
162 The O-ring must be placed correctly onto the regulator or the unit
will
not
fit
properly
FUEL TANK 7.
Tank Assembly
8.
Remove Remove
the fuel tank protector. the bolts holding the tank to the vehicle and
carefully lower the tank.
broad piece
REMOVAL & INSTALLATION
9.
of
Remove
It
is
recommended
that a jack with a
lumber be placed to support the tank.
pump assembly.
the fuel
^CAUTION
> See Figures 163, 164, 165, 166, 167, 168, 169 and 170
Even though the tank has been drained,
the same.
The gas tanks on all Toyota trucks are mounted basically Each one has a shield, straps, inlet pipe and so on. The procedure below is basic, and should help ease your way
highly explosive fuel vapor. Immediately place the tank outside; never store
to the tank removal.
tank
1.
Remove
2.
Raise the vehicle and support
3.
Remove
several gallons ers.
is
It
4.
5.
that
it,
in
but
it
still
pump and sending
unit.
the gravel shield from the tank. fuel lines.
Plug
all
Disconnect the
dirt
the lines to prevent
neck and vent
use a hose to
as possible. This
will
fill
To 10.
been
off
any
install:
Make
certain the fuel tank
flushed. Install the
line.
is
completely dry
if
it
has
pump assembly.
the fuel tank. Tighten the tank bolts.
11.
Install
12.
Connect the
lines
and hoses. Make
Make
certain the
hoses
sure the clamps are cor-
rectly seated.
Connect the negative battery cable.
the
flush remain-
and vapor from the tank and also carry which has accumulated.
13. filler
the house or garage. Unless the
are not crimped or pinched.
from leaking.
6.
leave 2 or 3
the tank.
Disconnect the
full
contains
possible to have
is
Empty on the gauge may
Disconnect the plug from the
Remove fuel
Remember
the tank; be prepared with sufficient contain-
best to run the tank as low on fuel as possible before
removing gallons
in
in
still
ing fuel
with jackstands.
the drain plug and drain any remaining fuel into
a suitable container.
it
to be immediately reinstalled,
tank with water as
the negative battery cable. it
is
it
FUEL SYSTEM
Fuel Hose Protector
Fuel
Pump
Fuel Tank
Fig.
163 Exploded view of the fuel tank components
— 1989-95
Pick-Ups
5-61
5-62
FUEL SYSTEM
Fuel Evaporator
?
Tube
X8
i
Non-reusable part 86825gjl
Fig.
164 Exploded view of the fuel tank components
— Tacoma
FUEL SYSTEM
86825gj2
Fig.
165 Exploded view of the fuel tank components
— 1989-95 4Runner
5-63
FUEL SYSTEM
5-64
3.5 (36, 31 In. Ibf) |
|
^x8 1.5(15, 13
In. Ibf)
Fuel Evaporation Vent
Tube
Gasket Fuel Cut off Valve
Fuel
Pump
Bracket Assembly
P
—
1
Fuel Fuel
Tube Clamp
[5.5 (56,
49
In. Ibf)
3 (31 27 ,
I
Tank
In. Ibf)
Filler
Pipe
Gasket
Tank Cushion
-^
|
Upper
Filler
Pipe
Bracket
Inlet
Fuel
Pipe Shield
Tank
Fuel Tank
30(310, 22)
Fuel
Cap
Tank Protector
Non-reusable part
Nm
(kgf
cm,
ft
Ibf)
: [
Specified torque 86825gj3
Fig.
166 Exploded view of the fuel tank components
— 1996 4Runner
FUEL SYSTEM
Fuel Evaporation
5-65
Tube
Gasket Fuel
Pump
Fuel Sender
Gasket
Fuel
Tank Cushion
Gauge
Gasket
Fuel
Tank
No.1 Fuel Hose
6>~!
Inlet
Pipe
i
Fuel Pipe
Clamp Inlet
Hose
Fuel
Tank
Filler
Pipe
Fuel Tank Protector
Fuel
Tank Band Pin
No.2 Fuel Tank Band
No.1 Fuel Tank Band
86825gj4
Fig.
167 Exploded view of the fuel tank components
— T1 00
5-66
FUEL SYSTEM
Fuel
Tank Cap
86825gj6
Fig.
168 Exploded view of the fuel tank components
— 1989-91
Land Cruiser
FUEL SYSTEM
Fuel
N-m
(kgf'cm,
ft - Ibf
5-67
Tank Breather Tube
Specified torque
Non-reusable part 86825gj7
Fig.
169 Exploded view of the fuel tank components
— 1992-94
Land Cruiser
5-68
FUEL SYSTEM
Fuel
Tank Breather Tube
Fuel Pump w/ Sender Gauge
Gasket
Fuel Cut Off Valve
Gasket
Fuel Tank Cushion
Moulding
Gasket
—
Drain Plug
Fuel
Tank Protector
Location of Fuel Tank Cushion
Non-reusable part 86825gj8
I
Fig.
170 Exploded view of the fuel
tank components — 1995-96
Land Cruiser
AIR CONDITIONER A/C AMPLIFIER 6-24
COMPRESSOR 6-19 CONDENSER 6-22 EVAPORATOR CORE, EXPANSION VALVE AND THERMISTOR 6-22 PRESSURE SWITCH 6-24 RECEIVER/DRIER 6-23
REFRIGERANT LINES
6-24
AUXILIARY HEATER
SERVOMOTOR 6-25 SERVOMOTOR 6-25 AIR OUTLET SERVOMOTOR 6-25 BLOWER MOTOR 6-24 REAR BLOWER RESISTOR 6-25 AIR INLET AIR MIX
REAR HEATER UNIT 6-26 BATTERY CABLES DISCONNECTING THE CABLES CIRCUIT PROTECTION CIRCUIT BREAKERS 6-60 FLASHERS 6-60 FUSE AND CIRCUIT BREAKER
SAFETY PRECAUTIONS 6-2 TROUBLESHOOTING 6-3 UNDERSTANDING BASIC ELECTRICITY 6-2 WIRING HARNESSES 6-8 WINDSHIELD WIPERS AND WASHERS
REAR WIPER MOTOR 6-38 WASHER FLUID RESERVOIR 6-41 WASHER PUMP 6-42 WINDSHIELD WIPER ARM 6-37 WINDSHIELD WIPER BLADE 6-37 WINDSHIELD WIPER MOTOR 6-37 WIPER LINKAGE 6-40 WIRING DIAGRAMS 6-76
6-11
APPLICATIONS 6-60
FUSES 6-59 RELAYS 6-60 CRUISE CONTROL
COMPONENTS
6-29
SYSTEM DIAGNOSIS 6-28 ENTERTAINMENT SYSTEMS RADIO
AIR CONDITIONER 6-19
AUXILIARY HEATER 6-24
6-36
BATTERY CABLES
SPEAKERS 6-36 HEATER BLOWER MOTOR 6-14 BLOWER SWITCH 6-19 CONTROL ASSEMBLY 6-16 CONTROL CABLES 6-18 HEATER CORE 6-16 HEATER UNIT 6-14 HEATER WATER CONTROL
6-47
6-56
MARKER AND INTERIOR
LAMPS 6-55 SUPPLEMENTAL RESTRAINT SYSTEM (AIR
BAG)
GENERAL INFORMATION
6-13 6-43
6-11
TRAILER WIRING 6-59
LIGHTING
SIGNAL,
6-35
SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG)
COMBINATION SWITCH 6-47 INSTRUMENT CLUSTER 6-44 SPEEDOMETER CABLE 6-49 SPEEDOMETER, TACHOMETER AND
HEADLIGHTS 6-50 LIGHT BULB APPLICATIONS
6-28
LIGHTING 6-50
6-49
GAUGES
CRUISE CONTROL
ENTERTAINMENT SYSTEMS HEATER INSTRUMENTS AND SWITCHES .
VALVE 6-16 INSTRUMENTS AND SWITCHES
CLOCK
6-11
CIRCUIT PROTECTION 6-59
6-11
TRAILER WIRING 6-59
UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS ADD-ON ELECTRICAL EQUIPMENT 6-11
UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS WINDSHIELD WIPERS AND
6-2
WASHERS
6-37
WIRING DIAGRAMS
6-76
CHASSIS ELECTRICAL
6-2
UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS Over the years import and domestic manufacturers have
•
incorporated electronic control systems into their production
systems are so prevalent
lines. In fact, electronic control all
new
cars and trucks
built
today are equipped with
parts) should theoretically last the
moving
damage
provided that nothing external happens to or
memory While
wear
any computer-based system
and cannot
electrical voltages
is
do occur.
tolerate careless or
cause major damage looking
for
is
It
•
also
haphazard
individual
can
a minor problem by
leads/connectors with the ignition switch ON.
make
equipment,
that the tester
check
Read
all
instructions carefully
test points before installing
all
selecting
the pin side, to avoid accidental shorting of
Never remove or attach wiring harness connectors with
Do
not drop any
are applied directly to the connector.
Remove
•
placed
probes or making any
in
the electronic control unit
if
the vehicle
is
to
be
an environment where temperatures exceed
approximately 176°F (80°C), such as a paint spray booth or
when
arc/gas welding near the control unit location.
following section outlines basic diagnosis techniques for
dealing with automotive electrical systems. Along with a
Understanding Basic
general explanation of the various types of test equipment available to aid
modern automotive systems, basic
servicing
in
harnesses and connectors are also
repair techniques for wiring
given.
NOT
ON, especially to an electronic control unit. components during service procedures and never apply 12 volts directly to any component (like a solenoid or relay) unless instructed specifically to do so. Some component electrical windings are designed to safely handle only 4 or 5 volts and can be destroyed in seconds 12 volts
is
and double
test connections.
The
connectors
if
sure the manufacturer’s instructions state
compatible with whatever type of system
is
being serviced.
When
into
the ignition switch •
using the wrong kind of test equipment or connecting test
test
probes
inserting test
good contact without damaging the connector or spreading the pins. Always probe connectors from the rear
terminals during, test procedures.
extremely sensitive to
An inexperienced
testing/service procedures. literally
the circuits
components should never
out, in the real world malfunctions
true that
when
• Exercise care to insure
(wire) side,
true that electronic
of “hot shot” (24 volt)
starting aid.
no
chips.
is
it
(with
of the vehicle,
life
any type
battery or attempt to use
that
at least
one on-board computer. These electronic components
Always remove the battery cables before charging the Never use a high output charger on an installed
battery.
Read
the basic information before attempting any
repairs or testing. This
Understanding the basic theory troubleshooting
much
will
it
electrical
gauges are used
see inside the
Without a basic understanding,
most common and obvious
makes
of electricity
easier. Several
electrical troubleshooting to
provide the background of
will
information necessary to avoid the
Electricity
be
circuit
in
being tested.
understand
difficult to
testing procedures.
mistakes that can cost both time and money. Although the
replacement and testing procedures are simple
in
themselves,
the systems are not, and unless one has a thorough
understanding of
components and
all
particular system, the logical test
demand cannot be big difference, so
is
important to
affects the operation of the overall
Electricity is the flow of electrons
make a
know how each component system
in
order to find the
ultimate cause of a problem without replacing good components unnecessarily. It is not enough to use the test
a
their function within
sequence these systems
followed. Minor malfunctions can
it
THE WATER ANALOGY
thought to constitute the basic
have been taught In
would be the water. As the flow
in
a pipe, the electrons
water can be measured,
of
the flow of electricity can be measured.
measurement is amperes, ammeter will measure the
Safety Precautions
the
**CAUTION
volts.
amount
actual
When
is
damage
between the two parts
components.
will
battery cables with the key
Jumper cables should be connected avoid power surges that can damage
the engine running. the key
OFF
to
electronic control units. Engines equipped with
controlled starts
due
made
ON
or
with
computer
systems should avoid both giving and getting jump to the possibility of serious
from arcing
in
the engine
with the ignition
damage
compartment
ON.
if
to
in
live
flow through the voltmeter and produce
components
connections are
in electrical
pressure
of the circuit.
While increasing the voltage
remove
such as
measured
portions of an electrical circuit with different electrical
pressures, current
or
is
a voltmeter's two probes are placed on two
a reading which indicates the difference
install
in units
pressure
precautions to prevent the possibility of personal injury or
Never
An
of current flowing in
measured
inch, electrical
electronic systems, always observe these general
•
unit of
circuit.
pounds per square electrical or
The
frequently abbreviated amps.
Just as the water pressure
to electronic
an analogy with water.
electrical theory using
a comparison with water flowing
particles
Many people
correct
equipment; the test equipment must be used correctly.
Whenever working on or around any
— hypothetical
stuff of electricity.
of current, the actual flow
in
a
circuit will
increase the flow
depends not only on
voltage, but
on
The standard unit for measuring circuit resistance is an ohm, measured by an ohmmeter. The ohmmeter is somewhat similar to an ammeter, but incorporates its own source of power so that a standard voltage is always
the resistance of the
present.
circuit.
CHASSIS ELECTRICAL on the instrument panel, and then back
CIRCUITS
voltage drop would occur
These
actual electric circuit consists of four basic parts.
power source, such as a generator or
are: the
which conducts the
wire,
under a
electricity
component supplied by the
voltage to the
such as a lamp, motor,
which carries the current back
wire,
low voltage.
In
such a
the bulk of the resistance exists
circuit
between the point where the hot wire
and the
where the load
point
Remember connected
to the load,
used as
of steel, is
the voltmeter
is
connected
one
at
becomes a
and the ammeter inserted so
that
all
power
the
the portion of the circuit to be
end by one For any
complete
probes
of the
electrical circuit.
system
it
to function (such
as
off
and
must make a
it
When
circle.
a
lighting
on which the
component
electrical
Perhaps the easiest way connecting a
light
an
light
light
If
it
of the
circuit.
is
to light.
It
light bulb,
where
would then leave the
bulb (from the previous
don’t try
circuit.
To prevent damage
to the
component
to
use the power
— the
circuit
two wires attached
The most common causes
the is
of short
rubber insulation on a wire breaking or rubbing
metal part of the car, or a shorted switch.
Some
electrical
systems on the vehicle are protected by a
breaker which
basically,
is,
a self-repairing fuse.
When
system which
is
protected by a circuit breaker, the circuit breaker opens the circuit the
to the
battery
— less
phenomenon
through to expose the current carrying core of the wire to a
your
to
it
system,
—
components from damage, Because grounding a
power source makes a complete
either of the described events takes place in a
and
the battery,
short
is
same way a
breaker resets
circuit
fuse does. However,
removed from the itself
circuit or
when
either the
the surge subsides, the
and does not have
to
be replaced
as a fuse does.
Current from the battery to
it
and
would pass through causing
it
light
connected
to the battery by two and touch the two wires together (please
this;
circuits are: the
to think of
would flow out one post, through the wire attached then to the
turned
is
similar thing
called a short circuit.
circuit
the other wire
you would have a complete
A
to
and then
was attached to the negative post of the was attached to the positive post of
bulb
light-bulb being
to the
your vehicle has two posts
in
one
to the
the control switch
it), the result will be a shower happens (on a smaller scale) when the power supply wire to a component or the electrical component itself becomes grounded before the normal ground
required
mounted.
to visualize this
battery
(negative and positive).
disconnect the
to
a
of
wire from a
electrical
bulb)
bulb with two wires attached to
The
vehicle’s battery.
is
you were
protecting the
power flow from
that the
usually (but not always) the metal part of the vehicle
is
An
SHORT CIRCUITS
connection for the
returns to the battery through the ground of the circuit. This
ground
When
the fuse for the circuit blows to interrupt the circuit
component, passes through the component causing perform
circuit.
of sparks.
at either
power flows from the battery
operating,
is
to operate,
make a complete
the
take our word for
is
self-
is
measured contacted
means
it
wires) from the wires
it
the circuit should be
in
normally open,
is
circuit.
grounds the smaller wire from the relay and completes
on,
example
of the meter.
This simply
the battery must
component
and the ohmmeter
part of the circuit);
powered; so
relay
connected from the relay
is
control switch for the circuit.
If
in
series with the load (the circuit
in
point
and from the opposite
The
is
being tested (without
voltage between the locations of the two probes; that the
separated
of the relay,
an automobile,
In
disconnecting any wires) and measures the difference
ammeter
(relay) is
of the electrical devices.
that, in electrical testing,
parallel with the circuit
in
connected
made
is
many
circuit for
is
grounded.
is
the vehicle’s frame or body, which
a part of the ground
additional, smaller wire
source under very
to the
one side
preventing current from passing through the
the load,
this
the circuit are connected from the
in
side of the relay to the component.
and the ground
resistor or relay coil;
large wires
vehicle battery to
battery; a hot
relatively high
circuit;
The
used.
component, a
to the
To prevent
circuit.
an electromagnetic switch
potential drop in voltage,
An
the
in
6-3
light bulb, travel
Troubleshooting
it
through the
When
other wire, and return to the other post of the battery.
diagnosing a specific problem, organized
troubleshooting
is
a must. The complexity of a modern
automobile demands that you approach any problem
AUTOMOTIVE CIRCUITS
logical,
in
a
organized manner. There are certain troubleshooting
techniques that are standard: 1
The normal automotive example
in
two ways.
circuit differs
First,
from
this
simple
instead of having a return wire
from the bulb to the battery, the
light
chassis
is
made
is
of electrically
conductive metal, the chassis of circuit.
current to
these
components which require a large amount operate also have a relay in their circuit. Since
circuits carry
the wire
in
the circuit (gauge size)
is
also greater.
component
If
symptoms?
problem area. To do
of
this large
to the control switch
this,
make some simple
and observations; then eliminate the systems
complicated
a large amount of current, the thickness of
wire were connected from the
Isolate the
for
that are
obvious problems such as broken
vacuum hoses.
Always check the obvious before assuming something
off.
electrical
Does the problem
the problem occurs.
wires, dirty connections or split/disconnected
3.
Some
when
working properly. Check
Secondly, most automotive circuits contain switches to turn
components on and
2.
tests
attached to the chassis and the
the vehicle can serve as a ground wire to complete the
Establish
odors, or other unusual
bulb return the current to
the battery through the chassis of the vehicle. Since the
negative battery cable
.
appear only under certain conditions? Were there any noises,
is
the cause.
Test for problems systematically
to
determine the cause
once the problem area
is
functioning properly?
Is
there
and motors?
Is
vacuum
actuators?
there a mechanical problem such as bent linkage
Is
there
isolated.
Are
all
power going at
the
components
to electrical
switches
vacuum switches and/or
CHASSIS ELECTRICAL
6-4
4.
checks
up most causes on the
often turn
will
components
without wasting time checking
Test
the problem
is
done
Some causes can be
is fixed.
one component, so a important
work
repairs after the
all
(•Never substitute the jumper wire
make
to
sure that
traced to more than
careful verification of repair
work
is
order to pick up additional malfunctions that
in
Experience has shown that most problems tend a
(for
corroded connectors or
makes
be the
to
air
leaks
in
power source. the bulb
If
problems generally that
fall
into
one
not functioning
is
light
goes on, then the current
not working
in
is
the car. This
itself is
defective.
The above test procedure can be applied to any of the components of the chassis electrical system by substituting the component that is not working for the light bulb. Remember any
clean and
The component
is
neither test located the source of the trouble, then the
If
bulb
that for
•
the test
first of the three possible causes. Connect the power supply wire and connect a jumper wire from the bulb to a good metal ground. Do this with the switch which controls the bulb works with jumper wire installed, then has a bad ground. This is usually caused by the metal area on which the bulb mounts to the vehicle being coated with some type of
light
BASIC TROUBLESHOOTING THEORY
Electrical
in
eliminates the
6.
testing
and accurate troubleshooting.
essential to quick
for the bulb, as the
use the power from the
to
foreign matter.
the intake system. This
components during
careful inspection of
component required
it
simple and obvious cause, such as loose or
fairly
the
is
getting to the bulb that
example) may go undetected.
result of
bulb
5.
may
cause a problem to reappear or a different problem to arise. A blown fuse, for example, is a simple problem that may require more than another fuse to repair. If you don’t look for a problem that caused a fuse to blow, a shorted wire
defective.
is
or
little
problem.
to the
no relationship
have
that
whatever was bypassed
inspection
first
the jumper wire installed, the switch or
light illuminates with
or loose mounting screws? Performing careful, systematic
system
electrical
to work,
all
connections must be
tight.
of three areas:
TEST EQUIPMENT
not receiving
is
current.
The component The component
• •
Problems
that
complicated.
wire.
A
not functioning.
into the first
category are by far the most
system can be checked with a test light is
a device that looks
screwdriver with a wire attached to
A jumper
handle.
alligator clip If
a
light
(••Pinpointing the exact cause of trouble in an electrical
not properly grounded.
component
the switches, relay, fuses, etc.
all
electrical
jumper
is
the current supply system to the
is
It
which contains
The
fall
itself is
wire
is
it.
It
has a
test light
and a
a pointed
like
bulb
light
in its
a piece of insulated wire with an
procedures.
attached to each end.
bulb
is
not working, you must follow a systematic
plan to determine which of the three causes
the
is
Jumper Wires
villain.
1.
Turn on the switch that controls the inoperable bulb.
2.
Disconnect the power supply wire from the bulb.
3.
Attach the ground wire to the test
light to
Jumper wires are simple, yet extremely valuable, pieces of equipment. They are basically test wires which are used to bypass sections of a circuit. The simplest type of jumper test
a good metal
ground.
wire
Touch the probe end
4.
power supply wire bulb
the bulb
key
that
of the test light to the
was disconnected from
receiving current, the test light
is
end
of the
the bulb.
If
make sure
is
a length of multi-strand wire with an alligator
the
turned
equipped wires
on.
in
If
the test
this
Turn
light
does not go on, then the problem
between the battery and the
includes to
all
bulb.
the switches, fuses, and relays
a wiring diagram and
is
As mentioned in
in
the
the system.
Follow the wire that runs back to the battery. The problem
an open
circuit
between the battery and the
bulb.
If
short circuit
in
terminals
there
This
is
is
it
are
more terminals In
made
splice for
cramped, hard-to-reach areas
it
is
in
order to prevent accidental grounding, sparks, and
fire,
on either the ground
side of the circuit or on the
circuits,
a
component fails to operate, connect the jumper wire between the component and a good ground. If the component operates only with the jumper
the system which must be located and repaired.
a switch
jumper
different styles of
Some jumper wires coming from a common
is
in the system, bypass with a jumper wire. done by connecting one end of the jumper wire to the power supply wire into the switch and the other end of the jumper wire to the wire coming out of the switch. If the test If
have several
is
well
especially when testing fuel system components. Jumper wires are used primarily to locate open electrical
is
is
will
The
advisable to have insulated boots over the jumper wire
possible
the fuse
blown and, when replaced, immediately blows again, there
box
tool
special purpose testing.
before,
on the diagram.
find the bulb
pin connector) that
several different lengths.
with three or
circuit
spade connector or
required for the particular vehicle being tested.
ignition is
of
standard automotive wire and whatever type of connector (alligator clip,
the key
clip at
each end. Jumper wires are usually fabricated from lengths
go on.
will
one which works only when the
is
turned on (turn signal),
is
system can sometimes only be accomplished by the use of special test equipment. The following describes different types of commonly used test equipment and explains how to use them in diagnosis. In addition to the information covered below, the tool manufacturer’s instructions booklet (provided with the tester) should be read and clearly understood before attempting any test
hot (+) side.
installed, the
If
an
(-)
electrical
ground
circuit is
open.
If
the ground circuit
good, but the component does not operate, the
circuit
is
between
the power feed and component may be open. By moving the jumper wire successively back from the lamp toward the power
CHASSIS ELECTRICAL source, you can isolate the area of the circuit where the open is
located.
power
When
cut
is
sure the component uses 12 volts
in
about 4 volts and running 12 volts terminals can cause
By
an
inserting
leads, a fused
designed
directly to the injector
in-line
When
in
to
is
of voltage) is present;
voltage
present.
is
make sure
posts to
It
is
The self-powered
terminals across the battery
its
the light
is
operating properly.
bypassing open
for
in
design to the 12
and the
doubt, use a voltmeter to check the
type of self-powered test
the
toward the open
light
the contact point.
light illuminates
open
for either
Never use jumpers made from wire that is of lighter gauge is used in the circuit under test. If the jumper wire is of too small a gauge, it may overheat and possibly melt. Never use jumpers to bypass high in
The self-powered
bypass lengths
This may,
cause
in turn,
is
used
destroyed by even
A
used
light is
and ground
different styles but
or to
amount
of voltage applied directly
check
to
all
is
tests.
circuits
circuit.
It
Twelve
can also be used
check continuity
to
by indicating current flow from one end
in
in
a
of
a
a wire or
to the other.
Analog voltmeters usually have various scales on the meter
and
flowing through them.
dial
parts;
and a selector switch
to allow the selection of different
It
volt test lights
have three main
is used to measure voltage at any point measure the voltage drop across any part
a ground
The voltmeter has a
voltages.
avoid
damage
to the meter,
to the negative
can be probed
will
a probe, and a
Many engine sensors can be
so.
voltmeter
circuit,
The most commonly used 12 volt test lights have pick-type probes. To use a 12 volt test light, connect the ground clip to a good ground and probe wherever necessary with the pick. The pick should be sharp so that clip,
do
this small
Voltmeters
circuit
electrical current
for voltage
in
used on any computer controlled system or component unless
to
Unpowered Test Lights
come
when power is isolated from A powered test light should not be
test).
specifically instructed to
of wire.
The 12 volt test components while
is
to test
to the terminals.
Jumper wires should only be used
fire.
test light
can be used
It
tip.
so that the
a circuit. Bypassing resistances, in
effect, creates a short circuit.
damage and
tip,
or short circuits
the circuit (continuity
than that which
.5 volt
This type has both the battery
volt unit.
a dual purpose piece of test equipment.
^CAUTION
1
light is similar
the handle, along with a pick-type probe
light in
The second type has
how much
a
test light usually contains
One
penlight battery.
normally being applied.
resistance loads
only detects
it
advisable before using
Self-Powered Test Lights
provide protection against
voltage input to the component and measure voltage
some
the test light to touch
fuse holder between a set of test
jumper wire can be used
voltage spikes.
make
that
electrical
operate on
to
between the probe and point
damage.
Use a 5 amp fuse
circuits.
first
Some
operation.
fuel injectors, are
components, such as
amount
particular
the jumper wire directly from
the battery to the hot terminal of the component, but
is
’•’The test light does not detect that 12 volts (or any
the jumper and the point previously tested.
You can sometimes connect
glows, the open
it
which was probed previously.
component stops functioning, or the the open is in the segment of wire between the
off,
When
glow.
6-5
light.
ground side
positive
and a negative
lead.
To
always connect the negative lead
side of the circuit (to ground or nearest the
(-)
and connect the
of the circuit)
positive (+) side of the circuit (to the
positive lead to the
power source or the
nearest power source). Note that the negative voltmeter lead
it
into tight
spaces.
always be black and that the positive voltmeter
be some color other than black (usually
^CAUTION
Depending on how the voltmeter circuit,
Do not use
a test light to probe electronic ignition spark
it
has several uses.
either in parallel or
A
high resistance to current flow.
probe wiring on computer controlled systems unless
only a small
specifically instructed to
do
Any wire
so.
insulation that is
current path
with silicone after testing.
voltmeter
Like the jumper wire, the 12 volt test light
opens
bypass the open used light
But,
in circuits.
to
to locate the
glows, you
the 12 volt test into the wire or circuit
whereas the jumper wire
know
of voltage in
that there
is
Move
toward the power source
know
the test until
the
a
is
circuit.
power up
does not glow when
connector, you
(no power).
used
to isolate
used
operate the load, the 12 volt test
presence
light
is
its
probe
light in
is
is
When
and
it
connected
has a very in parallel,
will
flow through the normal circuit
work normally.
circuit will in
When
the
series with a circuit, only a small
amount of current can flow through the circuit. The circuit will the not work properly, but the voltmeter reading will show if
circuit is
complete or
not.
light is
the test
to that point;
that there
light in
If
to
and the
connected
is
into the
of current will flow through the voltmeter
current path; the rest
pierced by the test light probe should be taped and sealed
connected
series with a circuit
in
always
voltmeter can be connected
plug or coil wires. Never use a pick-type test light to
amount
is
will
red).
if
inserted
an open
successive steps back the handle does
Ohmmeters The ohmmeter measured
in
is
ohms
designed or
Q)
in
read resistance (which
to
a
circuit or
there are several different styles of ohmmeters,
meters
will
usually
measurement
is
component. Although all
analog
have a selector switch which permits the
of different
ranges
of resistance (usually the
selector switch allows the multiplication of the meter reading by 10, 100, 1000,
meter
to
be set
and 10,000). A at
calibration
knob allows the
zero for accurate measurement. Since
ohmmeters are powered by an
internal battery, the
all
ohmmeter
CHASSIS ELECTRICAL
6-6
can be used as a self-powered is
test light.
When
ohmmeter
the
connected, current from the ohmmeter flows through the
component being tested. Since the ohmmeter’s internal resistance and voltage are known values, the amount of current flow through the meter depends on the resistance of circuit or
component being tested. The ohmmeter can be used to perform a continuity test for opens or shorts (either by observation of the meter needle or as a self-powered test light), and to read actual resistance in a circuit. It should be noted that the ohmmeter is used to check the resistance of a component or wire while there is no the circuit or
voltage applied to the
circuit.
Current flow from an outside
voltage source (such as the vehicle battery) can
ohmmeter, so the
circuit or
component should be
the vehicle electrical system before any testing the
ohmmeter uses
connected
^When
to
any
its
own
damage
isolated from
voltage source, either lead can be
test point.
checking diodes or other solid state components,
ohmmeter leads can only be connected one way in order to measure current flow in a single direction. Make sure the positive (+) and negative (-) terminal connections the
reduced current draw can cause
battery, while a
motors to run slowly,
lights to
not operate properly.
The ammeter can
dim and other components
to
help diagnose these
conditions by locating the cause of the high or low reading.
Multimeters jH
Different combinations of test
meters can be
single unit designed for specific tests.
common testers,
Tach/Dwell meters, or
Volt/Amp tester
is
used
of the
a
more
and consists
two ranges
of
a voltmeter, an ammeter and a
The voltmeter
use with
for
The
Digital Multimeters.
charging system, starting system or
for
variable resistance carbon pile. at least
Some
built into
combination test devices are known as Volt/Amp
battery tests
the
done. Since
is
and drain the
6,
usually have
will
12 and/or 24
volt
systems.
The ammeter also has more than one range for testing various levels of battery loads and starter current draw. The carbon pile can be adjusted to offer different amounts of resistance. The Volt/Amp tester has heavy leads to carry large amounts of current and many later models have an inductive ammeter pickup that clamps around the wire to simplify test connections.
On some
models, the ammeter also has a zero-
are as described in the test procedures to verify the one-
center scale to allow testing of charging and starting systems
way diode
without switching leads or polarity.
operation.
A
multimeter
digital
is
a
ammeter and ohmmeter combined in an instrument which gives a digital readout. These are often used when voltmeter,
using the meter for making continuity checks, do not be
In
concerned with the actual resistance readings. Zero resistance, or
any ohm reading, indicates continuity
resistance indicates an
open
the
in
the
in
A
circuit.
circuit.
Infinite
high resistance
reading where there should be none indicates a problem circuit.
Checks
as checks
open
for
are
for short circuits
circuits
made
the
in
except that the
circuit
power and normal ground.
isolated from both
in
the
same manner must be
Infinite
resistance
indicates no continuity to ground, while zero resistance indicates a
dead short
to ground.
used
circuit is
equal to the
circuit resistance,
circuit
any decrease
amount of amps most circuits have a
a
in
circuit.
in
resistance
increase
will
amount of amperes, called measured using an ammeter. By current draw rating, measuring the
characteristic
a specified
amperes, and comparing the two values, one can determine what is happening within the circuit to aid in diagnosis. An circuit, for
example,
ammeter reading
a heavily loaded
will
will
not allow any current to flow so
be zero. More current flows through
is
circuit or
when
the charging system
always connected
All of
in
the current that normally flows through the
other path for the current to follow, the
The ammeter
itself
if
there
is
will
battery
like
powered
powered
power from the
testers usually
an ohmmeter) before
testing.
Open
Circuits
To use the self-powered test light or a multimeter to check open circuits, first isolate the circuit from the vehicle’s 12 volt power source by disconnecting the battery or wiring harness connector. Connect the test light or ohmmeter ground clip to a good ground and probe sections of the circuit for
sequentially with the test circuit).
ammeter reading
has very
little
If
is
the
light is
light,
(start
out/or there
is
between the probe and the
from either end of the infinite
circuit
resistance, the
ground.
on/or the meter
shows
probe and end of the
continuity, the
circuit
open
is
If
the light
between the
toward the power source.
Short Circuits
any will
resistance
and therefore will not affect the circuit, but measure current draw only when the circuit is closed and electricity is flowing. Excessive current draw can blow fuses
to current flow
The
(much
their
is
series with the circuit
must also flow through the ammeter;
not be accurate.
use.
electronic
TESTING
is
An ammeter
in
require calibration
open
operating.
being tested.
vehicle battery
some
of
tach/dwell meters are
At normal operating voltage,
“current draw” which can be
circuit
check the duty cycle (operation)
Some
is
increasing voltage also increases the current
the
the
systems, dwell
but the dwell meter can also be
voltage divided by the total
level (amps). Likewise,
open
to
ignition unit,
by an internal battery, while others take
An ammeter measures the amount of current flowing through circuit in units called amperes or amps. Amperes are units of electron flow which indicate how fast the electrons are flowing through the circuit. Since Ohms Law dictates that current flow
referring to
most electronic
engine control systems.
a
a
rotation. In
determined by the control
Ammeters
in
because of their high input impedance (usually 10 megohms or more). The tach/dwell meter that combines a tachometer and a dwell (cam angle) meter is a specialized kind of voltmeter. The tachometer scale is marked to show engine speed in rpm and the dwell scale is marked to show degrees of distributor shaft testing solid state circuits
it
By isolating the circuit both from power and from ground, and using a self-powered test light or multimeter, you can check for shorts to ground in the circuit. Isolate the circuit from
power and ground. Connect the clip to
test light or
ohmmeter ground
a good ground and probe any easy-to-reach test point
l
CHASSIS ELECTRICAL in
the circuit.
is
a short
the
If
comes on
light
somewhere
a test point at either
the
in
end
or there
To
circuit.
continuity, there
is
of the isolated circuit (the light should
be on/there should be continuity). Leave the test
probe
light
engaged and open connectors, switches, remove parts, sequentially, until the light goes out/continuity is broken. the light
goes
out, the short
is
between the
component opened and the previous
See Figure 17
Safely discharge the system this must be performed by
.
the exposed ends of the lines to
when discharging
conditioning.
air
adjoining component.
to the
Consult your local laws concerning refrigerant discharge and recycling. In many areas it may be illegal for anyone
the
its
refrigerant lines.
Please refer to Section air
from
minimize contamination.
REMOVAL & INSTALLATION
sor or disconnecting
line
the lines are connected with flare nuts, use a back-up wrench
a properly trained and certified mechanic with refrigerant recovery/recycling
in
equipment
a
facility
that
equipped
meets
SAE
1.
Remove
2.
Disconnect the amplifier harness.
3.
To
standards.
the glove box or the glove box door.
Unbolt the amplifier from the cooling
unit.
install:
the A/C amplifier to the cooling
2.
Separate the harness from the switch.
4.
Install
3.
Hold the switch mount on the tube with an open end
5.
Attach the electrical harness to the back of the
6.
Install
wrench.
Remove
the switch with another wrench; be careful
unit. unit.
the glove box or glove box door.
not to deform the tube. Discard the O-ring.
To
install:
4.
Install
5.
7
a
Install
new
O-ring lubricated with compressor
8 or an equivalent to the
Oil
lbs.
ft.
oil
ND-
liquid tube.
the switch to the tube, then tighten on the tube to
(10 Nm).
6.
Attach the harness to the switch.
7.
Evacuate the system.
8.
Have an authorized
service station recharge the system
with refrigerant. Operate the system
and check
for leaks.
Refrigerant Lines
REMOVAL
1
& INSTALLATION
Properly discharge the
.
air
conditioning system using reFig.
covery/recycling equipment.
17 The A/C amplifier
is
located behind the glove
box
Disconnect the negative battery cable.
2.
AUXILIARY HEATER Certain Land Cruiser and
4Runner models may be equipped
with an additional heating unit for the rear of the vehicle.
These small
units contain
an additional heater core, fan and
blower motor. Coolant hoses or pipes run to either the un-
derdash heater or the engine piping under the hood. The Land Cruiser unit unit
is
is
Blower Motor
located under the right front seat; the
located at the rear of the center console.
REMOVAL & INSTALLATION
4Runner
Land Cruiser 1
.
Disconnect the negative battery cable.
2.
Remove
3.
Separate the connectors from the blower motor and the
the right front seat.
rear heater relay. 4. 5.
Remove Remove
the bolt and the rear heater relay. the screw retaining the side cover.
If
CHASSIS ELECTRICAL Remove
6.
1996
the bolt and 7 screws, then the upper cover
Remove
with the motor.
the screw retaining the motor from the 1
.
6-25
MODELS Remove
the front seats.
cover.
Remove
7.
the nut holding the
separate the cage from the
cage
Roll
3.
Disconnect the resistor wiring harness.
to the motor, then
unit.
4.
To
up the carpet.
2.
Remove
the mounting screws and the resistor.
install:
8.
Attach the cage to the motor with the mounting nut.
9.
Secure the blower motor
to the
upper cover and
To 5.
install
install:
the resistor, then attach the harness wiring to the
Install
it
unit.
into the vehicle. 6.
Attach the side cover.
10.
11.
Install
12.
Check
Install
Roll the carpet into place, then install the front seats.
the rear heater relay.
the harness connection to the motor.
connections are secure, then
all
the right
install
Servomotor
Air Inlet
front seat.
Connect the negative battery cable.
13.
REMOVAL
& INSTALLATION
4Runner 1
Disconnect the negative battery cable.
.
Remove Remove Remove Remove
2. 3.
4. 5.
1
the rear heater unit from the vehicle. the wire harness clamps. the screws and
clamp securing the case halves.
the motor attaching screws, then
lift
out the
motor. 6.
Remove
the nut holding the cage to the motor, then
separate the cage from the
To
unit.
8.
Install
the motor into the heater case.
9.
Install
the heater cases together, then attach the wire
harness clamps. the rear heater unit into the vehicle.
10.
Install
1 1
Connect the negative battery cable.
.
Remove
Set the damper to the
4.
Disconnect the
5.
Disconnect the linkage from the
6.
Remove
Check the operation
of the
the glove box compartment door.
air inlet
RECIRC
position.
servomotor
wiring.
air inlet
servomotor.
the mounting screws and the air
inlet
servomotor.
7.
Attach the cage to the motor with the mounting nut.
Disconnect the negative battery cable.
3.
To
install:
7.
12.
.
2.
install:
the
Install
screws
air inlet
servomotor, tighten the mounting
snug.
until
8.
Connect the linkage
9.
Attach the
air inlet
to the air inlet
servomotor.
servomotor harness.
the glove compartment door.
10.
Install
11.
Connect the negative battery cable.
system.
Servomotor
Air Mix
Rear Blower Resistor
REMOVAL REMOVAL & INSTALLATION
1
Land Cruiser 1.
2. 3.
To 4.
Remove
the right front seat.
Disconnect the resistor wiring harness.
Remove
the mounting screws
and the
resistor.
the resistor, then attach the harness wiring to the
Install
the front seat.
4Runner
EXCEPT
1996
Remove
Disconnect the wiring harness from the
4.
Disconnect the linkage from the
5.
Remove
3.
Remove
the instrument panel. air
mix servomotor wiring. air
mix servomotor.
the mounting screws and the air mix
servomotor.
6.
install: Install until
the air mix servomotor, tighten the mounting
snug.
7.
Connect the linkage
8.
Attach the Install
air
to the air
mix servomotor.
mix servomotor harness.
the instrument panel.
Connect the negative battery cable.
the console box.
Air Outlet
Servomotor
resistor.
the mounting screws from the resistor, then the
REMOVAL & INSTALLATION
resistor.
install: Install
the resistor, then attach the harness wirinq to the
Install
the console box.
unit.
5.
Disconnect the
MODELS
1.
4.
Remove
3.
9.
2.
To
Disconnect the negative battery cable.
screws
unit.
5.
.
2.
To
install: Install
& INSTALLATION
10.
1
.
Disconnect the negative battery cable.
2.
Remove
3.
Disconnect the
4.
Disconnect the linkage from the
the instrument lower finish panel. air outlet
servomotor wiring. air outlet
servomotor.
CHASSIS ELECTRICAL
6-26
Remove
5.
the mounting screws and the air outlet
To
Install
screws
until
the air outlet servomotor, tighten the mounting
and top
7.
Connect the linkage
to the air outlet
8.
Attach the
servomotor harness.
9.
Install
air outlet
servomotor.
or 2 minutes, but no more.
heater and check
iary
level in the radiator
the coolant as necessary.
off
Restart the engine and
20.
snug.
10.
1
Stop the engine. Inspect the coolant
19.
install:
6.
Set the heater temperature control to HOT. Start and run
18.
the engine for
servomotor.
warm
fully;
it
operate the auxil-
function. Inspect the
its
hose
joints for
leaks.
the instrument lower finish panel.
Check
21.
Connect the negative battery cable.
off
the coolant level
NOT
as necessary. Do
in
the overflow reservoir and top
remove the
radiator
cap on a hot
engine.
Rear Heater Unit
4Runner
See Figure 18
1
REMOVAL & INSTALLATION
Disconnect the negative battery cable.
.
2.
Drain the engine coolant.
3.
Set the heater temperature control to
4.
You
5.
Remove
will
away from
Land Cruiser
its
need
to
Disconnect the negative battery cable.
.
Set the temperature control valve to
4.
Remove
5.
Disconnect the hoses running to the auxiliary heater.
Remove Remove
to contain
drainage from the core
6.
Disconnect the wiring harness running to the
7.
Remove
unit.
desired.
if
Assemble the heater core and blower motor
unit.
Place the unit on the workbench.
into the
Attach the case halves.
.
the clips and screws securing the case halves. 12.
Separate the case. 1
Remove the core from the may be removed desired. To install: 9.
fan
case.
Install
the heater unit and
the retaining hardware.
install
Attach the rear heater ducts and control assembly.
3.
The blower motor and 14.
Use new clamps and connect the heater hoses.
15.
Install
if
Place the core
10. tion
fan and motor
case. 1 1
Remove
unit.
the retaining bolts holding the unit to the vehi-
remove the heater
8.
the retaining hardware securing the heater unit
Remove the blower To install: 10.
cle;
unit.
Separate the case halves and remove the heater core.
9.
Have a pan and rags handy
it
the rear heater ducts and control assembly.
and remove the
and hoses.
lifting
gained.
7. 8.
the right front seat.
is
Disconnect the hoses from the auxiliary heater
COOL.
3.
careful
6.
Drain the engine coolant.
2.
Be
the rear center console box.
mountings; disconnect the wiring harness from
the rear controls as soon as access 1
COOL.
up the carpet on some models.
lift
and supports are
into the case, in
the console
making certain the
place. Install the blower fan
if
it
17.
Set the heater temperature control to HOT. Start and run
was
18.
and
the unit into the vehicle.
Make
outlet pipes are correctly placed in the
certain the inlet
grommets. Tighten
or 2 minutes, but no more.
off
level in the radiator
the coolant as necessary.
Restart the engine and
19. iary
1
Stop the engine. Inspect the coolant
and top
the retaining screws. 13.
position.
Fill
the engine for
Install
its final
the cooling system.
16.
Assemble the case halves.
12.
in
insula-
removed. 11.
the console, connecting the wiring harness before is
heater and check
its
warm
it
fully;
operate the auxil-
function. Inspect the
hose
joints for
Connect the wiring harness. leaks.
new clamps.
14.
Install
the hoses, using
15.
Install
the right front seat.
20. off
16.
Connect the negative battery cable.
17.
Fill
Check the coolant
as necessary. Do
engine. the cooling system.
level in the overflow reservoir
NOT
remove the
radiator
and top
cap on a hot
CHASSIS ELECTRICAL
6-27
CHASSIS ELECTRICAL
6-28
CRUISE CONTROL sure the ignition switch
System Diagnosis
OFF. Check
is
that the
normal code
displayed after connecting the fuse.
INDICATOR CHECK Ei
Turn the tor light
ON. Check
ignition switch
comes on when
is
turned
CRUISE
indica-
the cruise control main switch
turned on, and that the indicator switch
that the
turns off
light
when
Tc
-
is
the main
off.
DIAGNOSTIC TROUBLE CODES (DTC)
If
a malfunction occurs
driving, the
CRUISE
ECM
in
the system during cruise control
Fig.
19 Tc and El terminal locations
the
in
DLC1
cancels the cruise control, and blinks the
indicator light 5 times to inform the driver of a mal-
same
function. At the
memory as a
time, the malfunction
is
stored
the
in
Normal code diagnostic trouble code.
Reading Codes I
See Figures 1.
Turn the
2.
Using
connect
19,
20 and 21
ignition switch
ON.
SST 09843-18020 or an equivalent jumper wire, terminals TC and El of the DLC1. The DLC1 is lo-
cated under the hood next to the fusebox. 3.
Read
the diagnostic trouble code on the
tor light. Write the
codes down and compare them
Turn the
5.
Disconnect the jumper wire.
ignition
Malfunction codes It and 21 0.5 sec 0.5 sec
indica-
to the chart.
OFF.
4.
Clearing
CRUISE
Codes
After completing repairs, the diagnostic
by removing the
ECM-B
code can be cleared
fuse for 10 seconds or more.
86826g46
Make Fig.
20 Blink pattern examples for normal system and
codes
11
and 21
CRUISE MAIN
Indicator Light Blinking Pattern
Code No. -
11
Diagnosis
“fJUITUUUUUUL
Normal
o
e Duty ratio of 100% output to motor acceleration side e Overcurrent (short) in motor circuit.
o
12
o o
13
SUUUUL
21
o o
•23
o o
s
• Overcurrent (short) in magnet clutch circuit, e Open in magnet clutch circuit. e
6E3931
s
Open
in actuator
motor
circuit,
e Position sensor detects abnormal voltage, e Position sensor signal value does not change when the motor operates. e Speed signal
is
not input to the Cruise Control
juuuifuin_
32
srF
34
otfJUITLJUL
e Voltage abnormality in control switch circuit.
oz o5
•
41
ECU.
e Actual vehicle speed has dropped by 16 km/h (10 mph)or more below the set speed during crusing
p=]
• Short
When
in
control switch circuit.
41 code
control
is
indicated, replace the cruise
ECU. 86826g47
Fig. 21
Cruise control diagnostic codes
is
CHASSIS ELECTRICAL \
Components I
See Figure 22
Main Switch
DLC1
86826 g€l
Fig.
22
Common
cruise control
component locations
— T1 00 shown
6-29
CHASSIS ELECTRICAL
6-30 TESTING
Check continuity between terminals 3 and
Cruise Control Main Switch
Control Switch Position
T100
Condition
OFF
t See Figures 23 and 24
ON
1 Unplug the switch connector. It may be necessary to remove the steering column covers for access. 2. Check for continuity between terminals 3 and 5 with the switch both on and off. 3. Next, measure the resistance between terminals 3 and
No
(pushed)
Control Switch Position
OFF
in
the
0
98
0
Approx. 418
0
Approx.
CANCEL the switch did not perform as indicated
(No continuity) Approx. 60
SET / COAST
4.
0
Resistance
See Figures
^Testing
and 32
31
performed from the back of the combination
is
meter assembly. Unplug connector
1.
C
from the combination meter, then
inspect the connector on the wire harness side. 2.
there continuity between terminal
Is
not, there is Tester connection
Switch position
CIO
terminal Switch pin free (Brake
-
an open
circuit in
of the
combination meter and ground or there
2
Continuity
a ground
3-4
Continuity
the connector from the cruise control
1
CIO and ground?
If
the wire harness between
Specified condition is
fault.
pedal depressed)
Engage connector A
3.
Switch pin pushed
in
of the
combination meter. Unplug
ECM,
then inspect the
(Brake pedal released)
connector on the wire harness side. 86826g54
4.
If
there
is
continuity repeatedly
ground, replace the cruise control
between terminal 20 and
ECM, then recheck
the
system. 5. in
If
there
and CIO Fig.
28
On Land
Cruiser,
check
for continuity
between
the terminals indicated
is
no continuity, there
is
an open or short
the wire harness between terminals 20 of the cruise
short
in
terminal
of the
combination meter. Or, there
is
circuit
ECM
an open or
the circuit plate of the combination meter between
CIO and
the
speed sensor.
Actuator
LAND CRUISER f
See Figures
To check the actuator magnetic clutch: Check that the arm moves smoothly by hand.
1.
a.
Switch position
Tester connection
Switch pin free (Brake
and negative lead
2-4
Continuity
-
Continuity
Check
c.
in 1
3
to terminal 4.
Have the magnetic
arm does not move by hand
that the
86826g66
^WARNING Do not connect the wires to the wrong battery You will damage your cruise control actuator. 2.
29
On
illustration
T100, test the switch as indicated
at this
point.
(Brake pedal released)
Fig.
clutch
turned on.
pedal depressed)
Switch pin pushed
Attach the positive lead from the battery to terminal 5
b.
Specified condition
35 and 36
33, 34,
in
the
If
the operation
the actuator motor.
is
not as specified
in
terminals.
the test, replace
CHASSIS ELECTRICAL
6-32
Fig.
30 Connect the voltmeter and battery as shown to
test the
speed sensor
Fig.
33 Check to see that the actuator arm moves freely
w/o TACHOMETER M/T
A/T Connector *C*
Connector *D*
12
1110987654 32
Fig. 31
1
1098 7654
Connector *B*
8765432
3 21
Connector “A*
121110987664321
1
Connector "D*
1211 108 8
785432
Connector “C"
Connector *B*
1098 7854321
1
8
7664321
Connector *A*
121110987664321
Terminal locations on the T100 without a tachometer
w/ TACHOMETER M/T
Connector ’O'
11109878502'
-
Connector C’
109
8
765
4
32
Connector *B'
'
8 7 6
54
3
1
6
Connector *0"
Connector 'A'
1211 10 98
7
6
12
1 1
109876 54
3 2
Connector "B*
Connector *C"
1
10
9878543
2
1
87
6
643
21
Connector "A"
1211 10 9 8
7
6
5432
1
86828glz
Fig.
32 Terminal locations on the T100 with a tachometer
CHASSIS ELECTRICAL To check the operation
3.
6-33
of the motor:
With the magnetic clutch on, connect the positive lead
a.
from the battery to terminal
6,
then attach the negative lead
Check that the arm moves When the arm reached to the open
to terminal 7. b.
to the
open
position,
side.
check
that
the motor operation stops.
While the magnetic clutch
c.
is
on, attach the positive
lead from the battery terminal 7 and the negative lead to
Check
terminal 6.
see 4.
arm moves
that the
to the close side.
While the arm reaches the closed position, check to
d.
the motor operation stops.
if
To inspect a. Measure
the position sensor: the resistance between terminals
1
and 3
of
1.
the connection. Resistance should read approximately 2k
ohms.
When
b.
position,
the
check
arm to
is
moving from the closed
to the
open
see the resistance between terminals 2
and 3 increases from approximately 500-700 ohms.
T100 >
See Figure 37
To check the actuator magnetic clutch: Check that the arm moves smoothly by hand.
a.
Attach the positive lead from the battery to terminal 5
b.
and negative lead turned on.
Check
Have the magnetic clutch arm does not move by hand.
to terminal 4.
that the
l-t'CAUTION Do not connect the high tension cables to the wrong You will damage your cruise control
bat-
tery terminals.
actuator.
2.
If
the operation
is
not as specified
in
the test, replace
the actuator motor.
To check the operation
3.
a.
from the battery to terminal
6,
then attach the negative iead
Check that the arm moves When the arm reached to the open
to terminal 7. b.
of the motor:
With the magnetic clutch on, connect the positive lead
the motor operation stops.
to the
open side. check that
position,
CHASSIS ELECTRICAL
6-34
While the magnetic clutch
c.
on, attach the positive
is
lead from the battery terminal 7 and the negative lead to terminal 6.
Check
see
arm moves
to the close side. to
the motor operation stops.
if
To inspect Measure
4.
that the
While the arm reaches the closed position, check
d.
a.
the position sensor: the resistance between terminals
1
and 3
of
the connection. Resistance should read approximately 2k
ohms.
When
b.
position,
the
check
arm to
is
moving from the closed
to the
open
see the resistance between terminals 2
and 3 increases from approximately 500-800 ohms. Clutch Start Switch
See Figures 38 and 39 1
.
2.
Remove
the switch from the vehicle.
Check the
continuity of the switch as indicated
in
the
illustration. 3.
If
the switch does not operate as indicated, replace the
switch.
Tester connection
Switch position
Specified condition
Switch pin free (Clutch pedel
1
-
2
Continuity
depressed)
Switch pin pushed
in
(Clutch pedal
-
No
continuity
released) 86826g72
Fig.
39 Check that the switch operates as indicated
CHASSIS ELECTRICAL
6-35
ENTERTAINMENT SYSTEMS I
See Figure 40
is
disconnected from the
until
i-WARNING
useless
Never operate the radio without a speaker; severe damage If the speaker must be
to the output transistors will result.
replaced, use a speaker of the correct or the output transistors will be
impedance (ohms)
damaged and
require
replacement.
The
audio systems have an anti-theft system
a
3-digit
system unit,
code
is
into the unit.
If
is
installed, the anti-theft
after
power
is
restored after disconnection. Complete
instructions for installing the for the vehicle.
to the unit,
it
As
may be used
code are found
long as in
in
the owners
power remains connected Once power
the normal fashion.
the audio unit
unit,
re-entered. This is
no way
in
is
made
appears
in
the digital window.
the word
will
not function
render the unit
to retrieve the stored
code.
the vehicles owners manual.
during the procedure, the designation
HELP appears and
codes or power.
must be taken
All of
will
code may be canceled or changed following
an error
built into
inoperative; the audio unit functions as a normal
even
manual
no code
is
stolen; there
if
anti-theft
less of
them. The system requires the operator to select and program
code
an exact procedure explained
unit
Some
the correct
to a
If
Once 10
errors
the system
will
to
be
have occurred,
not work regard-
HELP message
the
Toyota dealer
If
ERR
appears, the
reset.
the units equipped with this system have the words
ANTI THEFT
SYSTEM
visible
on the
front of the unit, usually
on the tape player door. Care must be taken when working on these vehicles anytime the battery cable must be disconnected or
if
fuses are removed during other test procedures.
vehicle,
chances are good
installed);
if
its
that
you know the code
a friends vehicle, you could be
in
(if
If
its
your
one was
trouble.
Always check with the owner before beginning any work which
CHASSIS ELECTRICAL
6-36
could interrupt power to the audio
mation on your particular
For any further
unit.
infor-
To
see your owners manual.
unit,
and
Radio
install:
Loosely
6.
the unit into place and
fit
the unit into the dash and
7.
Fit
8.
Hold the large dash panel
9.
Install
install
the retaining screws.
in
place and engage the wir-
all
the clips at once and
each switch.
ing connectors to
REMOVAL & INSTALLATION
engage the antenna
electrical connections.
the trim by aligning
gently pushing each into place. Install the retaining screws.
•
10.
Excluding Land Cruiser 1.
If
audio unit carries the designation ANTI
SYSTEM, make
certain
security code.
the code
the unit 2.
1 1
If
THEFT
you or the vehicle owner knows the is
to
remove the heater
Remove
the bolts holding the audio unit to the dash.
Pull the unit out of the
move the radio To install:
with
system
lines
under or around the
Be unit.
in
Connect the negative battery cable. Turn the
ignition switch to
on and enter the security code
careful not to pinch Install
the retaining
2.
if
ACC one
or is
ON. Turn the radio required. Check the
for correct operation.
Dash mounted speakers can be accessed after removing the These panels are usually retained by screws and clips. Be sure you have removed all of the attachscrews before prying the panel from the dash. Do not use this will only lead to
ing bolts/screws, then pull the
unplug the
speaker from the dash and
electrical connection.
Door mounted speakers can be accessed
Remove the ashtray holder. Remove the 3 screws holding trim panel
Remove
the ash-
the lower instrument panel
Be sure you have removed
all
removing the
of the attaching
before prying the panel from the door.
purchased panel as
gently pried loose.
after
door panel. These panels are usually retained by screws and clips.
also held by six clips; each must be
is
damage.
the panel has been removed, loosen the speaker attach-
Door Mounted
Disconnect the negative battery cable.
The
trim.
at-
appropriate trim panel.
Once
Land Cruiser
tray.
the negative battery cable before
tempting to remove the speakers.
place; connect
the heater control assembly.
9.
.
for this
this will
purpose.
Do
only lead to
A
screws
special tool can
be
not use excessive force on the
damage. Once the panel has
been removed, loosen the speaker attaching bolts/screws, then pull
''-•'WARNING
the speaker from
its
mount and unplug the
electrical
connection.
The
trim panel is long
and
thin;
it
is
easily broken by
Rear Speakers
rough handling.
Removing the 3.
Once
the panel
is
loose, unplug the wiring connectors to
the switches and remove the panel from the area. 4.
Remove
5.
Pull the unit
outward enough
to allow
access
Remove
the radio unit.
cedure as the panel, then
the screws holding the audio unit to the dash. to the
sides and back. Unplug the antenna cable and the electrical
connectors.
-
for correct operation.
excessive force on the panel as
8.
1
is
REMOVAL & INSTALLATION
ing
system
one
-
ON. Turn the radio required. Check the
Speakers
screws. Install
or
Dash Mounted
the unit gently into position.
any wires or
7.
if
ACC
bracket.
its
the audio unit and bracket loosely
Work
on and enter the security code
^Always disconnect
the antenna and wiring connectors. 6.
ignition switch to
lower dash enough to allow access to
Unplug the antenna cable and wiring connectors. Re-
Fit
Connect the negative battery cable. Turn the
in this
the rear and sides.
5.
s
not operate.
will
On some models you may need
section.
4.
the ashtray holder and ashtray.
not re-entered after installation,
control assembly, Following the procedures given earlier
3.
.
12.
Install
rear speakers involves basically the
front speakers.
Remove
remove the speaker. The
same
pro-
the appropriate trim
rear speakers
models can be accessed from inside the rear hatch.
on some
|
CHASSIS ELECTRICAL
6-37
WINDSHIELD WIPERS AND WASHERS Windshield Wiper Blade
REMOVAL & INSTALLATION (Wiper 1
blade element replacement
is
covered
in
Section
.
Toyota has two types
and the
of
wiper blades. The screw-on type
clip-on type.
To remove the windshield.
blade-to-wiper
clip-on type,
lift
up the wiper arm from the 2.
up on the spring release tab on the wiper
Lift
arm connector, then
pull
the blade assembly
off
the wiper arm.
To remove the screw-on type, lift up the wiper arm from the Loosen and remove the two screws retaining the
windshield.
blade to the arm, then
lift
the blade assembly off the wiper
86826pll
arm.
42 Loosen and remove the retaining nut
Fig.
Windshield Wiper
Arm
To
install: Install
REMOVAL & INSTALLATION
Make
sure
blade
will
it
arm by placing the arm onto the linkage
the is
seated correctly;
if
slap the bodywork at the top or bottom of
Tighten the nut to approximately 15 I
See Figures 1
41
and 42
access the
nut.
With the arm
upward and
off
it
ft.
lbs.
its
stroke.
(20 Nm).
If
There may be a cover over the
the nut which secures
shaft.
not correctly aligned, the
in
the
nut,
remove
down
position,
this to
unscrew
to the pivot. Carefully pull the
arm
the pivot.
one wiper arm does not move when turned on or only a little bit, check the retaining nut at the bottom of the arm. The extra effort of moving snow or wet leaves off the glass can cause the nut to come loose the pivot will move without moving the arm.
moves
—
Windshield Wiper Motor
REMOVAL & INSTALLATION I See Figures 43, 44, 45 and 46
The wiper motor secured 1
located
Gently pry the wiper
Remove
3.
4.
the engine compartment and
link it
from the crank arm.
may be
Fig. 41
Remove
the cover concealing the nut
Its
a
ball
tight.
the motor.
Connect the wiper arm Install
5. lbs. (6 6.
it
install:
linkage.
actly aligned with the ball before 86826pl0
is
firewall.
and socket arrangement, but
To
in
Disconnect the wiring from the wiper motor and unbolt
.
from the 2.
is
to the firewall.
The socket must be
ex-
snapping them together.
the motor, tighten the mounting nuts to 47 inch
Nm).
Attach the electrical lead.
CHASSIS ELECTRICAL
6-38
86826pl3
Fig. 43 Unplug the wiring harness from the motor assembly
Rear Wiper Motor
REMOVAL & INSTALLATION 4Runner
TOP MOUNTED I
See Figure 47 1
.
2.
10.
Make certain the ignition switch is OFF. Pop up the acorn nut cover, remove the
and
nut
pull off
the rear wiper.
86826pl4
3.
Remove
4.
Inside,
Remove
44
from the
the bolts securing the wiper motor
firewall
pop out the
tailgate,
clips
and remove
the wiper motor cover. 5.
Fig.
the pivot nut.
above the
Disconnect the
move the mounting To install:
electrical lead
bolts
and
lift
and the washer hose,
and
the mounting bolts.
6.
Position the wiper motor
7.
Connect the lead and the washer hose.
8.
Position the wiper motor cover over the opening
press 9.
in
install
and
the retaining clips.
Install
the pivot nut and tighten
Install
the wiper
inch lbs.
re-
out the wiper motor.
Snap
arm and
it
to
8
ft.
lbs.
(1 1
tighten the acorn nut to
Nm).
48
the cover down.
BOTTOM MOUNTED I See Figures 48 and 49 1.
Remove
2.
Separate the weatherstrip from the door, then remove
the back door trim, plate and door glass run.
the rear glass.
86826pl5
Fig.
45 Pull the motor from the firewall, then using a
prybar
.
.
3.
Remove
4.
Disconnect the wiring harness from the motor.
5.
Remove
6.
Loosen the wiper motor seat
the rear wiper arm.
the nut securing the packing holder.
assembly. 7.
To
Remove
the washer nozzle.
install:
.
8.
Install
the washer nozzle.
bolts,
then the motor
CHASSIS ELECTRICAL
N
m
(kgfcm,
ft
lbf)
:
6-39
Specified torque 86826g97
Fig.
48 Bottom mounted rear wiper system
CHASSIS ELECTRICAL
6-40 9.
Tighten the wiper motor bolts, then
install
sembly. Tighten the motor bolts to 48 inch 10.
Install
the motor as-
lbs. (5
the packing holder and nut, tighten to 48 inch
lbs.
Nm).
(5
1 1
.
12.
Attach the harness to the motor. Install
the wiper
When
illustration.
Fig.
slider 0.39
turning slide, then tighten the wiper
on the block as shown
Tighten to 48 inch
Install
push the
lbs. (5
in
in.
arm
Nm).
trim.
in.
(10mm) towards the arm set nut
Land Cruiser 1.
Insure the ignition switch
2.
On some models you If
4.
Lift
5.
is
OFF.
need
to
remove the
remove the backdoor
Remove arm
remove
and remove the wiper arm.
the large nut on the wiper motor axle (the part
bolts to).
Disconnect the wiper motor wire harness.
7.
Remove
the retaining bolts holding the motor and re-
the motor. Don’t
bend or damage nearby linkages or
components. 8.
Unbolt the wiper control relay, then disconnect the
harness. 9.
Reassemble
in
reverse order.
Wiper Linkage
REMOVAL & INSTALLATION > See Figures 50, 51, 52 and 53 1
han-
trim.
6.
move
pull
the cover at the base of the rear wiper arm,
the retaining nut
that the
will
handle bezel.
presents,
3.
Remove
To 5.
Unclamp the
down
grilles that
into the
body
the wiper motor.
cover the linkage, then push the
cavity. Pull the linkage out of the
motor hole.
install:
Insert the wiper linkage through the hole
Press the wiper arm onto
retaining nuts. 7.
49 Push the slider 0.39
pull
shafts
6.
the back door glass, outer weatherstrip, glass run,
and door
and
the nuts/bolts and spacers holding the wiper
and
install
nuts and spacers.
the
turning slide, then tighten the wiper
dle
their retaining nuts
off their shafts.
cavity through the wiper
off.
tightening the rear arm,
(10mm) towards the
plate
Remove
3.
4.
arm and operate the wiper once, then
set nut with the step liner
14.
Separate the wiper arms by removing
shafts.
turn the wiper switch 13.
2.
and working them
Nm).
Install
the wiper motor.
their shafts
and
install
the
the
CHASSIS ELECTRICAL Washer
6-41
Fluid Reservoir
REMOVAL & INSTALLATION I See Figures 54 and 55 1
Unbolt the washer reservoir from the upper radiator
.
support. 2.
Lift
the unit from the engine compartment, then slide the
hose from the
Unhook
3.
unit.
the wiring harness for the
pump
from the side of
the reservoir.
Disconnect the wiring harness from the pump, then
4.
move
the
pump
grommet that the pump To install: Install
5. is
in
good
6.
pump
Fig.
53 Exploded view of the front wiper linkage
the
re-
from the reservoir. Check the condition of the
pump
sits into.
into the reservoir,
ensure the grommet
condition.
Attach the wiring to the pump, then run the hose for the
along the side of the reservoir.
CHASSIS ELECTRICAL
6-42
Unhook
2.
the wiring harness for the
pump
from the side of
the reservoir.
Disconnect the wiring harness form the pump, then
3.
move
grommet
To
re-
from the reservoir. Check the condition of the
that the
pump
sits into.
install: Install
4. is in
pump
the
good
5.
pump 6.
the
pump
into the reservoir,
ensure the grommet
condition.
Attach the wiring to the pump, then run the hose for the
along the side of the reservoir.
Seat the reservoir
into the
engine compartment. Secure
with the mounting bolt.
86826p20
Fig.
54 Unbolt the reservoir bracket from the upper
radiator support
86826p22
Fig-
56 Unhook the wiring harness for the
pump from
the side of the reservoir
86826p21
Fig.
55
7.
the unit from the engine compartment, then hose from the unit
Lift
slide the
Seat the reservoir
into the
engine compartment, secure
with the mounting bolt.
Washer Pump REMOVAL & INSTALLATION >
See Figures
56, 57, 58, 59,
60 and 61 86826p23
1.
Remove
the washer reservoir from the vehicle. Fig.
57 Disconnect the wiring harness form the pump, pump from the reservoir
then remove the
CHASSIS ELECTRICAL
6-43
86826p26 86826p28
Remove
58
Fig.
the bolts retaining the
pump
to the
60 Remove the hose from the
Fig.
reservoir
pump
86826p29 86826p27
Remove
Fig. 61
59 Pull the
Fig.
pump from
the
grommet
the
grommet and screen, then inspect
for deterioration
INSTRUMENTS AND SWITCHES To keep our terms
straight, we’ll
use Toyotas names
for
various dash components.
The instrument panel
may
runs completely across the front of
is
what you
When
disassembling components, always suspect the hidden
screw or
Much
clip.
of the
and
fit
finish in the interior is
accomplished by using concealed retainers
to
the vehicle.
place. Don’t force anything during removal;
if
surface
felt,
the dashboard;
call
it
The instrument panel is covered with a soft vinyl called the safety pad. The safety pad is the part you
see; the instrument panel
is
the framework under
instruments and warning lamps tained
it.
All
the
the driver are con-
sometimes called the gauge The combination meter is removed
the combination meter,
in
set or instrument cluster.
as a
in front of
numbered components use a numbering system with item 1 on the left side of the vehicle. Knowing how many numbered components there are can be helpful, too. For example, heater ducts Nos. 1 2 and 3, must be removed, its a if
,
to
bet that No. 2
Nos.
right of
1
assemble only
and
2,
is
in
the center.
If
one may be on the
the passenger compartment.
the procedure only refers left
side and 2 on the
in
Some
each
into
in is
of the panels
the correct order; pay attention.
which bolts and screws go
retainer;
Take note
of
a too-long bolt
can damage wiring or components behind the assembly being held. Finally,
unit.
Generally,
fair
search out the hidden connector.
keep panels
any resistance
and each
understand that
carefully
so as not
electrical
plastic
this
to
is
a lengthy project. Work slowly
damage
connector as
it
is
anything. Label or
disconnected;
many
mark of the
connector shells can be marked with an indelible laun-
dry pen or similar marker.
As a panel
moved, disconnect the wiring running nents held by the panel.
Be
or to
component
is
re-
switches or compo-
careful working
around wires and
CHASSIS ELECTRICAL
6-44
harnesses; most are held by retainers and do not allow a
lot
of slack.
Instrument Cluster
Disable the
Disconnect the negative battery cable.
3.
Remove Remove
the steering wheel.
Remove
the retainers securing the lower finish panel,
4.
'
SRS
1.
2.
system.
the cowl side trim and the front door scuff
plate. 5.
REMOVAL
& INSTALLATION
then remove the hood and fuel tank release lever screws.
Pick-Up and 4Runner 1989-95 1
MODELS
Remove Remove Remove
2. 3. 4.
it
Its
held
the lower center instrument panel cover.
1
lower finish panel; this
is
the panel
speaker and running under the steering
left
heater control knobs, remove the A/C switch
equipped and gently pry up on the heater control it.
The
For
transmissions, Pull the trim or
connectors.
Attach the No. 2 and No.
13.
Install
the ignition switch bezel.
14.
Install
the lower finish panel, then attach the hood and
Install
the cowl side trim and the front door scuff plate.
16.
Install
the steering wheel.
17.
Connect the negative battery cable.
Tacoma
•--{-CAUTION
remove the 3 screws holding the meter trim. surround panel outward and disconnect the
On 4Runner, remove
Your vehicle may contain an air bag system. Read the procedure in this section of how to disarm the system before proceeding.
the two screws and the cup
For Pick-Ups with 4 speed manual transmissions, the
12.
held only by two screws. Disconnect the connectors
is
and remove the 13. 14.
Work
Remove Remove it
3.
Remove Remove
Its
held by 2 screws.
the four screws holding the combination meter.
out of the panel
Remove
location out of the
until
access
is
gained to the
the meter assembly, placing
it
rear.
in
install;
15.
Install
the lower center instrument panel cover.
16.
Install
the cowl side trim (kick panels).
17.
Attach the hood release and bracket.
18.
Install
the steering column covers. the steering wheel.
19.
Install
20.
Connect the negative battery cable.
21.
Start the engine, allowing
to idle.
lock release lever
Fuse box cover
Remove Remove
6.
the lower
hand
finish panel.
Ignition switch bezel
b.
No. 2 heater-to-register Steering column
7.
Remove
8.
With the aid of a flat-bladded
the cup holder and the heater control knobs. tool,
remove the heater
control panel.
10.
Check the
function of
all switches, heater and A/C and dashboard warning lamps and
instruments.
Disconnect the hazard harness.
Remove
the mounting screws for the center cluster finish
panel. 1 1
.
12.
13.
Detach the heater control assembly.
Remove Remove
the radio. the screws mounting the cluster finish panel,
MODELS
then lower the panel.
-•-CAUTION
ometer cable.
14.
15.
Your vehicle may contain an air bag system. Read the procedure in this section of how to disarm the system before proceeding.
left
the following parts;
a.
c.
each dash component including output, speaker operation
Hood
Combination switch
9.
it
the following:
Steering column cover
c.
d.
a safe
the steering wheel.
b.
5.
work area.
To
1996
Disconnect the negative battery cable.
a.
air outlet.
system.
Disable the
trim panel.
the No.1
SRS
1.
2.
4.
Disconnect the speedometer cable and remove the electrical connectors.
heater-to-register duct.
15.
holder from the panel.
trim
1
tank release lever.
unit to
models except Pick-Ups with 4 speed manual
all
Tighten the cluster finish panel.
12.
prying tool should have a taped or protected
edge. 11.
11.
the heater duct to No. 2 outlet.
Pull off the
remove
from the
to the vehicle.
fuel
the ignition key cylinder cover.
column.
if
it
Attach the harness to the combination meter, then attach
the hood release lever from the panel.
Detach the No.
Remove
the screws securing the meter, then remove
install:
8.
9.
Disconnect, the harness for the combination meter. Re-
To
Remove Remove
10.
9.
heater-to-register duct.
1
the cluster finish panel, then remove.
10.
as the kick panel.
holding the
Remove
the upper and lower steering column covers.
7.
6.
8.
the ignition switch bezel.
the steering wheel.
Separate the cowl side trim on each side. You might
refer to
Detach the No. 2 and No.
vehicle.
by two screws. 5.
Remove
7.
move
Disconnect the negative battery cable.
.
6.
To 1
6.
Remove
the combination meter screws and the speed-
Disconnect the harness. install:
Attach the harness to the combination meter.
CHASSIS ELECTRICAL
6-45
g.
17.
Install
the speedometer cable, then the combination
18.
Install
the cluster finish panel. the radio.
19.
Install
Place the heater control assembly
21
Reinstall the
ish
mounting screws
in
the dash.
for the center cluster fin-
Install
15.
Attach, then tighten the front door scuff plate
Place the heater control panel
24.
Install
25.
Reattach the following parts:
the cup holder and the heater control knobs.
Connect the negative battery cable.
1989-90 1
Ignition switch bezel
b.
No. 2 heater-to-register
2.
c.
Steering column
3.
26.
Tighten the lower
27.
Install
left
hand
finish panel.
Disconnect the negative battery cable.
.
Remove Remove
the steering wheel.
the Nos. 2 and 3
Disconnect the
4.
the following:
Hood
MODELS
and
lock release lever
Combination switch
6.
Fuse box cover the steering wheel, then connect the negative bat-
fuel
8.
Remove
Remove
the heater control lever knobs.
Remove
the five screws and two clips holding the center
the ash
Remove
the panel and disconnect the
before proceeding.
9.
SRS
system.
Disconnect the negative battery cable.
3.
Remove
the front
pillar
12.
garnish. it
Unscrew the
door scuff plate and the cowl side
front
trims.
Remove Remove
6.
the steering wheel. the following:
puter
14.
Steering column cover
b.
Disconnect the hood lock release lever
c.
Detach the No.
Remove Remove
d. e.
g.
15.
the four screws holding the glove box;
Remove
remove
remove the glove box.
the mounting bolt holding the EFI computer; pul!
in
a very safe location out of the work area.
Remove
air
ducts Nos.
1,
3 and
4;
each
is
held by a
remove only the lower screw and
At the side defrosters,
finish
Remove
the four screws and four nuts holding the safety
16.
Remove
17.
Disconnect the
the glove box door
panel
switch, the
center panel 18.
retaining the center cluster finish 19.
panel, then detach the harness from the unit.
Remove Remove
Remove
pad. Loosen two clips and remove the pad.
the combination switch
Remove the lower Remove the screws
the courtesy
disconnect the defroster hose.
lower finish panel
Detach the No. 2 lower
f.
Remove
single screw.
a.
1
the glove box door.
light.
out gently and disconnect the wire harness. Place the com-
13.
5.
the radio.
the latch striker and
2.
4.
Remove Remove
switch and 11.
Disable the
the seven screws holding the instrument cluster Loosen the panel, disconnect the wiring and un-
hook the speedometer cable. 10.
.
Remove
trim panel.
Your vehicle may contain an air bag system. Read the procedure in this section of how to disarm the system
the heater control panel. electrical
dimmer and
Remove Remove
4WD
the fuse box;
connectors at the mirror control
control. its
held by two screws.
the two upper side mounting bolts holding the
steering column.
the stereo opening cover.
is held by 15 bolts. Once move the panel towards the rear of the Once removed, the various components to remove desired. the panel may be removed To install:
20.
the screws securing the meter, then
remove the
combination meter from the dash.
The instrument panel
are removed, it.
To
opener
lid
wiring harnesses.
'•-•'CAUTION
9.
and remove the cable.
and the
lever
tray. 7.
T100
8.
set nut
lever.
instrument finish panel.
7.
cable from the accelerator pedal
throttle
Remove the cable Remove the hood release
retainer.
5.
tery cable.
1
These are above
air ducts.
the drivers knees under the dash.
a. Steering column cover
Install
garnish into position and tighten the
Land Cruiser
the dash.
in
a.
28.
pillar
the harness for the hazard switch.
Install
23.
c.
Place the front
16.
17.
22.
d.
and the
screws.
panel and tighten.
b.
the steering wheel.
14.
cowl side trims.
20. .
the lower center panel
Install
meter.
install:
the bolts vehicle still
on
if
10.
Tighten the combination meter into place.
11.
Attach the stereo opening cover.
12.
Attach the cluster harness, then
21. install
and
tighten the Fit
screws that
Assemble the instrument panel
retain the center cluster finish panel.
retaining bolts. 13.
Install
the following:
a.
Steering column cover
b.
Install
c.
Attach the No.
d.
Install
the combination switch
e.
Install
the glove box door
the
hood
f.
Install
the No. 2 lower finish panel
Make
certain the panel
is
flush
and
level.
The
Make
any needed adjustments now. 22.
lower finish panel
any items removed.
heater vent ducts must match up exactly with no leaks.
lock release lever 1
with
the panel into place, connect the wiring and secure the
Install
the upper side mounting bolts holding the steering
column. the fuse box and cover.
23.
Install
24.
Connect the mirror
4WD
switch connectors.
control switch, the
dimmer and the
CHASSIS ELECTRICAL
6-46
Connect the cables and install the heater controls. Install the safety pad, making sure the clips are properly
25. 26.
seated and that the piece
Connect the side defroster hoses
27.
to the grilles
and
install
the lower screws.
Attach the Nos.
1, 3,
and 4
air
29.
Connect the harness
to the
EFI computer and
Make sure
30.
Install
and
light
the harness
ducts. install
striker.
the
firmly.
Connect the switch and
the glove box door.
the radio.
31.
Install
32.
Place the instrument
panel
finish
speedometer cable and the
electrical
in
place.
harnesses.
Connect the Install
33.
Install
the
the center lower trim panel, connecting the wiring Install
the ash tray and
install
position.
Connect the
Make
the meter
unit.
Make
Install
the cluster trim panel.
Install
the lower center trim panel.
sure the clips are
in
place. 17.
All six clips
must be
correctly seated. Install the retaining screws. 18.
Install
the ashtray holder and the ashtray.
19.
Install
the turn signal bracket and the combination
switch.
panel and the retaining screws.
as needed.
in
wiring connectors.
sure the electrical connectors are squarely and firmly seated.
16.
connected squarely and
is
and
the glove box
install
Place the combination meter
Install
28.
unit.
install:
speedometer cable and attach the
aligns perfectly.
is
To 15.
the heater control
20.
Connect the heater duct
21.
Install
22.
Attach the hood and fuel door levers.
23.
Install
to air outlet
No.
2.
the lower trim panel and the 4 screws.
the steering column covers.
Install
the steering
wheel.
knobs. the hood release and fuel door levers.
24.
Remove
25.
Connect the negative battery cable.
26.
Start the engine, allowing
the protective tape from the windshield
34.
Install
35.
Connect the
36.
Attach the Nos. 2 and 3
37.
Install
the steering column covers.
each dash component including
38.
Install
the steering wheel.
output, speaker operation
39.
Connect the negative battery cable.
40.
Start the engine, allowing
throttle
cable to the accelerator pedal. air ducts.
each dash component including output,
it
to idle.
to idle.
all
Check the
function of
switches, heater and A/C
and dashboard warning lamps and
instruments.
Check
the function of
1996
A/C speaker operation and dashboard warning lamps and all
it
pillars.
switches, heater and
MODELS
**CAUTION
instruments.
1991-95
Your vehicle may contain an air bag system. Read the procedure in this section of how to disarm the system
MODELS
before proceeding.
'CAUTION Your vehicle may contain an air bag system. Read the procedure in this section of how to disarm the system
1.
Disable the
2.
Disconnect the negative battery cable.
before proceeding.
3.
Remove
4.
Apply
SRS
system.
windshield
1.
Disable the
2.
Disconnect the negative battery cable.
5.
3.
Remove
6.
4.
Apply
windshield
strips of protective
pillar.
Remove Remove
5.
the steering wheel.
This
will
tape on the inside of each
protect the trim during removal.
8.
the upper and lower steering column covers.
system.
the steering wheel.
strips of protective
pillar.
Remove Remove Remove Remove
7.
SRS
This
will
tape on the inside of each
protect the trim during removal.
the upper and lower steering column covers. the hood release and fuel door release levers. the fuse box opening cover. the retaining screws for the lower trim panel
below the steering column.
Remove
7.
the hood release and fuel door release levers. Unscrew the lower trim panel below the steering column.
10.
Disconnect the No. 2 heater-to-register duct.
8.
Remove
1 1
Loosen the screws and remove the fuse
6.
(No. 2).
left dash outlet one under the dash, above the drivers
the heater duct running to the
The duct
is
the
knees. 9.
Remove
the combination switch from the steering col-
umn. The combination switch
is
umn; 1 1
.
12.
Remove its
the ashtray and
remove the ashtray
13.
trim.
Remove
14.
Remove
six clips
the instrument cluster trim;
screws and two
Remove
14.
Detach the cluster
Remove
Remove Remove
17.
which must be
18.
finish panel,
then the combination
the center cluster finish panel assembly with the
off
the 2 claws,
the ashtray. the center cluster finish panel with the heater
control assembly, then disconnect the harness. it
is
held by six
unhook the speedometer cable. Place the instrument
Remove
19.
the screws retaining the heater control assem-
bly from the center cluster finish panel.
disconnect the electrical harnesses and
a safe location out of the work area.
the steering column.
With the aid of a taped prytool, take
16.
the four screws holding the combination meter it;
13.
block.
finish panel.
then remove the cup holder hole cover.
holder.
clips.
and gently loosen
Detach the No. 2 center cluster
clock attached.
the three screws holding the lower instrument
The trim panel is held by released to remove the panel.
panel
12.
15.
the turn signal bracket from the steering col-
the piece just below the combination switch.
Remove Remove
.
the lower instrument panel.
meter.
the lighting control/turn sig-
nal/wiper control assembly. 10.
9.
cluster
in
Remove
20.
the following:
a.
Radio
b.
Glove compartment door
c.
Speaker panel
d.
Speaker
CHASSIS ELECTRICAL e.
Front console box
f.
Rear console box
Combination Switch
Loosen and remove the 5 screws and 9
21.
bolts holding
the instrument panel.
Remove
22.
the No.
To
1
REMOVAL & INSTALLATION
the lower instrument panel reinforcement, then
brace and the instrument panel. I
install:
23. Attach the No.
1
The
Tighten the 5 screws and 9 bolts holding the instrument
25.
Install
Radio
Glove compartment door
c.
Speaker panel
d.
Speaker
1
Connect the harness
to the heater control, then attach
Place the cup holder hole cover
pad and remove the steering
column so the wheel can be
Remove
5.
the center cluster finish panel assembly with the
place
the combination meter.
Install
32.
Attach the cluster finish panel.
33.
Install
34.
Attach the No. 2 center cluster finish panel.
it
the combination switch from the column and
air bag harness (if equipped). newer models, you will be able to remove the
Disconnect the
7.
On
the
each wire color running from the switch
tify
Install
the fuse block.
Insert
and attach the No. 2 heater-to-register duct. and tighten down the lower instrument panel.
Place the lower trim panel below the steering column,
These wires
(only) will
new ones can be installed. On all but 1989-90 Land
the
9.
of the
10.
into position,
then tighten
down
the hood release
be replaced)
(to
to
be removed so
to
Cruiser, the cover
on the back
connector must be raised to allow the wire terminal to
new
Diagram each wire and terminal wiring
must be
installed exactly
door release levers.
Attach the upper and lower steering column covers.
42.
Install
43.
Connect the negative battery cable.
lug
and the wire and
tool
the steering wheel.
dure 1 1
for .
pull
Speedometer, Tachometer and Gauges
stalk
To
terminal. Pry
down
See Figure 62
each wire from the switch
With the wires
the locking lug with the
free,
to
remove the
changed and remove has a spring and small ball with
cluster from the dashboard.
the printed circuit board from the back of the
can be done by removing any attaching screws
Remove
5.
Installation
the is
screws holding
retaining
The
it.
it;
lighting control
don’t lose them.
screws should be
13.
the lens covering the gauges.
4.
be replaced.
install:
Track the new wires
wire loosely
and by removing the bulbs from the
front
Assemble the new component(s) onto the switch. Retaintight enough to hold but not over tight. Components with cracked plastic won’t stay in place. ing
gauge
From the
between the locking
12.
REMOVAL & INSTALLATION
the
original.
the terminal out from the rear. Repeat the proce-
the switch to be
Remove Remove Remove
be removed. The
to
as
or plug end, insert a small pick or probe
41.
3.
need
be removed.
Attach the fuse box opening cover.
cluster. This
ect.) to replace.
Otherwise, identify the component to be replaced. Iden-
the connector.
35.
1.
Remove
on the workbench.
6.
8.
the steering column.
36.
2.
reinstalled straight.
the upper and lower steering covers.
two mounting screws retaining the arm (wiper
then tighten.
>
strongly recom-
is
Trace the harness down the column, then unplug the
4.
into position.
31.
fuel
switched OFF.
is
the steering wheel
column.
clock attached.
and
re-
is
exacting,
is
connector. Release the harness from the harness clamp(s).
Reinstall the ashtray.
Place
but
the retaining screws holding the combination switch to the
29.
40.
difficult
a steering wheel puller
of
Remove
3.
Tighten the screws retaining the heater control assembly
28.
39.
Use
steering
the center cluster finish panel with the heater control assembly.
38.
combination assembly
not
is
It
mended. Always scribe matchmarks on the wheel hub and the
Rear console box
Install
Remove
wheel.
Front console box
Install
Insure the ignition
.
2.
to the center cluster finish panel.
37.
individual switches within the combination switch are
individually replaceable after the
connector.
b.
f.
30.
and 65
requiring careful removal of wire terminals from the multi-pin
the following:
a.
e.
27.
63, 64
moved and disassembled.
panel.
26.
See Figures
brace and lower instrument panel, then
the instrument panel reinforcement. 24.
6-47
unit.
gauge attaching screws. the reverse of removal.
in
its
into the
harness and place each
correct terminal socket.
14. Use the removal (NOT on the wire) and
tool to
push on the back
of the terminal
force the terminal into the connector.
Each terminal must be pushed in until it overrides the locking Test each one by gently pulling the wire backwards;
lug.
it
should be positively locked 15.
Fit
in
place.
the combination switch assembly onto the steering
column and
install
the retaining screws.
Install
the upper and
lower steering column covers. 16.
Install
the wire harness into the clips and retainers; con-
nect the connectors. 17.
Align the rr^tchmarks
and pad.
and
reinstall the steering
wheel
6-48
CHASSIS ELECTRICAL
K(TACHOHETER)
V/O (TACHOMETER)
Fig.
62 Exploded view of the instrument cluster assembly
Combination Switch
Fig.
•
Light Control Switch
•
Headlight
Dimmer Switch
63 The switches are secured to the switch body with screws 5
CHASSIS ELECTRICAL
6-49
Speedometer Cable
REMOVAL & INSTALLATION See Figures 66 and 67
I
The speedometer cable connects a
rotating
gear within the
transmission to the dashboard speedometer/odometer assem-
The dashboard
bly.
of turns the
the cable and displays the information as miles per
hour and
total
Assuming
mileage.
that the transmission contains the correct
the vehicle, the accuracy of the
on in
86826ga6
number
unit interprets the
made by
and
condition
tire
gear
speedometer depends
for
primarily
diameter. Badly worn tires (too small
tire
diameter) or over-inflation (too large
diameter) can affect
in
the speedometer reading. Replacement tires of the incorrect Fig.
64 From the front or plug end, insert a small pick
or probe between the locking lug
and the wire terminal
overall diameter (such
as oversize snow
tires)
can also
affect
the readings. Generally, manufacturers state that speedometer/odometer
minus 10%
error of plus or
considered normal due to wear
is
and other variables. Stated another way, over a measured
mile course
1
anything between 0.9 and normal.
you plan
If
to
if
you drove the truck
and the odometer showed
miles, the error
1.1
is
considered
do any checking, always use a mea-
sured course such as mileposts on an Interstate highway or
Never use another truck
turnpike.
trucks inherent error
may
comparison; the other
for
further cloud your readings.
The speedometer cable can become dry or develop a kink its case. As turns, the ticking or light knocking noise makes can easily lead an owner to chase engine related
within
it
problems 86826ga8
in error.
If
such a noise
heard. Generally, the needle
the cable binds.
drivers shoulder at the
on
trates
>»The in until
it
18.
Turn the
each control
ignition switch
ON
and check the function
to
REMOVAL & INSTALLATION
unit
speedometer cable can cause
the cruise control system.
the
If
1
an
electrical pulse generator.
for the
meter and mileage
These
signal. Addi-
fuel injection control unit, the cruise control
.
Remove
the instrument cluster and disconnect the cable
speedometer.
On some models
it
may be
possible to
Some
found
to
be
disconnect the cable by reaching under the dash.
be removed and sent
to
an
nectors screw onto the back of the speedometer; others are
part of the radio. to
first.
and other components.
at the
facility for
in
the electric signals representing the speed of the truck
can be used by the
authorized
concen-
cables do not attach directly to the speedometer as-
may be used
tionally,
have
driver
speed symptoms, check the speedometer cable
Some
will
the back seat should look over the
of
Clock
defective the radio
each time
small and
cruise control exhibits intermittent surging or loss of set
item.
is
in
slightest bind in the
pulses
clock
which the noise
in
or deflect
driving.
sembly but rather
The
jump
speedometer while the
unpredictable behavior
overrides the locking lug
will
The needle motion may be very
hard to notice; a helper
65 Each terminal must be pushed
heard, carefully watch the
speedometer needle during the speed range is
Fig.
is
it
If
clock repair.
the clock
is
con-
held by plastic clips. 2.
Disconnect the other end
of the
the transmission extension housing jacket at the transmission end.
because
it
is
broken cable.
If
speedometer cable
and
pull
at
the cable from
its
you are replacing the cable
broken, don’t forget to remove both pieces of
CHASSIS ELECTRICAL
6-50
To
install:
Lubricate the
3.
lubricant,
and feed
new it
cable with graphite speedometer cable
Connect the cable
4.
cable jacket from the lower end.
into the
to the transmission, then to the
speedometer. Note that both ends
ends must
fit
properly
of the
cable are square; the
fittings.
Plug the electrical connector into the instrument cluster,
5.
and replace the
Fig.
the
in
cluster
if
it
was removed.
66 Unscrew the cable at the transmission to
remove
LIGHTING The replaceable bulb
Headlights
reflector are part of the
Headlights,
like
any other
broken filaments. The
lighting device,
front of
any truck
location for a lighting device since
it
is
is
can
fail
due
to
subject to impact,
—
all
life of the light. The front of the truck is also where good lighting is needed the most so its not uncommon to have to replace a headlight during the life of the vehicle.
and replaceable bulb
type.
beam
is
reflector
available
so
in
built
named because
and the lens
in
headlamps, the sealed beam
The sealed beam
includes almost
lamps found on vehicles
of
it
all
is
of the circular
by
far the
most
and rectangular
through the 1980s. The sealed includes the lamp (filament), the
one sealed
unit.
several sizes and shapes.
body
is
replaced, while the lens and
of the car. This
Sealed beams are
is
generally the
lighting
systems.
While the replaceable bulbs are more expensive than sealed
beams, they generally produce more and of
which shorten the
There are two general styles
newer technology. Using a small
the
found on wrap-around or “European”
style
the worst possible
extensive temperature change and severe vibration
common and
is
halogen bulb, only the lamp
better
light.
The
fixed
lenses and reflectors can be engineered to allow better frontal styling It
is
and better
light distribution for
a particular vehicle.
quite possible to replace a headlight of either type
without affecting the alignment (aim) of the
light.
Sealed beams
mount into a bracket (bucket) to which springs are attached. The adjusting screws control the position of the bucket which in
turn
back
aims the
light.
of the reflector.
Replaceable bulbs simply
The
separate adjusting screws.
lens
and
fit
into the
reflector unit are
aimed by
CHASSIS ELECTRICAL
6-51
Take a moment before disassembly to identify the large adscrews (generally two for each lamp, one above and
justing
one
and don’t change
at the side)
their settings.
With the exception of the oldest vehicles, sealed
beams
are
removed from the outside of the car. Start with the outer trim pieces and work your way in to the lamp and its retainer. Bulb type units are almost always replaced from under the hood.
REMOVAL & INSTALLATION Sealed
Beams
> See Figures 68, 69, 70, 71 and 72
-•'-•-CAUTION Most headlight retaining rings and trim bezels have very sharp edges. Wear gloves. Never pry or push on a headlamp;
1
.
2.
it
86826p30
can shatter suddenly.
Make sure
Fig.
the headlight switch
Loosen the parking and side
is
in
69 Remove the
grille
from the truck and set aside
the off position.
turn signal unit retaining
screws. Then remove the units unplugging the connectors. 3.
Next,
open the hood
Using a flat-bladded
and the 4.
The sealed beam
any
to the grille clips.
clips to release
them
grille.
either 2 or ing
access
to gain
push on the
tool,
is
4 small screws.
tools.
DO NOT
held
these screws before apply-
confuse the small retaining screws
with the larger aiming screws.
or adjustors for
place by a retainer and
in
Identify
There
will
be two aiming screws
6.
each lamp. (One adjustor controls the up/down
motion and the other controls the
left/right
motion.) Identify the
them during removal. If they are not disthe new headlamp will be in identical aim to the old
adjustors and avoid turbed,
one. 5.
Using a small screwdriver (preferably magnetic) and a
pair of taper-nose pliers
if
7.
necessary, remove the small screws
86826p3
Fig.
70
Remove
the headlight bezel which
is
secured by
screws in
the headlamp retainer.
into
unknown
DON’T drop
the screws; they vanish
locations.
^A
good kitchen or household magnet placed on the shank of the screwdriver will provide enough grip to hold the screw during removal.
Remove back
may be
the retainer and the headlamp
pulled free from
its
of the sealed
gently
mounts. Detach the connector from the
beam
unit
and remove the
unit
from the
car.
-•-•-CAUTION The
To
Fig.
68 After removing the parking lamp screws, push grille clips to
release the grille from the truck
new headlamp in position and connect the Remember to install the rubber boot on the new lamp; its a water seal. Make sure the head-
wiring harness.
back
Wear gloves.
install:
Place the
86826p88
on the
retainers can have very sharp edges.
of the
light is right-side
up.
CHASSIS ELECTRICAL
6-52
86826gb6
Fig. 71
Be
careful
when removing
the headlight bezels,
73
Fig.
Remove
the headlamp, then unplug the
connector
they can be sharp
location but
NOT
on the battery or engine. Don’t
spill
any
coolant. b.
If
the
left
Remove Remove
c.
d.
headlamp
is
to
be changed:
the air duct (3 bolts). the air suction silencer and the air switching
valve. Label the
hoses so they go back
in
the correct
places.
Remove
e.
the underhood cooling fan.
Its
held by 3 bolts;
don’t forget to disconnect the electrical harness. 4.
Unplug the connector from the back
connector
may be
very
tight
of the lamp.
and require wiggling
The
to loosen;
support the lamp while with your other hand while wiggling the 10.
connector loose. 5.
Turn the bulb socket about 45° counterclockwise to
loosen
72 Pull the
Fig.
light out,
harness from behind
Have an
8.
Install
Remove
the bulb.
then unplug the wiring
it
and check the
assistant turn on the headlights
new lamp for proper function, checking beams before final assembly. 9.
it.
both high and low
the retainer and the small screws that hold
Reinstall the headlight bezel and/or
it.
Bulb retaining ring
grille.
European Headlamps
RETAINING RING TYPE I See Figures 73 and 74 1.
OFF,
With the ignition switch raise
OFF and
the
headlamp switch
2. On Pick-Ups and 4Runners, remove the headlamp assembly. 3. On Land Cruisers: a.
If
86826gb5
and prop the hood.
the right
headlamp
is
to
be changed,
coolant reserve tank. Place the tank
in
grille
and
Fig. lift
an out
74 Turn the bulb retaining ring counterclockwise,
out the
of the
way
then take out the bulb
CHASSIS ELECTRICAL
6-53
6.
To
install: Install
certain
all
the
new
bulb with the socket pointing up.
three guide .tabs
socket clockwise to lock
it
into their correct slots.
fit
Make
Turn the
place.
in
^WARNING Hold the new bulb by the base; do NOT touch the glass The grease left on the glass
part with fingers or gloves. will
form hot spots and shorten the life of the bulb. If the is accidentally touched, clean the glass with alcohol.
glass
7.
Connect the wiring connector
8.
Turn the headlights
beam 9.
10.
ON
firmly.
and check both high and low
86826gb9
function.
Turn the headlights OFF. Reinstall the
hoses and ducting
underhood (left
fan, air switching valve, silencer,
side) or the coolant reservoir tank (right
side). 1 1
.
Fig.
Lower the hood.
76 Remove the rubber cover
RUBBER COVER TYPE > See Figures 75, 76, 77, 78 and 79 1
.
OFF,
With the ignition switch raise
OFF and
2.
Unplug the connector
3.
Turn the
plastic
4.
Remove
the rubber cover.
5.
To 6.
headlamp switch
for the bulb.
cover counterclockwise, then remove
it.
Release the bulb retaining spring, then remove the bulb. install:
Align the tabs of the bulb with the cutout of the mount-
ing hole 7.
the
and prop the hood.
and
Install
Make sure
install
the bulb.
the retaining spring, then attach the rubber cover.
the rubber cover
is
snug on the connector and the
Bulb retaining spring
86826gc0
headlight body. 8.
Install
the plastic cover with the
upwards. Turn 9.
Aiming
is
it
ON
mark facing
clockwise, then insert the connector. not necessary after replacing these types of
bulbs. Fig.
77 Removing and installing the retaining spring
86826gb8 86826gcl
Fig.
75 Turn the bulb retaining ring counterclockwise,
then remove the ring
Fig. 78 Make sure the rubber cover connector and the headlight body
is
snug on the
CHASSIS ELECTRICAL
6-54
Rock the vehicle
5.
suspension 6.
side-to-side a few times to allow the
to stabilize.
Turn the
lights on, adjust the
head lamps
to
achieve a
high intensity pattern.
Land Cruiser I See Figures 80 and 81 1
Before checking the headlamp aim:
.
Be sure
a.
that the
body around the headlamp
is
not
deformed. b.
Park the vehicle on a level spot.
c.
Bounce
in
the vehicle a few times to get the truck at a
level point. 2.
Look
at the
beam
angle gauge
bubble of the gauge should not
move
gauge by more than two marks on ward scale Fig.
79
Install
upwards. Turn
the plastic cover with the it
ON mark
facing
clockwise, then insert the connector
3.
The
of the
Excluding Land Cruiser I
See Figure 80
The head lamps should be aimed using a special alignment however this procedure may be used for temporary adjustment. Local regulations may vary regarding head lamp aimtool,
ing,
consult with your local authorities.
1.
Verify the tires are at their proper inflation pressure.
Clean the head lamp lenses and make sure there are no
heavy loads 2.
25
ft.
3.
in
the trunk.
The gas tank should be
(7.7
4.
Measure and record the distance from the
Fig.
wall
same
strip of
floor to the
tape across the wall
height.
Place strips of tape on the wall, perpendicular to the
measurement, line of
flat
m) away.
center of the head lamp. Place a at this
filled.
Position the vehicle on a level surface facing a
indicating the vehicle centerline
first
and the center-
both head lamps.
80 Headlamp adjusting screw locations
either the
upward or down-
at the beam angle gauge (horizontal movement). mark should not move by more than one mark on
either side of the gauge.
AIMING
movement). The
out of the center of the
gauge.
Look red
(vertical
CHASSIS ELECTRICAL 4.
to
the error
If
is
6-55
over the specified marks, take your vehicle
a specialized shop
to
have the headlamps adjusted
professionally.
and
Signal, Marker
Interior
Lamps
REMOVAL & INSTALLATION See Figures
I
The
lens
is
82, 83, 84, 85, 86,
removed
to allow
87 and 88
access
to the bulb. External
lenses usually have a rubber gasket around them to keep dust of the housing; the gasket must be present and good condition at reinstallation. Exterior lenses and the larger interior ones are held by one or more screws which must be removed. Once the lens is removed from the body,
and water out in
86826p40
removed from the socket and replaced. For the lamps, front marker lamps and some front turn signals,
the bulb rear
is
the socket and bulb
is
removed from the lens
with a counter-
clockwise turn.
Smaller
interior
lenses usually
fit
and must be pried or popped out tool is ideal for this job;
if
in
place with plastic clips
of place.
A
small,
flat,
plastic
other tools are used, care must be
taken not to break the lens or the
clip.
The bulbs used on Toyota trucks are all US standard and may be purchased at any auto store or dealer. Because of the variety of lamps used on any vehicle, take the old one with you when shopping
On some models others,
you have
for the
replacement.
the lens can be replaced separately.
to replace the lens with the plastic
On
backing
attached.
86826p37
Fig.
82
Remove
the screws securing the lens
.
.
.
Fig.
83
.
.
.
then twist and pull the bulb from the socket
6-56
CHASSIS ELECTRICAL
86826p35
Fig.
87
On these types
of lenses, twist then pull the
socket and bulb from the housing
Fig.
88 The bulb can
now simply be
pulled from the
socket
Light Bulb Applications >
See Figures
89, 90, 91, 92, 93,
94 and 95
These charts should be used as a general see your owner’s manual year and model.
86826p34
86 The front parking by screws Fig.
light
assemblies are secured
for the
reference. Please
exact specifications on your
CHASSIS ELECTRICAL
6-57
NOTICE: Only use a bulb of the Light Bulbs
listed type.
Bulb No.
W
Type
9005
65
A
9006
55
B
1156
27
C
168
5
D
194
3.8
D
1156
27
C
1157 1156
27/8
27
c c
Bulb No.
W
Type
168
5
D
-
10
E
10
Headlights (inner)
Headlights
Bulb
Light Bulbs
No.
No
(outer)
Wattage
Front turn signal
Front turn signal
1
lights
lights
1156
27
168
5
2 Parking lights
Parking and front side
marker
3 Front side marker
lights
194
lights
3 8 Rear turn signal
4 Rear side marker
lights
194
3 8
1157
27/8
1156
27
156
27
89
7 5
Interior lights
-
10
Personal light
lights
5 Stop and 6 Back-up
tail
lights
lights
Stop and
Back-up
7 Rear turn signal lights lights
Interior light
Glovebox
1 1
lights
License plate lights
Glovebox
10 Luggage compartment
tail
lights
Light Bulbs 1
8 License plate 9
lights
Rear side marker
—
light
1.4
-
10
E
-
3
E
-
light
-
light
light
Luggage compartment
10
'
C D
1
2
Vanity lights 86826gel
A HB4 halogen :
B
C
:
:
HB3
Single end bulbs
D Wedge base
bulbs
:
E
:
bulbs
halogen bulbs
Double end bulbs 86826ge3
Fig.
89 Light bulb applications -1989-90 Land Cruiser
No.
Light Bulbs
lulb No.
Fig. 91
Light bulb applications
No
Wattage
Front turn signal
1
1156
27
168
5
194
3 8
1157
27 8
1156
27
1156
27
89
5
8 Interior lights'
-
10
9 Personal
-
lights
side marker lights
lights
4 Stop and
tail
lights
5 Back-up lights
lights
License plate lights
7
1
Front turn signal
light
0 Glovebox 1
light
lights
4 Stop and 5
Luggage compartment
Back-up
_
— 1991-92
27
57
27 8
1
1
1156
27
—
3 8
—
5
-
5
10
Rear
10
8 Door courtesy
4
~
lights' light
3 1.4 86826ge4
10
Land Cruiser
1156
Xtra-cab Front
1
27
Interior lights
Normal-cab
Fig.
90 Light bulb applications
lights
lights
9 Glovebox light
tail
6 License plate lights 7
-
3 8
1156
lights
86826ge2
Fig.
2
3 Rear turn signal
6 Rear turn signal
1
Parking lights
Rear side marker
3
Land Cruiser
Bulb No. Wattage
Light Bulbs
1
Parking and front
2
— 1993-95
92 Light bulb applications -1989-91 Pick-Up and
4Runner
6-58
CHASSIS ELECTRICAL NOTICE: Use only
a bulb of the listed type.
Light Bulbs
No.
w
Bulb No.
Parking and front
1
_
5
1156
27
side marker lights"
2 Front turn signal lights
3 Rear turn signal lights
4 Stop and
lights
tail
1156
27
1157
27/8
-
18
89
5
-
10
_ -
10
5 Back-up lights"
6 License plate lights" 7 Interior light’
‘
8 Luggage compartment light’
9 Personal lights’
0 Door courtesy
1
1
lights’
Glovebox light"
1
5
3 1.4 86826ge5
Fig.
93 Light bulb applications
— 1992-93 CAUTION;
Pick-Up and 4Runner
iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiniliiiii
Halogen bulbs have pressurized gas inside and requite special handling. They can burst or snai'ct if scratched or dropped. Hold bulh u».l by its plastic or metal case Do not t^uch the glass part r
of
i
bulb
11111111.1
* I
.
k-.iib
bure ua.Kic.
>lli;.*ti ill
1 1
.till
1
Ml
i
•
III
:
1
1
1
dill Ilia III!
NOTICE Only use a bulb of the Light Bulbs
W
Type
-
65/45
A
Headlights Parking and front
lights
Rear turn signal lights
-
Personal lights
5
C
1156
27
B
Luggage compartment light
-
1156
27
B
Door courtesy
-
1157
27/8
B
A H4 halogen
-
18
C
B
921
18
C
C Wedge base
89
5
C
Glovebox
light
lights
Stop and
tail
lights
Back-up
Bulb No.
Light Bulbs Interior light
-
side marker lights
Front turn signal
listed type.
Bulb No.
lights
High mounted stoplight
:
lights
Type
10 1.4
D D C
10
D
3
D
5
'
bulbs
Single end bulbs
D Double end
License plate
W
bulbs
bulbs
86826ge6
Fig.
94 Light bulb applications
— 1994-95
Pick-Up and 4Runner
Light Bulbs
Headlights Parking lights Front turn signal lights
Rear turn signal
Bulb No.
W
Type
9003 168
60/55
A
5
C
1156
27
B
1156
27
B
1157
27/8
B
1156
27
B
stoplight
168
5
C
License plate lights
lights
Stop and Back-up
tail
lights
lights
High mounted
168
5
C
Interior lights
-
8
D
Personal lights
-
5
D
Glovebox
-
Step
light
A HB2 halogen B
;
-
lights
5
C
5
C
bulbs
Single end bulbs
C Wedge base bulbs D Double end bulbs :
86826ge7
Fig.
95 Light bulb applications
— 1994-96 T100
CHASSIS ELECTRICAL
6-59
TRAILER WIRING Wiring the vehicle for towing
number
of
good
is fairly
wiring kits available
When
easy. There are a
The
and these should be
used, rather than trying to design your own.
need brake
All trailers will tail
lights
marker
and side marker
lights.
overwide
lights for
and
lights
been
as
turn signals as well
Also,
most states have
cently required back-up lights for trailers,
ufacturers have
the industry.
and most
trailer
Additionally, III
ate with the
man-
signals,
building trailers with back-up lights for
lights
some Class
an accessories charge the
have
in
most Class
and
Add
just
necessary. The
bumper
kit will
or hitch,
into the trailer
all
number
equipment or
to
and you can have as many as
contain
all
trailer
and buy the wiring
the wires needed, plus a
plug adapter set which included the female plug,
the
about
to this
the harness.
Determine the equipment on your kit
II
wire, to operate trailer internal
trailers battery,
seven wires
I,
electric brakes.
and the male
mounted on
plug, wired into, or
One
plugged
same
usually standard throughout
some domestic
lights
and rear
and
vehicles,
turn signals.
On most
turn signals oper-
bulb. For those vehicles with separate turn
you can purchase an
to
diodes to wire
Diodes
will
isolation unit
so that the brake or,
your local electronics supply house and buy four series with the brake
in
and
turn signal bulbs.
brake and turn signals. The choice
isolate the
is
The isolation units are simple and quick to install, but far more expensive than the diodes. The diodes, however, require more work to install properly, since they require the cutting of each bulbs wire and soldering in place of the diode. yours.
One,
the best
final point,
kits
are those with a spring loaded
cover on the vehicle mounted socket. This cover prevent
and moisture from corroding the terminals. Never cle socket
harness.
is
point to note:
won’t blink whenever the turn signals are operated,
you can go
trailers will
follow the manufacturers instructions.
most imported vehicles, have separate
re-
several years.
Class
kit,
domestic vehicles, the brake
Most states require extra
trailers.
installing the
color coding of the wires
bumper
hang
always mount
loosely;
it
let
dirt
the vehi-
securely to the
or hitch.
CIRCUIT PROTECTION The underdash
Fuses
or
which can be used
underhood fusebox contains a fuse to grip
cannot be checked while
View the fuse from the
REPLACEMENT
and remove the the fuseblock;
in
side, looking for
puller
The fuse must be removed
fuse. it
a broken element
in
Sometimes the break is hard to see; if you can’t check the fuse with an ohmmeter for continuity, replace the the center.
See Figure 96
fuse. If
The fuse block is located below the left side of the instrument panel on all vehicles. Additional fuses are found on the underhood relay board. The radio or audio unit is protected by an additional fuse
in
anything electrical
isn’t
item checked.
the body of the
unit. In
the event that
working, the fuse should be the
a fuse should blow, turn
OFF
the ignition switch and also
same new fuse
the circuit involved. Replace the fuse with one of the
amperage
rating,
and
turn
immediately blows out, the
on the switches. circuit
If
the
should be tested for shorts,
broken insulation, or loose connections.
first
i**Do not use fuses of a higher
recommended.
amperage than
CHASSIS ELECTRICAL
6-60
Once
4.
Circuit Breakers
reset,
use an ohmmeter
the pins of breaker.
If
to
no continuity
check
for continuity at
present, the breaker did
is
not reset. Reinstall the circuit breaker
5.
REPLACEMENT
and connect the negative
battery cable.
I See Figure 97
Relays
amperage ones, are protected by resetable circuit breakers. Much like the circuit breakers in a household system, these units will trip when too much cur-
Many
circuits, particularly
rent attempts to
pass through.
does not automatically
To 1
.
high
REPLACEMENT
On Toyota vehicles, the breaker may be reset manually.
reset, but
reset the breaker:
As vehicles electrically
Disconnect the negative battery cable. ily.
2. 3.
Remove
the circuit breaker.
Use a needle probe or other thin and push the reset button.
reset hole
Many
rely
more and more on
relays are located
in
logical positions
and fuse board under the dash or tool to
reach into the
electronic
systems and
operated options, the number of relays grows stead-
on the relay
the engine compartment.
in
However, many relays are located throughout the vehicle, often near the component they control. During diagnosis of a
always suspect a
circuit,
proven otherwise.
failed relay until
Flashers
REPLACEMENT The
turn signal flasher
under the dash, on the replacement in
>
a
new
is
is
left
made by
located
in
the convenience center,
side kick panel.
unplugging the old
In all
unit
cases,
and plugging
one.
Fuse and
Circuit Breaker Applications
See Figures
98, 99, 100, 101, 102, 103, 104, 105, 106,
107, 108, 109, 110, 111, 112
The
and 113
following diagrams are to be used as a reference for
locations.
To
obtain the exact fuse type, look
manual or on the
label
under the
lid
of
in
your owner’s
each fuse box.
CHASSIS ELECTRICAL
Junction Block No.
6-61
Relay Block No. 2
1
Fuses 1
.
3.
IGN TAIL
4.
WIPER
5.
GAUGE
2.
7.
STOP RADIO
8
CIG
6.
.
9.
Fuses
ENGINE
1
15A 20A
12.
ECU-IG
13.
DEFOG
3.
HAZ-HORN
15A 15A 15A 10A 10A
DOME HEAD HEAD
5.
6.
7.5A
11.
7.5A
EFI
.
4.
10A 15A
TURN
CHARGE
2.
1
7.5A
RR ANTI LOCK —
10.
0A
7.
15A 10A 15A
8.
9.
— ALT
(RH) (LH)
80A
(H-Fuse)
100 A
(22R-E A/T) 10.
—
11.
20A 20A
12.
Relays and Circuit Breaker A. Starter Relay Taillight Control Relay B. Defogger Relay C. D. Power (CB) Moon Roof Relay E.
— AMI AM2
_ 40A 30A
(H-Fuse) (H-Fuse)
Relays Headlight Control Relay EFI Relay B. (CANADA Models) Fuses A.
5.
6. 7.
8.
HEAD (RH-LO) HEAD (LH-LO) HEAD (RH HI) HEAD (LH HI)
10A 10A 10A 10A
Relays D.
Relay Block No. 3
Dimmer Relay
Relay Block No. 4
Fuses
Fuse 10 A
1.
A/C
2.
RR HEATER 20A
1.
CDS FAN
30A
Relays Relays and Circuit Breaker A. RR Heater Relay B. Heater Relay C. Heater (CB)
A. B.
CDS FAN CDS FAN
No. 1 Relay No. 2 Relay
86826gf5
Fig.
98 Fuse and circuit breaker locations
— 1989-91
4Runner
CHASSIS ELECTRICAL
6-62
14. IGN. 7.5 A: Discharge warning light, emission control system, electronically controlled automatic transmission system
Fuses (type A) 1.
EFI 10 A:
2.
DOME
1
Electronic fuel injection
5 A:
Interior light,
system
personal lights, door courtesy
luggage compartment light, lights, clock, ignition switch light
HAZ-HORN 15
3.
A: Emergency flashers,
horns
5.
6.
DRL
7.
HEAD
(LH)
10 A: Left-hand headlight
(RH) 10 A: Right-hand headlight
HEAD
(LH-LO) 10 A: Left-hand headlight
(LH-HI) 10 A: Left-hand headlight
light (high
11.
(RH-HI) 10 A: Right-hand head-
lighter, digital
clock
parking and side
Tail lights,
lights, license plate lights,
instrument
18. STOP 15 A: Stop system cancel device 19.
TURN 10
20.
30 A:
A: Turn signal
lights,
back-up
conditioning
B)
Air conditioning fan
system
30 A: Power windows, power back window, power door locks, electric moon roof 26.
40 A:
Air conditioning control
system
Fuses (type C)
AM2
30 A:
All
components
in
"EFI” and
"IGN" fuses
AMI 40
all compo"WIPER”, "RADIO", "GAUGES", "CIG", "TURN", "ECU-IG", "DEFOG" fuses and No. 26 fuse
29.
nents
lights, cruise control
air
30.
in
A: Starting system,
"ENGINE",
ALT 80A (22R-E engined
vehicles with
manual transmission and 3VZ-E engined
REAR ANTILOCK 15
A:
Rear-wheel
system
vehicles) or
ALT 100A (22R-E engined
ve-
hicles with automatic transmittion): Start-
system, all components in "ENGINE", "WIPER", "RADIO", "GAUGES", "CIG", "TAIL", "STOP", "TURN”, "ECU-IG". "DEFOG” fuses and No 26 fuse
ing
A: Cruise control system,
21.
ECU-IG 20 A: Power
steering control
system, shift lock control system (automatic
WIPER 20
A: Windshield wiper and washer, back window wiper and washer
RADIO
7.5 A: Radio, power antenna, cassette tape player, Compact Disc player, power rear view mirrors 13.
marker
25.
A: Rear
system
Fuses (type
28.
TAIL 15 A:
anti-lock brake
beam)
ENGINE 10
charging system 12.
5 A: Cigarette
lights
beam)
HEAD
1
RR HEATER 20
control
27.
CIG.
panel lights, glovebox light
HEAD
10.
6.
17.
(RH-LO) 10 A: Right-hand headbeam)
(high
0 A: Automatic transmission control system, gauges and 1
display, radio
7.5 A: Daytime running light system
light (low 9.
GAUGES
overdrive meters, warning lights and buzzers (except discharge warning light), A D D control
1
(low beam) 8.
5.
system
HEAD HEAD
4.
1
24.
transmission)
22.
DEFOG 20 A
23.
A/C 10 A:
:
Back window defogger Air
conditioning
cooling
system
Fuses Vehicles sold outside
Canada
Vehicles sold
Engine compartment
in
Canada
Engine compartment
Driver's side kick panel
Behind glovebox
QD C23D C24J
86826gf7
Fig.
99 Fuse and
circuit breaker locations
— 1992-94
4Runner
CHASSIS ELECTRICAL
6-63
I
Fuses Engine compartment (22R-E engine
models sold
in
Canada)
rmmm 11
ftQjCl 73C223C24J [ 29 ]
L-J 1 1
1
;
CT
mnnrro; Engine compartment I3VZ E engine
6. CIG.
models sold outside Canadal
display, radio
15 A: Cigarette
lighter, digital clock
TAIL 15 A. Tail lights, parking and side marker lights, license plate lights, instrument panel lights, glovebox light 7.
STOP 15 A: Stop lights, cruise control system cancel device, high mounted stop8.
light
9.
TURN 10 A: Turn signal lights REAR ANTILOCK 15 A: Rear-wheel
10.
lock brake
anti-
system
27.
ECU-IG 20 A: Power steering control shift lock control system (automatic transmission), cruise control system (3VZ-E 11.
system,
Fuses (type A)
engine) 1.
ENGINE 10 A:
Cruise
control
system
I22R-E engine), charging system
WIPER 20 A: Windshield wiper and washer, back window wiper and washer 2.
3
RADIO 7.5
sette
tape
power
rear
4. IGN.
A: Radio, power antenna, casCompact Disc player,
player,
view mirrors
7.5 A: Discharge warning
light,
emis-
sion control system, electronically controlled
automatic transmission system
GAUGES
10 A; Automatic transmission overdrive control system, gauges and meters, service reminder indicators and warning buzzers (except discharge warning light), A D D. control system, back-up lights 5.
12.
DEFOG 20
13.
A/C 10 A:
A: Back
window defogger
Air conditioning cooling sys-
RR HEATER 20
A: Rear
air
conditioning
control system
15. EFI
15 A: Multiport
fuel injection
system/
system
DOME
15 A: Interior light, personal luggage compartment light, door courtesy lights, clock, ignition switch light
lights,
17.
HAZ-HORN 15
A:
Emergency
flashers,
horns 18. 19.
HEAD
HEAD HEAD
(LH)
22
10 A: Left-hand headlight
(RH) 10 A: Right-hand headlight
23.
HEAD
(RH-LO) 10 A: Right-hand head-
(low beam)
HEAD
(high
24.
A: Daytime running light system
ILH-LO) 10 A: Left-hand headlight
beam)
light
sequetial multiport fuel injection 16.
DRL 7.5
21. (low
tem 14.
20.
(LH-HI) 10 A: Left-hand headlight
beam)
HEAD
light (high
(RH-HI) 10 A: Right-hand head-
beam)
Fuses (type
B)
25. 30 A: Air conditioning fan system
26 30 A: Power windows, power back window, power door locks, electric rhoon roof 40
A. Air conditioning control system
Fuses (type C)
AM2 30 A: "IGN" fuses
28.
All
components
in
"EFI" and
AMI 40
29.
nents
in
A: Starting system, all compo"ENGINE", "WIPER", "RADIO",
"GAUGES", "CIG", "TURN", "ECU-IG", "DEFOG" fuses and No. 26 fuse 30.
ALT 80A (22R-E engined
vehicles with a
manual transmission and 3VZ-E engined vehicles) or
ALT 100A (22R-E engined
vehicles
with
automatic
Starting
an system,
transmittion):
"ENGINE",
all components "WIPER", "RADIO", "GAUGES", "CIG", "TAIL", "STOP", "TURN", "ECU-IG", "DEFOG" fuses and No. 26 fuse
31.
ABS 60
in
A: Anti-lock brake system
86826gfB
Fig.
100 Fuse and circuit breaker locations
— 1995 4Runner
6-64
CHASSIS ELECTRICAL
.
9.
Junction Block No.
1
Fuses 1.
2. 3.
4. 5.
Fuses
ENGINE
10A
1.
IGN TAIL WIP
CHARGE
7.5A
7.5A
2.
EFI
15A 20A
GAUGE
4.
10A 15A
6.
15A 15A 15A 10A 10A
7.
STOP RADIO
8.
CIG
6.
7.5A
TURN
15A 10A
11.
-
— —
12.
ECU-IG
13.
DEFOG
9.
10.
20A 15A
Relays and Circuit Braker A. Starter or Back Up Relay B.
Taillight Control Relay
C.
Defogger Relay [w/o Power Window] Power (CB) Defogger Relay [w/ Power Window]
D. E.
3.
5.
7.
8
.
10 11.
HAZ-HORN
DOME HEAD (RH) HEAD (LH) ALT AMI
(FL) (FL)
80A 40A 60A 30A
or 12.
AM2
(FL)
Relays Headlight Control Relay EFI Relay B. C. CMH Relay A.
Fuses 1.
A/C
2.
HEATER
10A 30A
Relay Heater Relay
A.
86826gf9
Fig. 101
Fuse and
circuit
breaker locations
— 1989-90
Pick-Up
CHASSIS ELECTRICAL
6-65
\
Junction Block No.
Relay Block No. 2
1
Fuses
Fuses 1.
ENGINE
10A
1
CHARGE
7.5A
2.
IGN
7.5A
2.
EFI
15A
3.
HAZ-HORN
4.
TAIL WIPER
20A
4.
DOME
15A 15A 15A
5.
GAUGE
5.
(USA)
6.
STOP
10A 15A
7.
RADIO
7.5A
6.
(USA)
CIG
15A 10A
7.
— —
3.
8. 9.
10.
TURN REAR
HEAD
HEAD
15A
11.
-
12.
ECU-lG
— 20A
13.
-
-
(RH)
10A
(LH)
10A _
ALT
(H-fuse)
11.
AMI
— 80A
(H-fuse)
40A
12.
AM2
(H-fuse)
8
ANTILOCK
.
.
9.
10.
— or
(CANADA) HEAD LO (RH) 6. HEAD LO (LH) 5.
Relays and Circuit Braker A. Starter or Back Up Relay Taillight Control Relay B. Power (CB) C.
7. 8.
HEAD HEAD
HI (RH) HI (LH)
60
30A 10A 10A 10A 10A
Relays A. (CANADA) B.
C.
D.
Fuses 1.
A/C
2.
HEATER
Headlight Dimmer Relay Headlight Control Relay
EFI Relay Relay
CMH
10A 30A
Relay Heater Relay
A.
86826gg2
Fig.
102 Fuse and circuit breaker locations
— 1991
Pick-Up
CHASSIS ELECTRICAL
6-66
Canada
U.S.A.
Enoine comoartment Engine compartment t
panel Driver's side kick
Oliver's side kick panel
1.
Behind glovebox
Behind glovebox
C223 C233
Fuses (type A) EFI 2.
10 A:
DOME
1
5
Electronic fuel injection
A
:
Interior lights,
lights, clock, ignition
3.
HAZ-HORN 15
switch
system
door courtesy
light
A: Emergency flashers,
horns
5.
HEAD HEAD
6.
DRL
7.
HEAD
4.
(LH)
10 A: Left-hand headlight
(RH) 10 A: Right-hand headlight
7.5 A: Daytime running
light
system
(LH-LO) 10 A: Left-hand headlight
HEAD
9.
(RH-LO) 10 A: Right-hand head-
(low beam)
light
HEAD
(high
(LH-HI) 10 A: Left-hand headlight
beam)
HEAD
10.
light (high
11.
(RH-HI) 10 A: Right-hand head-
A: Cruise control system,
WIPER 20
er,
6.
CIG.
1
5 A: Cigarette
ADD
control
lighter, digital clock
display, radio
17.
TAIL 15 A:
Tail lights,
parking
lights,
glovebox
light
18.
STOP 15
19.
TURN
A: Stop system cancel device
10 A: Turn
lights, cruise control
24.
30 A: Power windows, power door
locks
Fuses (type C) 25.
AM2 30 A:
All
components
in
"EFI" and
"IGN” fuses
AMI 40 A: Starting system, all components in "TURN", "GAUGES". "CIG", "ENGINE", "WIPER", "RADIO", "ECU-IG" fuses and type B fuse
26.
ALT 80
A: Starting system, all compo"TAIL", "STOP", "TURN", "GAUGES", "CIG", "ENGINE", "WIPER", "RADIO", "ECU-IG", "A/C", "HEATER"
27.
nents
in
fuses and type B fuse
signal lights, back-up
lights
RR ANTI LOCK 15
A: Rear-wheel
anti-
lock brake system
ECU-IG 20 A: Power steering control system, shift lock control system (automatic transmission), rear-wheel anti-lock brake system
RADIO
power
1
light),
Fuse (type B)
21.
A: Windshield wiper and
washer 13.
discharge warning system
20.
beam)
ENGINE 10
charging system 12.
15. GAUGES 10 A: Automatic transmission overdrive control system, gauges and meters, warning lights and buzzers (except
license plate lights, instrument panel lights,
(low beam) 8.
14. IGN. 7.5 A: Discharge warning light, emission control system, electronically controlled automatic transmission system
7.5 A: Radio, cassette tape playrear view mirrors
22.
A/C 10 A:
Air
conditioning
cooling
system 23.
HEATER 30
A: Air conditioning system 86826ggl
Fig.
103 Fuse and circuit breaker locations
— 1992
Pick-Up
CHASSIS ELECTRICAL
6-67
Fuses Fuses (type A)
Canada
USA.
1. EFI
15 A: Multiport
fuel injection
system/
sequential multiport fuel injection system Engine compartment Engine compartment
2.
DOME
15 A:
25
HAZ-HORN 15
3.
door courtesy
Interior lights,
lights, clock, ignition
switch
light
A: Emergency flashers,
horns
5.
HEAD HEAD
6.
DRL 7.5
7.
HEAD
4.
Oliver's side kick panel
Driver’s side kick panel
(LH)
10 A: Left-hand headlight
(RH) 10 A: Right-hand headlight A: Daytime running
light
system
(LH-LOI 10 A: Left-hand headlight
(low beam) 8.
HEAD
(RH-LO) 10 A: Right-hand headlight
(low beam) 9.
HEAD
(high
10.
HEAD
light (high
11.
10 A: Left-hand headlight
(LH-HI)
beam) (RH-HI) 10 A: Right-hand head-
beam)
ENGINE 10
A: Cruise control system,
charging system Behind gloveboi
12.
Behind gloveboi
WIPER 20
A:
Windshield
wiper
and
washer 13.
RADIO 7.5
player,
pq 033
power
rear
A:
Radio,
cassette
tape
view mirrors
|C22J|
bd 86826gg4
Fig.
104 Fuse and circuit breaker locations
— 1993-95
Pick-Up
CHASSIS ELECTRICAL
6-68
Fuses
Fuses (type A)
HEAD
7.
(LH) 10 A: Left-hand headlight
(high
(RH) 10 A: Right-hand headlight
8.
2.
HEAD HEAD
3.
A/C 10 A:
1.
HEAD
(high Air conditioning cooling
15 A: Multiport
system/ sequential multiport fuel injection system, electronically controlled automatic transmission system
HA2-HORN 15
5.
A:
fuel injection
Emergency
flashers,
horns 6.
DOME
15 A:
Interior light,
step lights, ignition switch sette
tape
personal lights, radio, cas-
light,
Compact Disc
player.
player,
power antenna, clock
beam)
(LH-LO) 10 A (3VZ-E engine): hand headlight (low beam)
18. CIG 15 A: Cigarette lighter, digital clock
system (automatic
10. HEAD (RH-LO) 10 A (3V2-E engine): Right-hand headlight (low beam)
ENG 10
A: Turn signal
lights,
emer-
WIP 20
10 A: Automatic transmission system, gauges and meters, service reminder indicators and warning buzzers (except discharge warning light), A.D.D. control system, cruise control system, back-up lights, power door lock system
system
control
STOP 15
stoplight,
12. IGN 7.5 A: Charging system, discharge warning light, multiport fuel injection system/sequential multiport fuel injection
A: Windshield wiper and washer
GAUGE
overdrive
16.
A: Charging system
A: Stop
cruise
cally controlled
lights,
control
High-mounted
system, electroni-
automatic transmission sys-
tem 17.
RADIO 7.5 A: Compact Disc
player,
power
rear
Radio, player,
cassette
tape
power antenna,
view mirrors
Fuse (type C) 28.
ALT 80
A:
All
components
"TAIL", "STOP", "ECU-B”,
transmission)
TURN 10
Left-
13. TAIL 15 A: Tail lights, parking lights, license plate lights, instrument panel lights, glovebox light
display, shift lock control
19.
IRH-HI) 10 A: Right-hand headlight
HEAD
11.
14.
15.
system 9.
4. EFI
(LH-HI) 10 A: Left-hand headlight
beam)
"HEATER"
in
"A/C",
"AMI"
and
fuses
gency flashers 20. ECU-B 15 A: Rear-wheel anti-lock brake system, SRS airbag system, cruise control system, daytime running light system 21.
DRL 7.5 A
light
system
ABS 15 A
(Canada): Daytime running
(U.S.A):
Rear-wheel
anti-lock
brake system 22. ECU-IG 20 A: Rear-wheel anti-lock brake
system 23. OBD D 7.5 connecter
A
(3RZ-FE engine): Check
Fuses (type B) 24. AMI 40 A: Starting system, nents in “ENG", "IGN", "WIP",
"RADIO",
"CIG",
all
compo-
"GAUGE".
"TURN" and "PWR"
fuses
25. AM2 30 A: Starting system, nents in "ENG", "IGN", "WIP",
all
compo-
"GAUGE", 86826gg5
Fig.
105 Fuse and circuit breaker locations
— T1 00
CHASSIS ELECTRICAL
6-69
Front Side
Relay Integration Relay
A.
Fuse
Medium Current Fuse
POWER
3QA
15A
2.
4WD GAUGE
3.
TURN
10A
4.
ECU-IG
15A
5.
WIPER
20A
6.
IGN
7.5A
7.
RADIO
7.5A
8.
CIG
15A
9.
ECU-B
15A
10.
Fuses 1
.
10A
Rear Side
Relays B.
HORN
C.
FLASHER
D.
BACK-UP LIGHT (Column
A/T)
86826gg6
Fig.
106 Fuse and circuit breaker locations
— Tacoma
6-70
CHASSIS ELECTRICAL
Relays A.
TAIL
B.
D.
HEATER HEAD STARTER
E.
EFI
C.
Fuses High Current Fuse a.
ALT
80A
d.
ABS
60A
Medium Current Fuses b.
HEATER
c.
AMI
40A 40A
e.
AM2
30A
TAIL
10A 15A
3.
STOP PANEL
4.
ALT-S
7.5A
5.
A/C
10A
6.
STA
7.5A
10A
8.
OBD HEAD
9.
EFI
Fuses 1
.
2.
7.
10.
HEAD
11.
HORN DOME
12.
10A
10A
(RH)
15A 10A
(LH)
15A 15A 86826gg7
Fig.
107 Fuse and circuit breaker locations
— U.S
Tacoma models
CHASSIS ELECTRICAL
Relays A.
DIMMER
B.
TAIL
C.
E.
HEATER HEAD STARTER
F.
EFi
D.
Fuses High Current Fuse a.
ALT
80A
d.
ABS
60A
Medium Current Fuses b.
HEATER
c.
AMI
e.
AM2
40A 40A 30A J
Fuses 1.
DRL
7.5A
2.
TAIL
10A 15A
4.
STOP PANEL
5.
ALT-S
7.5A
6.
A/C
10A
7.
STA
7.5A
OBD HEAD (HI RH)
10A
10.
EFI
15A
11.
10A
13.
HEAD (HI LH) HORN HEAD (LO RH)
14.
DOME
15.
HEAD (LO
15A 10A
3.
8. 9.
12.
10A
LH)
10A
15A 10A
86826gg8
Fig.
108 Fuse and circuit breaker locations
— Canadian Tacoma
models
6-71
6-72
CHASSIS ELECTRICAL
Relay Block
Relays
A
Taillight Control
B
Front Drive Relay Front Heater Relay
C
D
Relay
E
Turn Signal Flasher Headlight Control Relay
F
Ignition
Main Relay
Fuse Block
Fuses
Circuit Breakers
HEAD (RH)
2
TAIL
15A 15A
3 4
TURN
7.5A
DOOM
7
1
.
6
HEAD STOP
7.
WIPER
5A 15A 15A 20A
8 9
CHARGE
7.5A
CIG HAZ-
15A 15A
5.
10
(LH)
HORN
12 13
A/C GAUGE DOOR
14.
ENGINE
15.
_
1
0A
A.
Heater
7.5A
B
Power
1
30A 30A
15A 0A 1
16
SPARE
17.
EFI
5A 15A
18 19 20
IGN
7.5A
DEFOG SPARE
20A 15A
7
86826gh0
Fig.
109 Fuse and circuit breaker locations
— 1989-90
Land Cruiser
CHASSIS ELECTRICAL Relay Block No. 2 (Engine
Room)
Fuse and High Current Fusel
2.
HEAD HEAD
1
.
(RH) (LH)
3.
-
4.
CHARGE
5.
-
6.
EFI
15A 15A
Relays
8.
HAZ-HORN -
9.
-
7.
7.5A
15A
15A
A.
EFI Main Relay
B.
Charge Light Relay
'
C.
Headlight Control Relay
10.
DOME
10A
D.
-
11.
AMI -
50A
E.
Horn Relay
F.
-
12.
Fuse Block (Instrument Panel)
Fuse and 1
.
2.
Medium Current Fuse
CIG
TAIL
15A 15A
3.
4.
STOP
5.
6.
10.
ECU-B
10A
11.
REAR-HTR
20A
12.
IGN A/C DIFF
7.5A
13.
DEFOG
10A 20A
WIPER
20A
15.
10A
16.
8
GAUGE TURN
7.5A
17.
HEATER POWER
9.
ECU-IG
15A
18.
Spear
19.
Spear
7.
14.
10A
20A
30A 30A
86826gh3
Fig.
110 Fuse and circuit breaker locations
Relay Block No.
1
— 1991
Land Cruiser
(Cowl Side) Relay
B.
Cooling Fan Relay Blower Hi Relay
C.
-
A.
D.
Defogger Relay
E. F.
Power Main Relay Turn Signal Flasher
G.
Heater Relay
H.
Taillight Control Relay
I.
-
J.
Circuit
Opening Relay
86826gh6
Fig. Ill
Fuse and
circuit breaker locations
— 1991
Land Cruiser
6-73
6-74
Fig.
CHASSIS ELECTRICAL
112 Fuse and circuit breaker locations
— 1991
Land Cruiser
CHASSIS ELECTRICAL
6-75
Fuses Engine compartment
14. DIFF 15. FL
30 A:
Differential lock
HEATER 30
system
A: Air conditioning sys-
tem 16. FL POWER 30 A: Power windows, power door lock system, electric moon roof 17. CHARGE 7.5 A: Charging system, charge warning light
dis-
18. EFI 15 A: Multiport fuel injection system/ sequential multiport fuel injection system
1. CIG 15 A: Cigarette lighter, power rear view mirrors, digital clock display, radio, cassette tape player, power antenna, automatic transmission shift lock system
TAIL 15 A: Tail lights, license plate lights, parking and front side marker lights, instrument panel lights, clock, glovebox light 2.
3.
4.
FOG 15 A: No circuit STOP 10 A: Stop lights,
WIPER 20 A: Windshield wipers and washer, rear window wiper and washer 6.
GAUGE
10 A: Gauges and meters, service reminder indicators and warning buzzers (except discharge and open door warning lights), back-up lights 7.
8.
TURN
9.
ECU-IG 15 A: Cruise control system
multiport fuel
in-
system/sequential multiport fuel injection system, cruise control cancel device, automatic transmission shift lock system
DEFOG 20
A: Rear
lights
CDS-FAN 20
HEAD (RH) 15 A: Right-hand headlights HEAD (LHI 15 A: Left-hand headlights HAZ-HORN 15 A: Emergency flashers,
21.
22.
A: Electric cooling fan
horns
DOME
10 A: Interior lights, personal compartment light, ignition switch light, open door warning light, clock, radio, cassette tape player, power antenna, 23.
light,
luggage
vanity lights
window deffoger
AM 1 50 A: All components in "CIG", "WIPER", "GAUGE", "TURN", "ECU-IG", "REAR-HTR", "IGN", "DIFF" and "FL 24.
10.
ECU-B 10 A: No
1 1
REAR-HTR 20
jection
5.
7.5 A: Turn signal
19.
20.
.
circuit
A: Air conditioning system
IGN
7.5 A: Multiport fuel system/sequential multiport fuel system, emission control system 12.
13.
A.C 10 A:
Air conditioning
injection
POWER"
injection
25.
circuits
ABS 60
A: Anti-lock brake system
system 86826gh7
Fig.
113 Fuse and circuit breaker locations
— 1992-95
Land Cruiser
6-76
CHASSIS ELECTRICAL
WIRING DIAGRAMS
Fig.
114 Engine wiring
— T100
1993-94 3.0L
CHASSIS ELECTRICAL
A^S
Fig.
115 Engine wiring
— T100
1994 2.7L
6-77
CHASSIS ELECTRICAL
6-78
HOT
ft
START OR RUN
HOT
ft
START OR RUN
WPER
GUAGE
FUSE 20A
FUSE K)A
WASHER
(L LEVEL LOCATOR
WASHER MOTOR
(CANADA)
WPER MOTOR
WHT/BLK 1
WPER/
WASHER
WASHER
LEVEL
SWITCH
SENSOR (CANADA)
T
WHT/BLK l
HOT AT ALL TftCS
HOT AT ALL TfctS DOME
POWER
FUSE
FUSE 30A
ISA
i U/>
—
t
IUM.OCK WARI*NG SWITCH
I
/ HOT ft START OR RUN
LT GRN/RED
DOOR
GUAGE
LOCK ECU
FUSE 10A INTE-
GRATION RELAY
BLK/ORG
LT GRN/
I
WHT -
RED/WHTRED BLU/BLK
LEFT
DOOR COURTESY SWITCH
7
BLU/WHT
RK>fr
/
DOOR
RIGHT
COURTESY SWITCH
DOOR LOCK MOTOR AND DOOR UM.OCK DETECTION
SWITCH BLU/YEL
RED /WHT
RED/YEL
BLU/RED
BLU/WHT
RED/WHT LEFT
LEFT
DOOR LOCK CONTROL SWITCH
LEFT
DOOR KEY
RED/YEL
WHT/BLK
WHT/ BLK
DETECTION SWITCH
J
7\
BLU/WHT
i
WHT/BLK RED/GRN
RED/BLU
DOOR LOCK MOTOR AND DOOR UNLOCK
/
LOCK AND UNLOCK SWITCH
BLU/GRN BLU/YEL
RED/YEL
BLU/WHT
RED/YEL
BLU/WHT RIGHT
RIGHT
DOOR LOCK CONTROL SWITCH
•
j
DOOR KEY LOCK AM) UM.OCK SWITCH
L-ngD-
1
LEFT
WtCOW
MOTOR
Fig.
116 Chassis wiring
— T1 00
1993-94
Ht@J WINDOW MOTOR
RIGHT
FRONT
WMK)W SWITCH
CHASSIS ELECTRICAL
Fig.
117 Chassis wiring
— T100
1993-94 continued
6-79
6-80
Fig.
CHASSIS ELECTRICAL
118 Engine wiring
— T100
1995-96 2.7L
CHASSIS ELECTRICAL
DL£ AF CONTROL
EGfl vsv
FPU
A/C OLE- UP
VSV
VALVE
VALVE
EVAP VSV
MASS AR FLOW SENSOR
EGR GAS
ENGJNE
THROTTLE
TEMP.
COOLANT
SENSOR
posmoN
TEMP.
6-81
SENSOR
SENSOR 868‘26w06
Fig.
119 Engine wiring
— T100
1995-96 3.0L
6-82
CHASSIS ELECTRICAL
86826w07
Fig.
120 Chassis wiring
— T100
1995-96
CHASSIS ELECTRICAL
HOT AT
Fig. 121
HOT M RUN
Chassis wiring
— T1 00
HOT AT
1995-96 continued
6-83
6-84
Fig.
CHASSIS ELECTRICAL
122 Engine wiring
— Tacoma
1995-96 2.4 and 2.7L
CHASSIS ELECTRICAL
6-85
aC?\£s
86826wl0
Fig.
123 Engine wiring
— Tacoma
1995-96 3.4L
6-86
CHASSIS ELECTRICAL
86826 wll
Fig.
124 Chassis wiring
— Tacoma
1995-96
CHASSIS ELECTRICAL
HOT
Fig.
125 Chassis wiring
N START
— Tacoma
HOT
1995-96 continued
N START
6-87
6-88
CHASSIS ELECTRICAL
86826wl3
Fig.
126 Engine wiring
— Land Cruiser 1989-90
CHASSIS ELECTRICAL
6-89
BATTERY
HOT N START OR RUN
POWER CB.
30A
BLU *
,
BLU
BLU
LEFT FRONT
RIGHT FRONT
WNDOW MOTOR
RIGHT REAR
LEFT REAR
WNDOW MOTOR
WNDOW MOTOR
WIDOW MOTOR
HOT AT
HOT AT
ALL TlrfES
ALL TMES
86826wl4
Fig.
127 Chassis wiring
— Land
Cruiser 1989-90
6-90
CHASSIS ELECTRICAL
HOT AT ALL
VUES i.
HEATER
HOT N START OR RUN i GAUGE
JOB.
r
FUSE
30A
T
7.5A
T
WHT/GRN
va
HOT
N
START OR RUN
WPER MOTOR
WPER/ WASHER SWITCH
Fig.
128 Chassis wiring
— Land
Cruiser 1989-90 continued
CHASSIS ELECTRICAL
Fig.
129 Engine wiring
— Land
Cruiser 1991-92
6-91
CHASSIS ELECTRICAL
6-92
HOT N START OR RUN l C I
WPER FUSE 20A
BLU
WHT/BLK
WHT/BLK 1
HOT N START OR RUN 1 GAUGE
HOT AT ALL TMES
POWER
? FUSE T 10A
FUSE
UNK
( 30A
BLU I
DOOR LOCK CONTROL RELAY
WARMNG
POWER MAW
SWITCH
RELAY
UNLOCK
RIGHT FRONT
DOOR LOCK MOTOR
/
WHT/BLK BLU/YEL
LEFT FRONT
DOOR
WHT/
WHT/
BLK
BLK
1
i
LOCK CONTROL SWrTCH
BLU/YEL
Jt5i LEFT KEY LOCK UNLOCK SWITCH &
i
BLU/YEL
BLU/BLK
GRN/YEL
BLU/BLK
DOOR LOCK MOTOR
/
GRN/RED
BLU/BLK
RIGHT
RIGHT
KEY LOCK & UNLOCK SWITCH
DOOR LOCK
[J
CONTROL SWITCH (1991 ONLY)
BLU/BLK I
TT © Y 4-
~r
RIGHT
©
REAR LOCK
“T BACK DOOR
LEFT
©
REAR LOCK
Y MOTOR 4-
MOTOR
Y MOTOR 4LOCK
BLK/GRN RED/GRN |
BLU/RED
BLU/RED
—i—
—
i
/
V
RED/GRN LEFT FRONT
DOOR COURTESY SWITCH
I
RED /BLK
TO NTERJOR LIGHTS SYSTEM
'
RIGHT FRONT
DOOR COURTESY SWITCH
L(©}J LEFT FRONT
L-agn
1
RIGHT FRONT
WNDOW MOTOR WIDOW MOTOR
RIGHT REAR
LEFT REAR
WfOOW MOTOR
WNDOW MOTOR 86826wl7
Fig.
130 Chassis wiring
— Land
Cruiser 1991-92
CHASSIS ELECTRICAL
HOT AT ALL
TMES 1
HEATER
? FUSE T
40A
WHT/GRN
HOT N START OR RUN GAUGE J
Chassis wiring
— Land
SWfTCH
[
FUSE K)A
YEL
1
Fig. 131
IGMDON
l
Cruiser 1991-92 continued
BLX/WHT
6-93
6-94
CHASSIS ELECTRICAL
r
86826wl9
Fig.
132 Engine wiring
— Land
Cruiser 1993-94
CHASSIS ELECTRICAL
Fig.
133 Engine wiring
— Land
Cruiser 1995-96
6-95
6-96
CHASSIS ELECTRICAL
HOT
ft
START OR RUN 1
WPER
C FUSE I
20A
I
BLU I
WPER MOTOR
BLU/YEL BLU/RED |
0
BLU/GRN (1993-94)
LT GRN (1995-96)
WPER AND WASHER SWITCH
J/C 6 (1993-94) j/c e (1995-96)
WHT/BLK
m
J/C 5 (1993-94) J/C 7 (1995-96)
WHT/BLK 1
HOT
ft
START OR RUN
HOT AT ALL T*4ES
POWER MAft
RELAY
Fig.
134 Chassis wiring
— Land
Cruiser 1993-96
CHASSIS ELECTRICAL
6-97
86826w22
Fig.
135 Chassis wiring
— Land
Cruiser 1993-96 continued
CHASSIS ELECTRICAL
6-98
C5
E26
CIO
C3
(ECT) F2
(ECT) DIO (W/O)
(ECT)
(ECT)
B4
B3 (W/O)
(W/O)
(W/O)
II
||
A 15 (ECT)
C9
C2
02
(ECT)
(ECT)
Cl (ECT)
B14
FT1
F12
(W/O)
(W/O)
B5 (W/O)
(ECT) F0
(ECT)
B12
(W/O)
(W/O)
(W/O)
C11
i BRN
YEL
YEL/BLU
03
04
A9
05
C8
E23
En
04
E9
E22
C6
(ECT)
(ECT) F10
(ECT) BIO
(ECT) F7
(ECT)
(ECT)
(ECT)
F16
B12
(W/O)
(W/O)
(W/O)
(W/O)
F9 (W/O)
(ECT) B7
(ECT)
F17
(ECT) F4
(ECT)
E0 (W/O)
(W/O)
(W/O)
(W/O)
(W/O)
F3 (W/O)
GRN/ RED
GRN
PNK
BLK
PNK/GRN
F3 (W/O)
r
VIO/WHT
GRN/YEL
GRN/BLU
YEL
WHT RED/GRN
WHT WHT
GRN'
I
WHT
CONN
BRN
OXYGEN SENSOR
OXYGEN
TEMP SENSOR
SENSOR
KNOCK
(SUB)
SENSOR
(MAIN) I
EGR GAS
a
TEKff>
SENSOR
TO VEHCLE SPEED
SENSOR THROTTLE POSTDON SENSOR
AR FLOW METER
L BRN
Fig.
I
TEST
CONN
I
BLK BLK
TO
TO TEST
TO TEST CONNECTOR
WATER
±
136 Engine wiring
— 22RE
E10 (ECT)
1989-92 4Runner and 1989-90 Pick-Up
AS VALVE
FUEL PRESSUREUP
BRN
BRN
1
VALVE EGR VALVE
CHASSIS ELECTRICAL
(AT) E25 (MT) D9
(AT) E12 (MT) D4
(AT) E9
(AT)
El
(AT) E2
(MT) D2
(MT) F4
(MT) F6
(AT) E14 (MT) F7
(AT) E15 (MT) F5
(AT)
E3
(MT) F2
(AT) E21 (MT) D8
(ECT) A1
(AT) All
(MT)
D3
B2
(ECT) A 12 B14
(AT)
A 13
(MT) B13
(AT)
AS
6-99
(AT)
A6
(MT) B6
(MT) B19
ENGNE CONTROL MODULE C5
Ell
E13
E26
C2
C3
(ECT) B17 (W/O)
(ECT)
(ECT)
(AT)
A15 (AT)
D5
B4
B5
B24
(W/O)
(W/O)
(ECT) DIO (W/O)
(AT)
D7
(MT)
(MT)
(MT)
BRN
YEL/BLU
C9 (AT) F10 (MT)
Cl (AT)
B3 (MT)
C12 (AT) F13 (MT)
I
J I
|
C11
C13
C4
A9
E23
E8
(AT) F18
(AT)
(AT)
C15 (ECT)
C8
(AT) F14 (MT)
(ECT)
B7
F15
F16
(ECT) B18
(ECT)
FI
(MT)
(MT)
(MT)
(W/O)
(W/O)
(W/O)
n
GRN/
WHT GRN/
TO VEHICLE
WHT
SPEED
SENSOR
WATER TO TEST CONNECTOR KNOCK SENSOR
s
TEMP SENSOR
EGR GAS
ra SENSOR TEMP.
GRN/YEL I
Fig.
137 Engine wiring
THROTTLE
AR FLOW
POSITION
METER
SENSOR
— 6-cylinder
1989-92 4Runner and 1989-90 Pick-Up
I |
BRN WHT /RED
F8 (W/O)
C16 (ECT) B15 (W/O)
E22
C6
(ECT) F12
(ECT) B12
(W/O)
(W/O)
F3 (W/O)
BLK
PNK/GRN
E10 (ECT)
CHASSIS ELECTRICAL
6-100
FEDERAL AND CANADA
Fig.
HOT AT ALL T*tS
WATER
SPEED
TEMPERATURE SENSOR
SENSOR
i
X
— — VACUUM 1
/
SWITCH
BRN
WHT/BLK
WHT/BLK
i
i
i
138 Emissions computer wiring
— 1989-90 22R
CHASSIS ELECTRICAL
6-101
1
i
E3
El
E21
A1
A12
E13
A5
A6
(4WD AT)
(4WD AT)
(4WD AT)
(4WD AT)
(4WD AT)
(4WD AT)
(4WD AT)
(4WD AT)
F5
FI
D8
D1
B2
B8
B1
F8
(4WD MT) (2WD) E7
(4WD MT) (2WD) E21
(4WD MT) (2WD) E6
(4WD MT) (2WD) E15
(4WD MT) (2WD) C2
(4WD MT) (2WD) C9
(4WD MT) (2WD) Cl
(4WD MT) (2WD) CIO
B9 (4WD MT) (2WD) C12
1
ENGNE CONTROL MODULE
C5
E13
CIO
(4WD
(4WD
(4WD
C3 (4WD
C9 (4WD
-AT) F2
-AT)
-AT)
-AT)
-AT)
A15
(4WD
C2 (4WD
C12
cn
Cl
C13
(4WD
(4WD
(4WD
(4WD
-AT)
-AT)
-AT)
AT)
C4 (4WD
A9
CIS
A 20
Ell
C14
E9
E22
(4WD
(4WD
C8 (4WD
E23
(4WD
(4WD
(4WD
(4WD
(4WD
(4WD
-AT) BIO
-AT) F7
-AT)
-AT)
-AT)
-AT)
-AT)
-AT)
-AT)
C6 (4WD
D5
B4
B3
F14
B5
F6
FT1
-AT) F12
F3
-AT) F10
D6
F17
F9
F4
B7
-AT) F16
(4WD
(4WD
(4WD
(4WD
(4WD
(4WD
(4WD
(4WD
(4WD
(4WD
(4WD
(4WD
(4WD
(4WD
(4WD
(4WD
(4WD
(4WD
(4WD
(4WD
-MT)
-MT)
-MT)
-MT)
-MT)
-MT)
-MT)
-MT)
-MT)
-MT)
-MT)
-MT)
-MT)
-MT)
E16
E19
E17
Elfi
C6
(2WD)
(2WD)
(2WD)
(2WD)
(2WD)
E23 (2WD)
EM
(2WD)
E3 (2WD)
C7
(2WD)
E8 (2WD)
C15
(2WD)
E22 (2WD)
-MT) E10
-MT)
E5 (2WD)
-MT) C16
-MT)
E4 (2WD)
-MT) C13
-MT)
E13
-MT) E9
(2WD)
(2WD)
(2WD)
(2WD)
i
i
1
BLK
PNK/GRN
(2WD) I
I
BLK
BRN
^
~T
~1~
BRN/BLK
YEL/BLU
(2WD)
C8 (2WD)
r
nr
I
H
BLK BLK
TO VEHICLE
I
SPEED SENSOR
GRN/
WHT KNOCK SENSOR
]
£ f
WATER TEMP SENSOR
EGR GAS TEMP SENSOR
THROTTLE AIR
FLOW
POSITION
METER
139 Engine wiring
SENSOR
— Pick-Up
1991-92 4-cylinder
TO TEST CONNECTOR
TO
TO
TEST
TEST
CONN
CONN
I
BRN FUEL PRESSURE-
AS VALVE
UP VALVE
-AT) F15
(4WD El
r
H
I
F13
WHT RED/GRN
GRN/RED GRN
YEL
GRN/BLU
Fig.
EO (4WD
-AT) B12
T
T
BRN
BRN
J
i
EGR VALVE
6-102
Fig.
CHASSIS ELECTRICAL
140 Engine wiring
— Pick-Up
1993-95 4-cylinder
CHASSIS ELECTRICAL
Fig. 141
Engine wiring
— Pick-Up
1991-95 6-cylinder
6-103
6-104
Fig.
CHASSIS ELECTRICAL
142 Chassis wiring
— Pick-Up
1989
CHASSIS ELECTRICAL
6-105
86826w30
Fig.
143 Chassis wiring
— Pick-Up
1989 continued
6-106
CHASSIS ELECTRICAL
HOT N START OR RUN
WFER FUSE 20 A
WHT/BLK
TO TCCS ECU
i HOT
N
START OR RUN
HOT AT ALL 7TME8
HOT AT ALL TKC9
86826w31
Fig.
144 Chassis wiring
— Pick-Up
1990-95
CHASSIS ELECTRICAL
6-107
86826w33
Fig.
145 Chassis wiring
— Pick-Up
1990-95 continued
6-108
Fig.
CHASSIS ELECTRICAL
146 Chassis wiring
— 4Runner
1989
CHASSIS ELECTRICAL
6-109
86826w34
Fig.
147 Chassis wiring
— 4Runner
1989 continued
6-110
Fig.
CHASSIS ELECTRICAL
148 Chassis wiring
— 4Runner
1990-91
CHASSIS ELECTRICAL
Fig.
149 Chassis wiring
— 4Runner
1990 continued
6-111
6-112
Fig.
CHASSIS ELECTRICAL
150 Chassis wiring
— 4Runner
1991 continued
CHASSIS ELECTRICAL
HOT N START
6-113
HOT AT
868'26w38
Fig. 151
Engine wiring
— 4Runner
1993-96 4-cylinder
CHASSIS ELECTRICAL
6-114
HOT N START OR RUN
'
DISTRBUTOR
FUEL
FUEL
NJ.
NJ.
5
'
FUEL
FUEL
FUEL
NJ.
NJ
NJ
3
2
6
TO
TO COLD START NJECTOR
4WD NDtC
WHT/RED
r*«i |bL
[asi
niri
WHT
VIO/WHT B8 [|bL
A20| 1
1
|
r^
|
-B-
ii_
r^i
i
fcil
|C251
ENGNE CONTROL MODULE CIO [
B6 1
1
1
1
A 10
BLK
1
1
A 19
1
|
1
1
1
BS 1
j
|
AT7 |
|
1
BLK
WHT
BLU/BLK
BLK/WHT
A22
BIO
C24~|
1
C8
[Xl8 [
[
[
C22
C11 [
GRN
|
[
1
A15
C23[
[
BRN
B3 |
j
[
BRN/BLK
|
|
|
|
|
BLK /RED
BRN
BRN
PNK
GRN/RED
I
1
1
B2
I
|
|
YEL/RE
A9
|
RN/BLU
1
B12
B1
B11 1
1
1
YEL/WHT
|
1
|
YEL/BLK |
I
1
TO A/C SYSTEM
KNOCK SENSOR
EGR VSV
PRES
CONTROL VSV
I
DATA LNK CONNECTOR
WHT/RED
4 BRN
PAR NJ VSV
WHT/RED
L GRN/BLK BRN/BLK
WHT/RED I
BRN
(EXC 1995)
FUEL
WHT
WHT
BRN i
MAN OXYGEN SENSOR
Fig.
SUB OXYGEN SENSOR (EXCEPT 1993)
152 Engine wiring
— 4Runner
1993-96 6-cylinder
AR FLOW METER
COOLANT
EGR GAS
TEMP SENSOR
TEMP.
SENSOR
A.
I
GRN/BU
vV
THROTTLE POSITION SENSOR
CHASSIS ELECTRICAL
TO
HOT N ACC, START OR RUN
HOT AT ALL TMES
6-115
HOT AT ALL TMES
86826w40
Fig.
153 Chassis wiring
— 4Runner
1992-96
6-116
Fig.
CHASSIS ELECTRICAL
154 Chassis wiring
— 4Runner
1992-96 continued
AUTOMATIC TRANSMISSION ADJUSTMENTS 7-25 EXTENSION HOUSING SEAL
7-27
IDENTIFICATION 7-25
NEUTRAL SAFETY SWITCH 7-26 TRANSMISSION ASSEMBLY 7-27 UNDERSTANDING AUTOMATIC TRANSMISSIONS 7-23
CLUTCH ADJUSTMENTS 7-15 DRIVEN DISC AND PRESSURE PLATE
7-16
MASTER CYLINDER SLAVE CYLINDER
7-21
7-21
UNDERSTANDING THE CLUTCH
7-15
DRIVELINE
CENTER BEARING 7-57 FRONT DRIVESHAFT AND UNIVERSAL JOINTS
7-46
REAR DRIVESHAFT AND
U-
JOINTS 7-52 FRONT DRIVE AXLE DIFFERENTIAL CARRIER 7-67
DRIVE
FRONT AXLE, BEARING AND SEAL
7-58
MANUAL LOCKING HUB
TRAIN
7-58
PINION SEAL 7-64
MANUAL TRANSMISSION ADJUSTMENTS
AUTOMATIC TRANSMISSION CLUTCH
7-2
BACK-UP LIGHT SWITCH
7-2
7-15
DRIVELINE 7-46
IDENTIFICATION 7-2 SHIFT LEVER 7-2
TRANSMISSION ASSEMBLY 7-4 UNDERSTANDING THE MANUAL TRANSMISSION 7-2 REAR DRIVE AXLE AXLE SHAFT, BEARING AND SEAL 7-72 DETERMINING AXLE RATIO 7-72 DIFFERENTIAL CARRIER 7-80 PINION SEAL 7-80
UNDERSTANDING DRIVE AXLES 7-72 TRANSFER CASE APPLICATIONS 7-45
TRANSFER CASE ASSEMBLY
7-23
7-45
FRONT DRIVE AXLE MANUAL TRANSMISSION REAR DRIVE AXLE TRANSFER CASE
7-58 7-2
7-72 7-45
DRIVE TRAIN
7-2
MANUAL TRANSMISSION The G58, W56, W59 and are connected to the transfer case. The R150F is coupled to the 3VZ-E engine in 4WD applications. See Section 1 for more
transmissions; the others are 5-speeds.
Understanding the Manual Transmission Because it
of the
way an
can produce torque
internal
combustion engine breathes,
(or twisting force) only within
a narrow
and R150F are used
in
4WD
applications
information on models.
speed range. Most overhead valve pushrod engines must turn at about 2500 rpm to produce their peak torque. Often by
4500 rpm, they are producing so little torque that continued increases in engine speed produce no power increases. The torque peak on overhead camshaft engines is,
much higher, but much narrower. The manual transmission and clutch are employed
generally,
the relationship between engine
RPM
and the speed
to
vary
The
slippage.
from a
The
due
full
to
necessary or possible.
Back-Up Light Switch
all
be applied
clutch allows engine torque to
to the transmission input shaft gradually,
All models utilize a floor-mounted shifter and an internallymounted shift linkage. No external adjustments are either
of the
wheels so that adequate power can be produced under circumstances.
Adjustments
mechanical
vehicle can, consequently, be started smoothly
REMOVAL & INSTALLATION
stop.
The transmission changes the ratio between the rotating speeds of the engine and the wheels by the use of gears. 4-speed or 5-speed transmissions are most common. The lower gears allow full engine power to be applied to the rear wheels during acceleration
The
clutch driveplate
is
low speeds.
at
a thin disc, the center of which
is
and which
lining
is
capable
clutch cover
is
engage the
plate.
When
clutch.
of allowing slippage without
4.
Unscrew the back-up
6.
bolted to the engine flywheel
The cover
the clutch pedal
Unplug the
is
neutral.
in
it
on safety stands.
connector at the switch.
electrical
switch from the extension
light
install:
Screw the new switch
60 inch
lbs. (7
into the
housing and tighten
Nm).
Connect the wire and lower the
truck.
and
Shift Lever
incorporates a diaphragm spring which provides the pressure to
3.
5.
roughness or excessive noise.
The
Raise the truck and support
To
similar to brake
is
Position the shift lever
housing.
splined to the transmission input shaft. Both sides of the disc
are covered with a layer of material which
1.
2.
also houses the pressure released, the driven disc
is
REMOVAL & INSTALLATION
sandwiched between the pressure plate and the smooth surface of the flywheel, thus forcing the disc to turn at the
same speed as
the engine crankshaft.
>
See Figures
The transmission contains a mainshaft which passes all the way through the transmission, from the clutch to the driveshaft. This shaft is separated at one point, so that front and rear
2.
portions can turn at different speeds.
3.
Power
is
transmitted by a countershaft
and reverse. The gears
on the mainshaft, allowing power
the lower gears
in
mesh
of the countershaft
with gears
be carried from one
to
to the
other. Countershaft gears are often integral with that shaft,
while several of the mainshaft gears can either rotate
independently of the shaft or be locked to
gear
to the next
causes one
rotating with the shaft
of the
gears
and locks another
Shifting from
it.
to
to
one
be freed from it.
Gears are
locked and unlocked by internal dog clutches which slide
between the center
of the
gear and the
gears usually employ synchronizers;
smoothly bring gear and shaft
to the
The forward members which
shaft.
friction
same speed
before the
toothed dog clutches are engaged.
Identification The manual transmissions found in Pick-Ups, Tacomas, TIOOs and 4Runners are denoted by their Toyota model designations: G40, G57, G58, W46, W55, W56, W59, R150 and R150F. The G40 and W46 units are 4-speed
1.
1, 2, 3, 4, 5,
Unscrew the
Remove Remove
shifter
6 and 7
knob.
the console box
if
necessary.
the boot retainer mounting screws.
it
to
DRIVE TRAIN
7-3
86827p02 86827p04
Fig. 2
While pulling back the carpeting, loosen and
remove the bezel mounting screws the bezel up
and over the
4.
Lift
5.
Pull the
6.
Press down on the
Fig.
4
Lift
the bezel up and over the shifter shafts
shifter shaft.
boot up the shaft. shift lever
cap and
rotate
it
counter-
clockwise to remove. 7.
To
Put out the
shift lever.
install:
8.
Apply multi-purpose grease
9.
Insert the lever into the transmission housing.
10.
Push down onto the
tion, turn 1 1
.
to the tip of the shift lever.
retainer
and with a clockwise mo-
the shaft to lock into position.
Lower the boot over the shaft
into place.
the boot retainer retainer over the
12.
Install
13.
Tighten the mounting screws. Place the carpeting over
unit.
the unit. 14.
Install
the shifter knob.
86827p06
Fig. 5
Lift
the boot up the shifter shaft to gain access
to the lever
cap
86827p07 86827p03
Fig. 6 Fig. 3
Lift
the bezel while pulling the carpet aside
Press
down on
counterclockwise
the shift lever cap and rotate
it
DRIVE TRAIN
7-4
Tape a piece of wood about 8/io crossmember and then lower
14.
the front
(20mm)
in.
thick onto
the transmission.
16.
Remove Remove
17.
With a floor jack under the transmission case,
15.
Remove
the starter.
the stiffener plate bolts.
the remaining transmission housing bolts.
toward the rear and slowly lower the
removed from the
until
pull
it
can be
it
3VZ-E engine and
with the
transmission, turn the transmission about 45° clockwise.
R150 Slide
On models
truck.
end
front
toward the
it
lower the front and then remove
rear,
it
from the truck:
To
install:
housing between the crossmember
Insert the extension
18.
and the
floor. Slide
the transmission forward. Position the
transmission case so the input shaft splines align with the
and push
clutch disc
mounting 19.
fully into position.
the starter. Tighten the transmission bolts to 53
Nm) and
the stiffener plate bolts to 27
Tighten the starter bolt to 29 20.
Transmission Assembly
mount 22.
Lower the transmission the 4 bolts and tighten
23.
Remove
24.
Install
Disconnect the negative battery cable.
.
Remove Remove
2. 3.
and cover the shift lever
move 4.
lever boot retainer. Pull
shift
cap with a
shift lever
cap and
turn
it
counterclockwise to remove
it.
Re-
check the supports 5.
Drain the
6.
Remove
prevent
oil
for
fluid
on safety stands. Double
secure placement.
seepage.
9.
Remove
light
switch wire.
at the manifold
and remove the
then disconnect the pipe at the manifold and from the
the clutch slave cylinder mounting bolts and
pipe bracket; position the cylinder out of the way.
disconnect the 1 1
.
12.
Remove Remove
Do
not
fluid line.
the four bolts holding the stabilizer (sway) bar. the four bolts holding the frame auxiliary
crossmember. 1
3.
Remove
housing. Position a block of
engine bolts
slightly.
Remove
lbs.
to
14
ft.
lbs.
On 3VZ-E
(69 Nm).
29
ft.
engines,
(19
Nm) and
engines,
lbs.
(39 Nm.)
ft.
lbs.
(72 Nm). Tighten the slave
lbs.
ft.
(12 Nm).
them
(29 Nm). the frame auxiliary crossmember, tightening the
ft.
lbs.
(95 Nm).
switch.
Remove
the extension housing plug and
the transmission with
30.
Fill
31
Apply multi-purpose grease
.
groove
of the shift lever
Cover the and
turn
it
shift
lever
oil
install
the
and lower the
install.
truck.
to the shift lever; align the
cap and the
cap with a
clockwise to
cloth.
Install
pin part of the case.
Press down on the shaft the
shift
lever boot
and
the fan shroud bolts.
32.
Install
33.
Connect the battery cable and road
mount
wood on a
bolts at the extension floor jack
and
the 4 rear mount-to-support
I See Figure 12
manual transmission case attached.
is
removed with the
transfer
raise the
member
and remove the rear engine mount. Remove the rear
engine mount from the transmission.
test the truck.
4WD MODELS •The
the 4 rear engine
ft.
On 22R-E
(62 Nm).
lbs.
retainer with the four screws.
front of the catalytic converter.
Remove
70
(29 Nm).
lbs.
the front crossmember.
driveshaft.
clamp bracket from the clutch housing. For vehicles with 3VZE engines, remove the pipe bracket from the clutch housing
10.
wood from
ft.
Connect the speedometer cable. Connect the back-up
29.
the exhaust pipe clamp from the bracket; dis-
connect the exhaust pipe
22
to
the stabilizer bar retaining bolts and tighten
lbs.
ft.
Install
28. light
Disconnect the back-up
ft.
the clutch slave cylinder and tube bracket. Tighten
Install
22
bolts to
the driveshaft and plug the extension housing to
8.
to 51
cylinder bolts to 9
27.
from the transmission.
Disconnect the speedometer cable.
ft.
the pipe bracket bolts to 53
to
43
on the rear mount.
rests
it
them
upper pipe bracket bolts
Install
26. it
7.
first,
25.
the shift lever.
Raise the truck and support
until
tighten the pipe bolts at the catalyst to
up the boot
Press down on the
cloth.
position the rear engine
tighten the bolts to
the exhaust pipe, bracket and clamp. Tighten the
one
the lower
the four bolts holding the fan shroud. the
the piece of
exhaust pipe bolts to 46
10 and 11
and
slightly
member and
the support
in
tighten the 1
(25 Nm).
Install
2WD MODELS 8, 9,
lbs.
(59 Nm).
lbs.
Pick-Up and 4Runner
I See Figures
ft.
Raise the engine
21.
(39 Nm).
lbs.
ft.
lbs.
ft.
(37 Nm).
lbs.
ft.
the rear engine mount and bracket. Tighten the
Install
bolts to 19
REMOVAL & INSTALLATION
the 2 upper
Install
the transmission housing and stiffener plate bolts.
Install
Install
(72
it
bolts.
1
.
cable 2.
Disconnect the battery cables
at the battery,
negative
first.
Remove
the retaining bolts holding the fan shroud.
DRIVE TRAIN
p^cm
(ft
l
b.
N-m )]
Non reusable
:
7-5
Specified torque
part 86827gl8
Fig.
8 Exploded view of the manual transmission and related components
Fig.
— 2WD
Pick-Up
10 Engine series 22R-E (top) and 3VZ-FE (bottom)
bolt hole locations Fig.
9
A
piece of
crossmember
wood must be taped
to the front
is for
on
2WD
manual transmissions: “A”
transmission mounting, “B”
and “C”
is for
the starter
is for
the stiffener,
7-6
DRIVE TRAIN
DRIVE TRAIN
(3VZ-E) R150F Transmission and Planetary Gear Type Transfer
Transfer Shift Lever
Stiffener Plate
^380J2AJJ7|
’ 1
'2
To To
Qt g-cm
transfer
Front Differential
bracket
(ft lb.
N m )
^
Non
Specified torqi |
reusable part 86827g22
Fig.
12 Exploded view of the manual transmission and related components
— R150F with
3VZ-FE engine
7-7
DRIVE TRAIN
7-8 3.
On 3VZ-E
engines, loosen the clamp on the heater hose
and move the clamp up the heater hose out
at the firewall
of
25.
the way.
Remove
4.
tainer. Pull cloth.
the four screws holding the
up the boot and cover the
Press down on the
wise and remove the
shift lever
pliers,
lever retainer snapring, then
shift lever
cap, rotate
it
boot
re-
cap with a counterclock-
remove the
remove the
transfer
case
shift
Matchmark the
and the differential piThese marks must
driveshaft flanges
nion flanges to indicate their relationships.
be aligned during
installation.
end
of the front driveshaft
bly.
On
9.
vehicles with
Remove
G58 and R150F
transmissions,
it
nec-
is
Matchmark the
rear driveshaft
and the
slip
yoke
to indi-
the four bolts from the rearward flange of the
Lower the driveshaft out
the four bolts from the
slip
of the vehicle.
Re-
On 3VZ-E
at ihe
exhaust manifold. Disconnect the exhaust
way
with wire or
move the cylinder out of the way with the line attached. On 22R-E engines, the piping bracket must also be removed. 14. On 3VZ-E engines, support the front differential with a floor jack; remove the 3 bolts holding the front differential.
the 4 bolts from the rear engine mount. Raise
from the side frame
rails
Remove
For 22R-E engines, place a piece of
pan and the
the eight bolts
and remove the No. 2 crossmember.
wood between
the
Lower the transmission and
19.
Remove
the starter alongside the motor.
Remove
in
the
Remove the remaining transmission mounting bolts. 22. Remove the transmission by moving rearward; once it
lower the front of the transmission and remove the unit
from the vehicle. 23.
Remove
the breather hose between the transfer case
and the transmission case.
and 29
ft.
lbs.
(39
27
(37 Nm).
lbs.
ft.
if
was removed
it
Install
the breather
Support the transmission assembly on a jack. Move the
34.
and
align the input shaft spline
Push the transmission
On 3VZ-E
the starter. Tighten the transmission bolts to 53
install
(72 Nm), the stiffener bolts to 27
Raise the transmission
35.
fully into position.
the transmission and stiffener bolts.
Install
lbs.
ft.
ft.
lbs.
ft.
(37 Nm).
lbs.
(39 Nm).
a jack.
slightly with
Install
2 frame crossmember and tighten the bolts to 70
the No. (95
lbs.
ft.
Nm).
Lower the transmission assembly.
36.
the engine rear mount; tighten 37.
them
to
the 4 bolts to
Install
9
ft.
(13 Nm).
lbs.
the stabilizer bracket bolts, tightening
Install
them
to
22
(29 Nm).
lbs.
For 22R-E engines, remove ihe piece of wood from the
front axle.
For 3VZ-E engines,
39.
install
the front differential bolts.
Tighten the bolt holding the carrier cover to the frame to 108
(147 Nm); tighten the others to 123
lbs.
ft.
40.
14
the exhaust pipe. For
Install
lbs.
ft.
bolt to
14
ft.
lbs.
ft.
ft.
lbs.
and the clamp Install
to
29
ft.
lbs.
Install
lbs.
(167 Nm). tighten the
(62 Nm), the bracket to the clutch
lbs.
ft.
ft.
3VZ-E engines,
(39 Nm) and the On 22R-E engines
lbs.
(19 Nm).
46
bolts to
exhaust pipe clamp ,
to
tighten the manifold
(62 Nm), the upper clutch housing clamp (19 Nm), the lower bolt to 51
bolt to
14
ft.
lbs.
ft.
lbs.
the clutch cylinder; tighten the bolts to 9 install
(69
Nm)
(19 Nm). ft.
lbs.
the lower starter bolt and tighten
it
(39 Nm). the propeller shaft dust cover assembly
if
one was
removed. 43.
Support the transmission and transfer case with a jack.
units
damper
the dynamic
Install
with the clutch disc.
42.
the exhaust pipe bracket and the bolts
stiffener plate.
clear,
(25 Nm).
tighten the bolts to
41.
the two bolts holding the starter; place or hang
and
Install
(38 Nm).
the rear engine mount, tightening the bolts to 19
Install
(12 Nm); on 22R-E,
transfer case.
lbs.
R150F and G58
for
unit into installation position
front axle.
18.
ft.
units.
housing to 29
Remove
the transmission slightly with a jack.
21.
W56
manifold bolts to 46
the 4 bolts holding the stabilizer (sway) bar
brackets.
20.
for
38.
Remove
28
hose.
ft.
Disconnect the clutch slave cylinder retaining bolts and
oil
seal. Install
oil
the dust cover bolt to the bracket. Tighten to 17
Nm)
(23
lbs.
and
rope.
engine
adaptor
to the
the transfer case to the transmission.
Install
lbs.
Nm)
engines, remove the exhaust pipe clamp, the
the manifold. Support the pipe out of the
17.
shafts to the High-4 position.
shift fork
Tighten the starter bolts to 29
pipe from the front of the catalyst and remove the pipe. On 22R-E engines, remove the bolts holding the exhaust pipe clamp to the transmission and disconnect the exhaust pipe at
16.
seal during
oil
•
the two
Install
engines,
Disconnect the speedometer cable, reverse lamp switch
exhaust pipe
15.
Apply multi-purpose grease
31.
yoke flange then remove the
exhaust bracket from the clutch housing and disconnect the
13.
29.
33.
Remove
connector and transfer switch connector. 12.
Move
ft.
flange and yoke assembly. .
install:
32.
removed.
rear driveshaft.
1 1
To
ft.
installation.
move
adapter,
of the trans-
the transfer case rear
28.
30.
the four bolts from each
and remove the driveshaft assem-
cate their relationships. These marks must be aligned during
10.
damage
not
end
straight off the
tighten the retaining bolts to
essary to remove the propeller shaft dust cover before the is
Do
mission.
case
a new gasket on the transfer case adapter.
transfer case.
shaft
Pull the transfer
the
removal.
shift lever.
Drain the lubricant from both the transmission and the
8.
at the rear of the
it.
Remove the driveshaft upper dust cover from Remove the mounting bolts for the transfer
26.
stands. Double check the placement and security of the stand. 7.
equipped with a dynamic damper
If
bracket.
securely with jack-
is
mount from the transmission
the rear engine
case, remove
27.
Raise the vehicle and support
6.
shift lever
shift lever.
Using needle nose
5.
Remove
24.
case.
Connect the speedometer cable, reverse
light
switch and
transfer indicator switch wiring. 44.
Install
45.
Fill
the driveshafts.
the transmission and the transfer case with the
proper amount of
oil.
46.
Lower the vehicle
47.
Install
snapring.
the transfer
to the ground. shift lever
and secure
it
with the
DRIVE TRAIN 48.
Install
the transmission shift lever. Lightly grease the
groove
lever; align the
case cover. Cover the
of the shift lever shift
lever
cap and the pin
cap with a
on the cap and rotate the lever clockwise 49.
On 3VZ-E
engines,
to the correct location
move
down
the retaining bolts
4.
To
the clamp on the heater hose
and secure the clamp.
Connect the negative battery terminal.
52.
Test drive the vehicle, operating
in
5.
lbs.
the fan shroud.
Install
51.
modes. Check
press
3.
it
ease
of shifting, etc.
7.
Unbolt the rear engine mounting.
Attach the rear engine mounting bolts, tighten to 18
the transmission, tighten the engine mounting
Install
53
ft.
lbs.
(73 Nm).
Install
the starter to the engine, tighten to 29
Install
the rear end and stiffener plates with the mount-
ing bolts, tighten to 9.
RF150
ft.
lbs.
Install
27
ft.
lbs.
(37 Nm).
See Figure 13
On
vehicles with the
RF150 and RF150F
RF150F transmissions, the
engine and transmission are removed as an assembly. Refer to
Section 3 for
removal procedures. Separate the transmission
from the engine as follows: 1
.
2.
Unbolt the rear end plate.
Remove
the starter.
(39
the engine and transmission into the vehicle; refer
to Section 3.
I
ft.
Nm). 8.
T100 and Tacoma
bolts
transmission toward the rear.
(25 Nm).
6.
transmission and
Pull out the
install:
bolts to
in all
for correct operation,
Loosen and remove the transmission mounting
from the engine.
to install the lever.
50.
drive
cloth;
of the
7-9
I
See Figure 14 1
.
Remove
the transmission shift lever.
2.
Raise the vehicle, then drain the transmission
3.
Remove Remove
4.
the front propeller shaft. the rear propeller shaft.
fluid.
7-10
DRIVE TRAIN
Front Propeller Shaft
Shift
Lever Knob
No. 2 Dust Cover
Front Propeller Shaft
Front Console
Box
Transfer Shift Lever
Clutch Release Cylinder and Line
Engine Rear Mounting
Crossmember Stabilizer Bar
Cushion Non-reusable part 86827gl0
Fig.
14 RF150F manual transmission
— T1 00
DRIVE TRAIN 5.
Disconnect the speedometer cable.
6.
Unplug the back-up
light
4WD
switch and the
position
switch connector.
Remove Remove
7.
8.
move
1 1
.
the connection and wire from the starter. Re-
5.
To
the bolt for the starter lower side with the clutch line
6.
Remove
the front exhaust pipe, separate the oxygen
Remove Remove and
right
ft.
Unbolt the stabilizer bar.
Jack up the transmission
14.
Remove
15.
and nuts
Remove
17.
9.
for the
crossmember.
down and towards
Nm).
Install
the starter to the engine, tighten to 29
Install
the rear end and stiffener plates with the mount-
ft.
lbs.
(39
See Figures
I
the rear.
remove
the adapter rear
(37 Nm).
lbs.
and transmission
into the vehicle; refer
oil
seal with
the transfer input gear slide.
16, 17, 18, 19, 20, 21
and 22
1.
Remove
2.
Raise the vehicle, then drain the transmission
3.
4.
Remove Remove
5.
Disconnect the speedometer cable.
6.
Disconnect the back-up
from the
it
ft.
W59 — 4-WHEEL DRIVE
transmission.
damage
27
the engine
Pull
the transfer adapter rear mounting bolts. Pull
care not to
lbs.
ft.
the transmission. Tighten the mounting bolts to 53
Install
Install
the 4 bolts and the engine rear mounting.
the transfer case straight up, then
^Take
Attach the rear engine mount bolts, tighten to 48
to Section 3.
the 6 transmission mounting bolts from the en-
Remove Remove
the rear engine mount.
ing bolts, tighten to
slightly.
Disconnect the wire clamps from the transmission.
the transmission 16.
8.
the bolts from the engine rear mounting, then
bolts
Remove
Nm).
13.
remove the
the transmission mounting bolts from the en-
install:
lbs. (73 10.
the bolts and nuts retaining the rear end and
stiffener plates.
left
the starter.
(65 Nm). 7.
the starter.
12.
gine.
Remove Remove
gine. Pull out the transmission toward the rear.
the 2 bolts, then slave cylinder.
sensor from the pipe. 10.
Unbolt the rear end and stiffener plates.
3.
4.
bracket. 9.
2.
7-11
the transmission shift lever. fluid.
the front propeller shaft. the rear propeller shaft.
switch and the
light
4WD
posi-
tion switch connector.
To
install:
18.
Support the transmission and transfer case assembly.
19.
Attach the transfer case to the transmission. Tighten the
7.
adapter rear mounting bolts 27 20.
tighten to 18
21.
ft.
lbs.
(37 Nm).
Place the rear engine mounting bolts lbs.
ft.
in
9.
into position.
Attach
the wire clamps to the transmission, then tighten the 6 rear
22.
70
ft.
23.
9
ft.
1.
Install lbs.
(72 Nm).
the nuts and bolts for the crossmember, tighten to
(95 Nm).
Install lbs.
lbs.
(13 Nm). the stabilizer bar.
Install
25.
Attach the rear end plate and stiffener plates. Tighten to
ft.
lbs.
(37 Nm). the starter, tighten to 29
27.
Install
the front exhaust pipe with a
ft.
lbs.
(39 Nm).
the bolts
and nuts
retaining the rear
end and
remove the
11.
If
12.
Support the transmission rear side.
applicable,
stabilizer bar.
Remove
the bolts
from the engine rear mounting. Disconnect the O-ring, then bolts
and nuts
for the
13.
Remove
14.
Jack up the transmission
crossmember.
the rear mounting. slightly,
then remove the
15.
Remove
the 4 transmission mounting bolts from the en-
new
gasket,
install
Remove
down and towards
the rear.
the transfer adapter rear mounting bolts. Pull
remove
the transfer case straight up, then
it
from the
transmission.
28.
Attach the slave cylinder, tighten 9
29.
Engage
ft.
lbs.
the back-up light switch and the
(12 Nm).
4WD
position
"Take
care not to
damage
the adapter rear
oil
seal with
the transfer case input gear slide.
switch connection.
speedometer cable.
30.
Install
the
31
Install
the rear and front propeller shafts.
Lower the
the front exhaust pipe.
stiffener plates.
16.
oxygen sensor.
32.
Remove Remove
gine. Pull the transmission
Install
.
the connection and wire from the starter. Re-
starter.
26.
the
the slave cylinder.
the bolt for the starter lower side with the clutch line
remove the
the 4 bolts to the rear engine mounting, tighten to
24.
27
Remove Remove
bracket.
10.
Place the transmission/transfer case
ft.
move
place and
(25 Nm).
engine mounting bolts to 53
8.
vehicle,
fill
the transmission with clean fresh
To
install:
17.
Support the transmission and transfer case assembly.
18.
Attach the transfer case to the transmission. Tighten the
fluid.
adapter rear mounting bolts 17 33.
Install
the transfer case and transmission shift levers. 19.
W59 — 2-WHEEL DRIVE >
vehicles with the
W59
transmission, the engine and
transmission are removed as an assembly. Refer to Section 3
removal procedures. Separate the transmission from the engine as follows:
for
Remove
the transmission with the engine.
ft.
lbs.
into position,
engine mounting bolts to 53
See Figure 15
On
Place the assembly
ft.
lbs.
(24 Nm).
then tighten the 4 rear
(72 Nm).
the starter and tighten to 29
(39 Nm).
20.
Install
21.
Attach the rear mounting bolts for the engine, tighten to
48
ft.
22.
lbs.
23.
lbs.
(65 Nm).
Install
a
new
O-ring, then install the nuts
the crossmember. Tighten to 48
lbs.
ft.
Install
ft.
lbs.
and
bolts for
(65 Nm).
the rear engine mounting bolts, tighten to 14
(19 Nm).
ft.
7-12
DRIVE TRAIN
24.
Attach the rear end plate, tighten to 27
25.
Install
the front exhaust pipe with a
26.
Install
the starter set
27.
Attach the slave cylinder, tighten 9
28.
Engage the back-up
switch connection.
bolt, tighten to
light
ft.
new 29 ft.
ft.
lbs.
switch and the
lbs.
(37 Nm).
gasket. lbs.
(39 Nm).
(12 Nm).
4WD
position
29.
Install
the speedometer cable.
30.
Install
the rear and front propeller shafts.
31.
Lower the
vehicle,
fill
the transmission with clean fresh
fluid.
32.
Install
the transfer case and transmission
shift levers.
DRIVE TRAIN
7-13
Transmission Shift Lever Knob
Non-reusable part 86827g02
Fig.
16
W59 manual
transmission
— 4WD
Tacoma
7-14
DRIVE TRAIN
DRIVE TRAIN
7-15
CLUTCH be
^•-CAUTION
shifted into another gear.
A
type clutch return spring
coil
attached to the clutch pedal arm permits
release of the
full
away
pedal. Releasing the pedal pulls the throw out bearing
The clutch driven disc may contain asbestos, which has been determined to be a cancer causing agent. Never clean clutch surfaces with compressed air. Avoid inhaling any dust from any clutch surface! When cleaning clutch
from the diaphragm spring resulting position.
a reversal
in
of spring
As bearing pressure is gradually released from the edges of the spring bow outward,
spring center, the outer
pushing the pressure plate
surfaces, use a commercially available brake cleaning
As the
disc.
and
disc
plate
into closer contact with the clutch
move
closer together, friction be-
fluid.
tween the two increases and slippage spring pressure
full
speed
Understanding the Clutch
steam engines) so
(unlike
out any load vehicle.
until
To a
it
it
must be allowed
to
operate with-
enough torque
to
move
builds up
The 1
transfer of engine
2.
pedal. link
made
is
The
clutch
is is
compoThis gradual power
and pressure
engaged) physically the pedal
is
When
with the vehicle
The
can be moved
shift lever
when
the vehicle
is
freely
between
stationary
1st
and the
and
clutch
> See Figure 23
the disc and plate separate
in,
The pedal height measurement
of the flywheel, the clutch
pressure plate, the throw out bearing and
and the pedal. The flywheel and
If
fork,
it.
The
tween the flywheel and pressure
A
transmission shaft. the engine
driving
clutch disc
member
on the transmission
and
plate,
shaft.
is
a
circular
diaphragm spring
is fully
1989-95
A
•
1989-95 4Runner
member
(clutch disc) shaft.
released) this spring
is
(when the
convex; that in
is,
throw out
fork,
the clutch pedal
•
— 6.201 1995-96 Tacoma — 6.89-7.28
•
1995-96
pushes the
fork
of the
>
spring are secured to the pressure plate
so doing,
pull
to contact the
pressure plate. The outer edges of the
and are pivoted on
of the spring is
the throw out bearing, the outer
the pressure plate
compressed by
edges bow outward and, by in
the
(151.5mm)
(175.0-1
in.
(154.6-1
in.
85.0mm) 64.6mm)
See Figure 24 Check the pedal
depressed, the clutch
and bearing forward
so that when the center
(154.5mm)
in.
(157.5mm)
in.
T100- 6.087-6.480
in.
the clutch
until
diaphragm spring
- 6.0827 - 5.9646
FREE-PLAY
which hold the throw out
is
Pick-Up
is
it
pedal actuates the attached linkage. Connected to the other
When
Pick-Up
within the pressure
dished outward toward the transmission. Pushing
of this is the
2WD 4WD
1989-95
driving
located above the
is
is:
•
attached to
member member
plate cover (transmission side). In a relaxed state clutch pedal
pet)
to a driven
is
which
Correct pedal height from the floor pan sheet (not the car-
splined to the
that
bolt
adjustment.
located be-
so doing, turns the transmission
in
necessary, adjust the pedal height by loosening the locknut
and turning the pedal stop
•
(pressure plate) rotates (drives) a driven
on contact and,
is
is
one
is
and transfers engine power
(clutch disc)
gauged from the angled
is
pedal toward the driver’s seat. Tighten the locknut after the
clutch
pressure plate (driving members) are connected to the engine crankshaft and rotate with
same
direction
-
away
from the clutch disc. This action separates the disc from the plate,
if:
when released
section of the floorboard to the center of the clutch pedal pad.
the actuating linkage
rings
the engine
PEDAL HEIGHT
the clutch
and transmis-
joining the engine
pushed
Most clutch assemblies consists
linxage
operating properly
plate are the connecting
disengaged) disconnecting the engine from the
is
disc, the clutch
bearing.
is
will stall
released, the disc and plate contact each other (the
(the clutch
end
clutch It
Adjustments
transmission.
There
splined to the
same engine
possible by gradually releasing the clutch
clutch disc
When
sion.
is
it
turns at the
weren’t, drive line
it
between the engine and transmission.
pedal
now
disengaged.
to the transmission (the load)
if
nents would wear out or break quickly. transfer
.
reverse gears
power
rotating with the pres-
held stationary.
dis-
gine of any load or resistance.
The
now
is
speed.
connecting the engine from the transmission, relieving the en-
must be smooth and gradual;
clutch disc
transmission shaft, the shaft
the
up torque by physically
clutch allows the engine to build
all
the transfer of power from the engine to
in
The
sure plate at engine speed and, because
torque increases with engine rpm. The
point,
when
until,
releasing the pedal) the
a direct connection between the plate and
disc which results
the transmission.
reduced
is
fully
and plate are the same. This stops
of the disc
slipping, creating
The purpose of the clutch is to disconnect and connect engine power at the transmission. A vehicle at rest requires a lot of engine torque to get all that weight moving. An internal combustion engine does not develop a high starting torque
applied (by
is
disengaging the clutch and allowing the transmission to
free-play to
see
if
it
is
loosen the locknut and turn the pushrod
push
correct,
the beginning of the clutch resistance
is felt.
until
To
in
the free-play
correct. Tighten the locknut. After adjusting the free-play,
the pedal height.
•
- 0.20-0.59 — 0.20-0.59 1995-96 Tacoma — 0.197-0.591
•
1993-96
•
1989-95 Pick-Up
•
1989-95 4Runner
T100- 0.197-0.591
(5.0-1
in. in.
in.
5.0mm) 5.0mm)
(5.0-1
in.
(5.0-15.0mm)
(5.0-15.0mm)
on
adjust, is
check
DRIVE TRAIN
7-16
Push Rod Play Adjust Point
Driven Disc and Pressure Plate
REMOVAL & INSTALLATION I See Figures 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36,
50 and 51
37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49,
‘•^•'CAUTION The clutch driven disc may contain asbestos, which has been determined to be a cancer causing agent. Avoid inhaling any dust from any clutch surface! When cleaning clutch surfaces, use a commercially available brake cleaning fluid. Never clean clutch surfaces with
1
Remove
.
Fig.
23 Pedal height and pushrod play adjustments
air.
the transmission.
Matchmark the
2.
compressed
clutch cover (pressure plate)
and
fly-
wheel, indicating their relationship.
Loosen the clutch cover-to-flywheel
3.
turn at a time in a crisscross pattern.
clutch disc
clutch cover 5.
this
If
GRADUALLY.
must be released
Remove
4.
retaining bolts one The pressure on the
the clutch cover-to-flywheel bolts.
and the clutch
Remove
the
disc.
the clutch throwout bearing
is
to
be replaced, do so
at
time as follows:
Remove
a.
the bearing retaining clip(s) and
remove the
bearing and hub. b.
Remove
c.
The bearing
the release fork and the boot.
ing
is
press
is
hand while placing dom of motion and
it
fit
to the hub.
Turn the bearing by
under some pressure; check
lack of grinding or resistance.
for free-
The
bear-
permanently lubricated and cannot be disassembled or
greased. d.
and e.
Clean all
all
parts; lightly
grease the input shaft splines
of the contact points.
Install
the bearing/hub assembly, fork, boot, and retain-
ing clip(s) in their original locations. 6.
Inspect the flywheel surface for cracks, heat scoring
(blue marks),
and warpage.
If
oil
is
present on the flywheel
surface, this indicates that either the engine rear
The pedal pushrod
play
is
oil
seal or the
the distance between the clutch
master cylinder piston and the pedal pushrod located above the pedal towards the firewall. Since
it
is
measure
it
must be measured
this
distance at the source,
nearly impossible to at
the pedal pad. If
necessary, adjust the pedal play by loosening the pedal
pushrod locknut and turning the pushrod. Tighten the locknut after the
adjustment
to
0.039-0.197
in.
(1.0-5.0mm).
TCCS7115
Fig.
25 View of the clutch and pressure plate assembly
DRIVE TRAIN
TCCS7118
86827p09
Fig.
26 Matchmark the pressure plate and flywheel
7-17
Fig.
29
Remove
the clutch and pressure plate
TCCS7119 TCCS7116
30 View removed
Fig. Fig.
27
Remove
the clutch and pressure plate bolts
is
of the flywheel
once the clutch assembly
TCCS7117
Fig. 28 Carefully pry the clutch and pressure plate assembly away from the flywheel
TCCS7121
Fig. 31
Lock the flywheel
flywheel bolts
in place,
then remove the
7-18
DRIVE TRAIN
TCCS7125 TCCS7122
35 Place a straightedge across the flywheel
Fig.
Fig.
32 Removing the flywheel from the crankshaft
Fig.
33 Add a threadlocking agent to the flywheel bolts
gauge
surface, then use a feeler
check
to
for
warpage
TCCS7126
upon
installation
36 Checking the pressure plate for excessive wear
Fig.
transmission front seal(s).
If
oil
seal
is
leaking.
necessary, replace the
If
doubt concerning the condition
in
of the flywheel,
consult an automotive machine shop. 7.
Before
installing
any new
clean. During installation,
the components, as this
Grease or
fingerprints
make
parts,
will
shorten clutch
may be cleaned
8.
life
oil
on any
of
considerably.
with an evaporative
cleaner such as the type used on brake
To
sure that they are
do not get grease or
J
linings.
install:
Position the clutch disc against the flywheel.
The long
side of the splined section faces the flywheel. 9.
Install
the clutch cover over the disc and
loosely. Align the
cover assembly
is
matchmarks made. installed,
If
a
new
install
the bolts
or rebuilt clutch
use the matchmark on the old
cover assembly as a reference. TCCS7124
'Whenever
the clutch disc
is
replaced, replacement of
the pressure plate (clutch cover) and release bearing Fig.
34 Be sure that the flywheel surface
before installing the clutch
is
clean,
highly
recommended.
is
DRIVE TRAIN
TCCS7130
TCCS7127
Fig.
37
Install
a clutch alignment arbor, to align the
clutch assembly during installation
7-19
Fig.
40 Pressure plate-to-flywheel bolt holes should
align
TCCS7131 TCCS7128
Fig. 41 Fig.
38 Clutch plate installed with the arbor
in
place
Apply locking agent to the clutch assembly
bolts
TCCS7129
Fig.
39 Clutch plate and pressure plate installed with
the alignment arbor in place
TCCS7133
Fig.
42 Be sure to use a torque wrench to tighten
bolts in a star pattern
all
7-20
DRIVE TRAIN
TCCS7134
Fig.
43 Grease the clutch release fork
TCCS7137
Fig.
ball
46 Removing the clutch release fork bearing clips
TCCS7138
TCCS7135
Fig.
44 View of the clutch release fork; check
signs of
it
for
damage
Fig.
47 Grease the throwout bearing assembly
Fig.
the
TCCS7139
TCCS7136
45 View of the clutch release fork bearing clips;
make sure these
at
outer contact points
are not bent or broken
Fig.
48 Grease the throwout bearing assembly at the
inner contact points
DRIVE TRAIN 10.
Align the clutch disc with the flywheel using a clutch
aligning tool.
These handy
tools are available
parts stores at a reasonable price.
Do NOT
in
many
With the clutch aligning tool
cover bolts gradually
in
attempt to align
12.
14
REMOVAL & INSTALLATION
installed, tighten the clutch
a star pattern, as
nuts. Final tighten the bolts to
Master Cylinder
auto
the clutch disc by eye; use an alignment tool. 11.
ft.
lbs.
is
done
with lug
I See Figure 52
(19 Nm).
Apply molybdenum disulfide grease or multi-purpose 1.
grease to the release fork contact points, the pivot and the clutch disc splines. Install the boot, fork,
and bearing on the
Install
Remove
Have a container handy
Remove
the transmission.
the clip and pin at the top of the clutch pedal;
disconnect the master cylinder pushrod from the clutch pedal. 2.
transmission input shaft. 13.
7-21
damage
careful not to 3.
to catch
any spillage
of fluids.
the hydraulic line from the master cylinder, being
Remove
the
fitting.
the two bolts holding the master cylinder to the
engine compartment.
'•-•'WARNING Brake
To 4.
dissolves paint.
fluid
the body
when removing
Do not
allow
it
to drip onto
the master cylinder.
install: Install
the master cylinder. Partially tighten the hydraulic
then tighten the cylinder mounting bolts to 9
line,
lbs.
ft.
(13
Nm). 5.
Connect the pushrod
6.
Bleed the system. Adjust the clutch pedal.
to the clutch pedal.
Slave Cylinder
REMOVAL & INSTALLATION I
See Figure 53 1
.
Jack up the
front of the truck
and support
it
on
jackstands. 2. 3.
Remove Remove
careful not to 4.
To 5.
the tension spring on the clutch fork. the hydraulic line from the slave cylinder.
damage
Remove
the
Be
fitting.
the mounting bolts
and withdraw the
cylinder.
install:
Place the cylinder
Tighten to 9
ft.
lbs.
in
position, then install the bolts.
(13 Nm).
the hydraulic line from the master cylinder.
6.
Install
7.
Bleed the system.
HYDRAULIC SYSTEM BLEEDING This operation must be performed any time the clutch
master or slave cylinder has been removed or hydraulic lines have
if
any
of the
been opened.
'•-•^WARNING Do not TCCS7141
Fig.
50 View of the clutch release fork assembly
installed;
be sure
all
parts
move
will
spill
brake
fluid
destroy the paint.
If
on the bodywork fluid is spilled,
of the vehicle;
the surface with plenty of clean water.
freely 1.
Fill
it
immediately wash
the master cylinder reservoir with brake
fluid.
7-22
DRIVE TRAIN Pilot
Bearing
Non-reusable part
Fig. 51
Exploded view of the
common
clutch set-up
Pin
Non-reusable pan 86827gl7
Fig.
52 Exploded view of the clutch master cylinder
©
Fig.
53 Exploded view of the clutch slave cylinder
DRIVE TRAIN Remove
2.
the cap on the bleeder screw on the clutch
slave cylinder. other end
brake 3.
a clear
Install
submerged
vinyl
hose on the
a clear glass
in
Repeat the process
4.
place the
fitting;
no
air
Replace the
fluid.
Have an
pump
assistant
times. After several
the clutch pedal slowly several
pumps, hold the pedal down and open the
bleeder, allowing fluid to flow into the
jar.
valve almost immediately after opening only after the bleeder
it.
5.
Fill
air
bubbles
in
with the pedal depressed.
fully
plastic cap.
brake
fluid.
Check the system
6.
more
the clutch master cylinder reservoir to the correct
level with
Close the bleeder
the hose contains
fluid in
there are no
the system, tighten the plug
jar partially filled with
the
until
When
bubbles, tube.
7-23
for leaks.
Release the pedal
closed.
is
AUTOMATIC TRANSMISSION Under low speed acceleration, the torque converter functions
Understanding Automatic Transmissions
as follows:
The The automatic transmission allows engine torque and power be transmitted
to
enough
to
It
produce plenty
speeds, while keeping
speeds (and
does
it
wheels within a narrow range
to the rear
engine operating speeds.
transmission uses a
it
power and torque
of
at
of
slings
allow the engine to turn fast
will
The
a sensible rpm at high vehicle
as the medium
light fluid
sion of power. This fluid also
works
mission
fluid
performs
and as a
can easily
unit
and because
travel
all
of
lubricant.
Because the
of the complexity
will
reason,
this
and unusual operating
ples of the transmission, a very
basic principles of operation
trans-
these functions, trouble within the
from one part to another. For
sound understanding
It
picks up
princi-
was now
in
the torus.
returned directly into the torus, both
same speed
at
and torque
times,
all
input
and output
would both be the same. flowing through the torus
two types
simplify troubleshooting.
impinging upon the turbine blades,
In
of flow, or flow in
and
through the turbine blades, and
whose blades are
it
torus, the stator’s
ward the
The torque converter replaces the conventional
clutch.
It
has
when
in
curved blades turn the
fast
the torus picks
torus to turn
allows the engine to idle with the vehicle at a stand-
It
the vehicle
much
up. This
and
that engine
power output
during the
multiplied.
3.
vehicle
speed drops and
has the
shift
from range-to-range
shift.
multiplies engine torque to
It
throttle
being
has the
back
into the
Thus the
to-
fluid
already spinning
is
effect of allowing the
faster than the turbine. This difference
speed may be compared
gear.
the smaller
allows the transmission to
It
is
almost 90°
fluid
toward the torus, but it
smoothly, without requiring that the driver close the throttle
2.
The
spins with the engine.
stationary
direction of rotation of the engine.
does not flow as
when
three functions:
even with the transmission
flows
It
accelerated at low speeds, converts one type of flow into an-
See Figure 54
.
up
turbine, the fluid picks
two separate directions.
other. Instead of allowing the fluid to flow straight
1
to the difference in
larger gears in is
any gear
higher,
in
speed between
train.
The
result
and engine torque
is
is
an increasing extent as
opening
is
increased. This
making the transmission more responsive and reduces the amount of shifting required. effect of
The torque converter
is
a metal case which
is
shaped
sphere that has been flattened on opposite sides. to the rear
end
It
is
like
a
bolted
of the engine's crankshaft. Generally, the entire
metal case rotates at engine speed and serves as the engine’s flywheel.
The case contains three sets directly to the
of blades.
One
set
is
attached
case. This set forms the torus or pump. Another
connected to the output shaft, and forms the The third set is mounted on a hub which, in turn, is mounted on a stationary shaft through a one-way clutch. This third set is known as the stator. A pump, which is driven by the converter hub at engine set
is
directly
turbine.
speed, keeps the torque converter all
full
of transmission fluid at
times. Fluid flows continuously through the unit to provide
cooling.
It
halves of the converter would have to turn at approximately the
In
of the
TORQUE CONVERTER
still,
up speed.
then enters the outer edge of the turbine blades.
the fluid
stator,
I
moves
outward. Since the outer edge of the converter
fluid
fluid
through centrifugal force,
the fluid loses the energy picked up If
hydraulic control circuits
it
along the turbine blades.
for the transmis-
the operation of various
in
turning faster than the turbine.
then travels back toward the center of the converter case
The
this job without driver assistance).
is
faster than the portions at the center, the fluid picks
low
at very
torus
at the center of the converter and,
Fig.
54 The torque converter, which
is
rotated by the
engine’s crankshaft, turns the impeller. The impeller
then spins the turbine, which gives motion to the turbine shaft, thereby driving the gears
DRIVE TRAIN
7-24
As the speed and
faster
ability of
of the turbine increases, the fluid spins faster
the stator to redirect the fluid flow
cruising conditions, the stator
one-way
its
As a
the direction of engine rotation.
in
clutch
in
SUN GEAR DRIVES
the
result,
reduced. Under
is
eventually forced to rotate on
is
the direction of engine rotation.
Under
these conditions, the torque converter begins to behave aimost like
and turbine speeds being
solid shaft, with the torus
a
almost equal.
PLANETARY GEARBOX >
is
56 and 57
See Figures
55,
The
the torque converter to multiply engine torque
ability of
limited. Also, the unit
turbine tary
is
tends to be more
rotating at relatively high
gearbox
is
used
to carry the
efficient
when
power output
of the turbine
Planetary gears function very similarly to conventional trans-
mission gears. However, their construction
ments
are:
make up one gear system,
an outer gear that
is
DRIVEN
the
TCCS7013
Fig.
56 Planetary gears
range.
three elements are different from
PLANET CARRIER
HELD
speeds. Therefore, a plane-
to the driveshaft.
three elements
RING GEAR
is
The
in
maximum
the
reduction (low)
and a lower gear
ring gear is held
ratio is
obtained
different in that
and,
in
that
all
one another. The three eleshaped like a hoop, with teeth
cut into the inner surface; a sun gear,
mounted on a
shaft
and
located at the very center of the outer gear; and a set of three
planet gears, held by pins with both the sun gear
gear or the sun gear
in
a
ring-like planet carrier,
and the outer gear.
may be
meshing
Either the outer
held stationary, providing
more
than one possible torque multiplication factor for each set of gears. Also,
if
all
three gears are forced to rotate at the
speed, the gearset forms,
in effect,
Most automatics use the planetary gears reductions ratios.
same
a solid shaft. to provide various
Bands and clutches are used
to hold various
portions of the gearsets to the transmission case or to the shaft
on which they are mounted. Shifting
is
accomplished, TCCS7014
then, by changing the portion of is
each planetary gearset which
held to the transmission case or to the shaft.
Fig.
57 Planetary gears
(drive) range.
The
in
the
ring gear
minimum
is
reduction
allowed to revolve,
providing a higher gear ratio
SERVOS AND ACCUMULATORS > See Figure 58
SUN GEAR PLANET PINIONS SUN GEAR
The servos are RING OR INTERNAL
GEAR
hydraulic pistons
ble the hydraulic actuators
and
cylinders.
They resem-
used on many other machines,
such as bulldozers. Hydraulic
fluid
pressure, and forces the piston to
enters the cylinder, under
move
to
engage the band
or
clutches.
The accumulators are used to cushion the engagement of The transmission fluid must pass through the accumulator on the way to the servo. The accumulator housing contains a thin piston which is sprung away from the discharge
the servos.
Fig.
55 Planetary gears work
in
a similar fashion to
manual transmission gears, but are composed of three parts
passage
of the accumulator.
accumulator on the way
When
fluid
to the servo,
it
passes through the
must move the piston
against spring pressure, and this action smooths out the action of the servo.
DRIVE TRAIN The A340E, A340, and A340H are
also
fully
7-25
automatic trans-
missions, but rely on electronic computer control rather than the conventional reliance on internal
pressures. Because of
oil
the electronic controls, these units are referred to as Electronically Controlled
Transmissions (ECT).
these units were offered
On 1989-96
the Pick-Up, 4Runner,
in
models,
T100 and
Tacoma. The A340E contains a lock-up torque converter and is coupled to the 3VZ-E engine. The A340F employs a mechanically
4WD
controlled transfer unit for
also used
in
4WD
is
applications, while the
A340H,
an
con-
coupled
to
electrically
case.
trolled transfer 1
vehicles,
989-92 Land Cruisers were equipped with an A440F trans-
mission which
is
similar to the
lock-up torque converter and
A43D. The A440F contains a coupled
is
a 2-speed transfer
to
The A442F is used in the Land Cruiser from 1993-95. 1996, the A343F transmission was used.
unit.
In
Adjustments
THROTTLE CABLE The
comes
hydraulic pressure used to operate the servos
from the main transmission
oil
pump. This
fluid is
There
the various servos through the shift valves.
a manual
valve which
shift
is
to
generally
is
operated by the transmission
and an automatic
selector lever
channeled
valve for each automatic
shift
upshift the transmission provides.
(Many new
electrical
Remove
Push the accelerator
throttle plate
solenoids are used to better
There are two pressures which
One
affect the operation of these
the governor pressure which
is
The other
vehicle speed.
is
effected by intake manifold
the modulator pressure which
vacuum
nor pressure rises with an increase ulator pressure rises
sponding
may be
vacuum
surface on the
throttle
It
shift
bands
will
opening
throttle
cable which cable ad-
Fully
open the
by having an assistant press the
throttle
way
the
all
to the floor.
Adjust the cable housing so that, with the throttle wide
5.
stall
is
0-0.04
in.
(0-1
mm).
Tighten the nuts and double check the adjustment.
6.
the rubber boot and the
air
In-
cleaner.
Land Cruiser to
an
auxiliary circuit for
actuated by the throttle
applies pressure to a special
down-
A440F 1.
line
pressure,
way, the clutches and
be actuated with a force matching the torque output
of the engine.
Inspect the throttle cable and
its
mounts. Neither the
cable nor the mounts should be deformed or bent. 2.
With the
tween the end tance
valve or valves.
to actuate the servos. In this
throttle
Loosen the
output.
The transmission modulator also governs the used
that the
re-
which actuates the modulator, by a
line
cable or by a solenoid.
of
and modBy
wider.
and check
not, adjust the accelerator linkage
justment nuts so that the cable housing can be adjusted.
the cable stopper
is
valves cause the
shift
power
Most transmissions also make use downshifting. This circuit
shift
opened
throttle is
the best use of the engine’s
linkage the
vehicle speed,
be delayed with increased
upshift points to
make
as the
in
to the floor
If
open, the distance between the end of the rubber boot and
or throttle position. Gover-
these two pressures, the
to
effected by
is
fully.
to the transmission.
accelerator
valves.
opens
does.
down
runs
4.
by an electronic control module.
it
the air cleaner assembly.
Push back the rubber boot from the
3.
control the hydraulic fluid. Usually, the solenoids are regulated
1.
2.
so that
transmissions are electronically controlled.
On these models,
Pick-Up and 4Runner
3.
is
0.020-0.059
Have an
boot and the stopper. The correct disin.
assistant
(0.5-1. 5mm).
open the
distance. Correct distance 4.
If
measure the distance be-
throttle fully closed,
of the
is
throttle fully.
1.26-1.34
in.
Remeasure the
(32-34mm).
distances are not correct, adjust the cable via the
adjusting nuts at the bracket.
A442F AND A343F Identification 1.
The A43D
2WD, four speed transmission engaged overdrive. was first offered as an
a
is
with electrically
fully
automatic
A44F
is
the
4Runners.
in
and
trucks and
4WD
2.
With the
throttle fully closed,
It
option on 1981 models
model year
Inspect the throttle cable and
is
is
available through the current
now
offered
application found
in
in
the
Tacoma. The
1990 and 1991
its
mounts. Neither the
cable nor the mounts should be deformed or bent.
tween the end 0-0.04 3.
in. If
(0-1
of the
measure the distance be-
boot and the stopper. Correct distance
mm).
distances are not correct, adjust the cable via the
adjusting nuts at the bracket.
is
DRIVE TRAIN
7-26
REMOVAL & INSTALLATION
SHIFT LEVER POSITION
1
.
Loosen
or disconnect the nut holding the horizontal shift
rod to the bottom of the shift selector. 2.
Move
now loosened
the
towards the back
>
removed rod downward
or
cause the
of the vehicle. This will
(on the transmission case) to
move
A340E and A340F
into
^On
shift lever
On A43D, A44D and A340F upwards
horizontal rod is
transmissions,
move
in
N and
For A340F, A340H, A440,
move
turn or
arm
the
A442F and A343F
the 2nd notch
until
should put the transmission
in
N and
bring
is
9
6.
R
the
Set the
N
selector inside the vehicle to the
shift
assistant hold the shift selector lightly towards
position.
Reconnect and/or adjust the linkage selector
shift
and tighten the
off
for the neutral safety switch.
the washer and
remove the
nut,
then remove the
Attach the switch to the vehicle with the lbs.
ft.
bolt, tighten to
(13 Nm).
a
Install
new
and
lock plate
nut.
Tighten the nut to 35
inch lbs. (4 Nm).
to the
5.
Stake the nut with the lock
6.
Adjust the neutral safety switch.
7.
Attach the harness to the switch.
8.
Attach the
oil
plate.
cooler pipes.
bolts.
engine and make sure that the vehicle moves when shifted from N into the D range and moves rearward when shifted into R. 7.
oil
install:
position.
Have an
lower part of the
Pry
4.
at
the transmission near the vertical position. 5.
Disconnect the harness
3.
engaged. This
arm
be necessary to remove the
1.
To
units, re-
bring the small
will
bolt for the switch.
the small arm at the transmission near the vertical position. 4.
it
2.
the
or towards the front until the 3rd notch
engaged. This should put the transmission
some models
cooler pipes for access.
approximately the 9
o’clock or horizontal position. 3.
See Figure 59
or
A43D
Start the
forward
I
See Figures 60 and 1
.
2.
TRANSFER CASE LINKAGE
61
Unstake the lockwasher.
Remove
the nut and
bolt,
then the lockwasher and
grommet. 3.
This adjustment
only possible on the
is
To
A340E and A340H
4.
transmissions.
case lever
1.
Shift the transfer
2.
Disconnect the No.
to the
transfer
1
H2
shaft,
position.
5.
case linkage from the
Position the transfer case indicator switch to the
6.
H2
4.
Connect the No.
transfer
1
case linkage
to the
7.
cross
Install
the
8.
35 inch
lbs. (4
Using the control shaft
and
lever, turn the It
is
only possible on the
is
1
.
Loosen the
transfer
L4
the
bolt
48 inch
and set the
Unplug the
3.
Connect an ohmmeter between the terminals and adjust
electrical connector.
the switch so there 4.
Connect the
48 inch 5.
lbs. (5
continuity.
is
electrical lead
and
tighten the switch bolt to
Nm).
Check the
idle
speed.
Neutral Safety Switch The
neutral safety switch prevents the vehicle from starting
unless the gearshift selector the vehicle
placement
will
start in
is
in
either the
P
or
N
positions.
any other positions, adjustment or
If
re-
Fig. of the switch
is
required.
lever
neutral.
lbs. (5
position.
2.
in
the tabs of the lockwasher over the nut.
A340E and A340H
case position switch
and
and the switch groove, then
transmissions.
shift position to
Install
manual valve
now
TRANSFER POSITION SWITCH This adjustment
lever
Nm).
return two notches.
Align the switch basic line
Bend
manual
bolt.
grommet and a new lockwasher.
tighten the adjusting bolt. Tighten to
shaft.
shaft.
then temporarily tighten the adjusting
shaft forwards
position.
manual lever
Insert the neutral safety switch onto the
tighten the nut to
cross shaft. 3.
Slide the switch off the install:
59 Neutral safety switch nut locations
Nm).
DRIVE TRAIN
7-27
Extension Housing Seal
REMOVAL & INSTALLATION I See Figures 62 and 63
Removal
of the extension
housing seal
is
only possible on
A43D, A44D and A340E transmissions.
the 1
.
2.
Elevate and safely support the vehicle. Position a catch
pan below the work area
to contain
spilled fluid. 3.
Remove
4.
Clean the extension housing area thoroughly before
moving the
the driveshaft.
seal.
No
dirt
must be allowed
re-
to enter the trans-
mission during replacement. 5.
Fig.
60 Exploded view of neutral safety switch
Using a seal extractor such as
equivalent,
mounting
remove the
To
install:
6.
Use a
seal driver such as tool
equivalent. Drive the
tool
09308-10010 or
seal.
new
09325-20010 or
seal into place
until
it
seats.
the driveshaft.
7.
Install
8.
Lower the vehicle and
start the engine.
applied, shift the transmission through
each
With the brake
position,
pausing
enough to allow the gear to fully engage. Place the selecin P and check the fluid level, topping the fluid as needed.
long
Bolt
tor
Do NOT Neutral Basic Line
overfill
the
fluid.
Transmission Assembly
Groove
REMOVAL & INSTALLATION 86827g62
Pick-Up and 4Runner Fig. 61
A43D, A44D
Align the switch basic line and the switch
groove, then tighten the adjusting bolt to 48 inch lbs. (5
>
AND A340E
See Figures
Nm) 1
.
2.
64, 65,
66 and 67
Disconnect the cables
at the battery, negative
Remove
the air cleaner assembly.
62 Use
SST 09308-10010
first.
ADJUSTMENT
1
Loosen the
.
neutral start switch bolt.
Place the gearshift selector lever
3.
Align the shaft groove of the switch with the neutral
Basic
line.
Hold the switch
switch bolts on the to
N
2.
9 4.
ft.
lbs.
A43D
in this
to
48
in
position
the
and
inch lbs. (6
position.
tighten the
Nm) and
all
others
(13 Nm).
With the parking brake set and the brake pedal
applied, attempt to start the engine
engine should only
start in
N
in
each
fully
shifter range.
The
or P.
Fig.
the extension housing seal
or equivalent to
remove
DRIVE TRAIN
7-28
* Support the transmission using a jack with a wooden
14.
Do wooden
block placed between the jack and the transmission pan. not raise the transmission, just raise the jack
until
the
block touches the transmission pan.
Place a wooden block
15.
pan and the
front
"The wooden
damage
lowered,
components.
between the engine
block(s) should be no
(6mm) away from the engine so
in.
is
(or blocks)
more than about
when
that
not occur to any underhood
will
Remove
17.
Raise the transmission SLIGHTLY,
the transmission mount-to-crossmember bolts.
the weight of the transmission
off of
just
enough
the crossmember-to-frame mounting bolts and
crossmember from the vehicle. For vehicles with remove the bracket and rear transmission mount. Slowly lower the transmission
18.
wooden
the engine rests on
until
the engine undercover
in
order to gain access
engine crankshaft pulley.
to the
Remove
20.
remove the A43D,
block placed earlier.
Remove
19.
to take
the crossmember. Re-
the
the
0.2
the engine
*
16.
move
oil
frame crossmember.
the rubber plugs from the service holes located
at the rear of the
engine
in
order to gain access to the torque
converter bolts. 21
Rotate the crankshaft as necessary
.
to
remove the torque
converter retaining bolts. Access to these bolts
is
through the
service holes mentioned earlier.
same dimensions as
Obtain a bolt of the
22.
converter bolts. Cut the head
off of
the torque
the bolt and cut a screw-
driver slot in the bolt opposite the threaded end.
^This modified
bolt is
used as a guide
pin.
Two
guide
pins are needed to properly install the transmission.
Thread the guide
23.
bolt holes.
The guide
pin into
pin
will
one
of the torque converter
help keep the converter with the
transmission. 24.
Remove
25.
Carefully
the transmission-to-engine mounting bolts.
move
the transmission rearward by prying on
the guide pin through the service hole.
•As 3.
Disconnect the transmission
4.
Raise the vehicle and support
throttle cable.
safely with jackstands.
it
Double check the security and placement
of the stands.
5.
Unplug the wiring connectors near the
6.
Disconnect the starter wiring at the
and remove
starter
it
Matchmark the
8.
pinion flange.
away from the engine
Unbolt the
help keep the converter
upward SLIGHTLY
to
in place.
Pull the
26.
transmission rearward and lower
it
out of the
fluid.
rear driveshaft flange
and the
These marks must be aligned during
Unbolt the rear driveshaft flange.
9.
is
in.
from the vehicle.
Drain the transmission
7.
0.1
the nose of the transmission pointed
starter.
starter.
soon as the transmission
(3mm), feed wire through the front of the transmission and secure the wire in order to keep the converter attached to the transmission. Also, try to keep
about
If
differential
installation.
the vehicle has a two
vehicle.
•Do
not allow the attached cables to catch on any com-
ponents during removal.
piece driveshaft, remove the center bearing bracket-to-frame bolts.
27. With the transmission out of the vehicle,
the driveshaft from the vehicle.
Disconnect the speedometer cable from the transmission
10.
and
Remove
tie
11. 12.
it
out of the way.
Disconnect the
shift
linkage at the transmission.
Disconnect the exhaust pipe clamp at the
and remove the transmission 13.
dipstick
Disconnect the transmission
transmission.
oil
and
oil
bell
filler
housing
tube.
cooler lines at the
remove the
torque converter as follows: a.
Place a drain pan under the front of the transmission.
b.
Pull the converter straight off the transmission
low the
and
al-
fluid to drain.
•-Prior to installation of the transmission, Toyota recom-
mends checking dimensions.
maximum
If
the torque converter and flywheel run-out
either of these run-out limits are
beyond the
allowable limits, excessive wear of the front
transmission seal
will
occur.
DRIVE TRAIN
Oil Cooler Pipe
Fig.
65 Exploded view of the A43D transmission and components to be removed
7-29
DRIVE TRAIN
7-30
400 29 39 (
|
k g-cm
[_
(ft-l b,
N m)]
;
,
)
[
$
Specified torque
Non-reusable part 86827g53
Fig.
66 Exploded view of the
A44D transmission and components
to
be removed
DRIVE TRAIN
7-31
DRIVE TRAIN
7-32
Mount the torque converter on the flywheel and tighten 20 ft. lbs. (27 Nm) for A43D and A44D transmissions. For A340E, tighten them to 30 ft. lbs. (41 Nm). 28.
the converter bolts to
Mount the
29.
of the converter
touches the outer surface
Slowly rotate the converter and read the indicator needle should not deviate
dial indicator.
more than
0.01
33.
Mount the
1
touches the flywheel
ring
just inside of the
34. Zero the indicator needle
rotate the flywheel.
more than
0.01
install:
Apply a coat
grease
of multi-purpose
and the corresponding
verter stub shaft
36.
Install
to the torque
pilot
hole
in
the
rotating
it
the guide pins into two opposite mounting lugs of
the torque converter.
Raise the transmission to the engine and align the trans-
mission with the engine alignment dowels. Also, position the converter guide pins into the mounting holes of the flywheel.
bolts.
Install
and
Tighten the bolts to 47
41.
Remove
mounting
tighten the transmission-to-engine ft.
(64 Nm).
lbs.
the converter guide pins and
5.
Remove
6.
Raise the vehicle, support
there are 5 connec-
the upper starter mounting it
bolt.
on safety stands and drain
fluid.
7.
Remove
8.
Disconnect the exhaust pipe
9.
Disconnect and plug the 2
the driveshafts. at the
oil
pipe.
tail
cooler lines at the trans-
10.
the con-
1 1
.
and disconnect the No.
Pull the cotter pins
transfer
case
gain access to the guide pins and bolts through the service
shift
1
and No. 2
linkages at the cross shaft over the trans-
shift
Remove
mission case.
the cross shaft.
12.
Disconnect the speedometer cable.
13.
Disconnect the 2
14.
Using a transmission jack, or a
cooler lines at the transfer case.
oil
wood, raise the transmission
just
floor jack
enough
to
and a block
of
remove pressure
from the rear support member. 15.
wood between
Position a piece of
rear support
verter mounting bolts. Rotate the crankshaft as necessary to
and disconnect the manual
Pull out the cotter pin
linkage at the neutral safety switch.
remove the 8
rear of the cylinder head,
install
chamber
mission case.
To make sure that the converter is properly installed, measure the distance between the torque converter mounting lugs and the front mounting face of the transmission. The proper distance is 0.79 in. (20mm) for A43D and A44D; for A340E, correct distance is 0.71 in. (18mm).
40.
air intake
unplug them.
to
37.
39.
throttle
from the rear of the engine.
it
Underneath the
the transmission
completely couple the torque converter to the transmission.
Install
connector.
air intake
linkage, then unplug
con-
the torque converter into the front of the transmis-
Push inward on the torque converter while
38.
Disconnect the negative battery cable.
Loosen the adjusting nuts and disconnect the
4.
flywheel.
sion.
for leaks.
Unplug the
tors;
To
and check
test the vehicle
3.
in.
(0.20mm).
35.
need
cable housing at the bracket. Disconnect the cable at the
and slowly
indicator needle should not deviate
will
fluid.
2.
gear teeth
(surface faces the rear of the vehicle).
The
.
so that the indicator probe
gear
the torque
If
See Figure 68
the torque converter from the flywheel. dial indicator
Road
fluid.
drained, the transmission
A340F AND A340H >
Remove
was completely
in.
(0.30mm). 32.
the transmission with the correct
Fill
converter
55.
Adjust the dial indicator to zero.
31
throttle cable.
the air cleaner assembly and connect the battery
about 7 quarts of
30.
The
Install
54.
extension sleeve
(90° to the converter centerline).
.
Connect and adjust the transmission
53.
cables.
so that the indicator probe
dial indicator
52.
16. 17.
the firewall and the bolts
and
lift
out the
member.
Remove Remove
the engine under cover. the 6 torque converter mounting bolts.
holes. 42.
(27
Evenly tighten the converter mounting bolts to 20
Nm)
for
A43D and A44D them
missions, tighten
to
30
transmissions. For ft.
lbs.
(41
Nm).
A340E
Install
ft.
lbs.
trans-
•Rotate the crankshaft
the rubber 18.
plugs into the access holes. the engine undercover.
Install
44.
Raise the transmission
19. slightly
block(s) from beneath the engine
oil
and remove the wood
Install
pan.
the transmission crossmember. Tighten the cross-
member-to-frame missions,
install
bolts to
70
ft.
(95 Nm). For
lbs.
A43D
trans-
46.
43
ft.
(58 Nm).
Remove
the starter and then
bolt)
remove the transmission
bolts.
Using the guide pin
.
to
keep the transmission and torque
With a large drip pan under the assembly,
converter.
Lower the transmission onto the crossmember and
an old
mission assembly moving rearward. Be careful!
the rear mounting bracket and tighten the
lbs.
of
converter together, pry on the end of the pin to get the trans-
21 bolts to
head
of the torque converter bolt holes.
housing mounting 20.
45.
order to gain access to the
Insert a guide pin (just cut off the
one
into
43.
in
torque converter mounting bolts.
Remove
the
filler
pull off
the
tube from the side of the transmis-
install
sion case.
the transmission mounting bolts. Tighten the bolts to 18
ft.
••Prior to installation of the transmission, Toyota recom-
(25 Nm). 47.
Install
the
oil filler
tube and connect the exhaust pipe
clamp. 48.
mends checking dimensions.
Connect the
oil
tighten the fittings to 49.
Connect the
50.
Install
51.
lbs.
cooler lines to the transmission and
23
shift
ft.
lbs. (31
Nm).
maximum
If
the torque converter and flywheel run-out
either of these run-out limits are
beyond the
allowable limits, excessive wear of the front
transmission seal
will
occur.
linkage and the speedometer cable.
the driveshaft and the starter.
Connect the wiring harnesses.
22.
Mount the torque converter on the flywheel and
the converter bolts to 30
ft.
lbs.
(40 Nm).
tighten
DRIVE TRAIN
Oil Cooler Pipe
Transfer Shift Lever
Transfer Under Cover
f 300
Stiffener Plate
(
22 29 ,
)
Rear Support
Member
Engine Under Cover
[
300 22 29 (
,
Rear Propeller Shaft )
^750 |
kg
cm
(ft -lb,
N-m)^
Non reusable
:
(
54 74 .
)
Specified torque
part 86827g54
Fig.
68 Exploded view of the A340F transmission and components to be removed
7-33
DRIVE TRAIN
7-34
Mount the
23.
Tacoma
so that the indicator probe
dial indicator
touches the outer surface
of the converter extension
sleeve
A340E AND A340F
(90° to the converter centerline). 24.
Adjust the dial indicator to zero.
25.
Slowly rotate the converter and read the
The
2.
Remove Remove
3.
Disconnect the
1.
dial indicator.
more than
indicator needle should not deviate
0.01
in.
26.
Remove
27.
Mount the
the torque converter from the flywheel.
5.
gear just inside of the gear teeth
ring
Remove Remove
4.
so that the indicator probe
dial indicator
touches the flywheel
case
fer
(surface faces the rear of the vehicle).
The
more than
indicator needle should not deviate
0.01
b.
install:
Use a new O-ring and press
the
filler
tube
into the
Coat the
hole
in
the crankshaft
and the center hub
Using calipers and a straightedge,
make
32.
lip
1.02
is
and
align
one
with
it
2 sleeves on the cylinder
of the driveplate holes. Align the
block with the converter housing and temporarily
install
the
tilt
a
bolt.
shift
If
all
pull
out
When
reinstalling,
apply multi-purpose grease to the
8.
Disconnect the front exhaust pipe.
9.
Disconnect the following:
the fluid level pipe.
the front and rear driveshafts.
Speedometer cable
•
No. 2 vehicle speed sensor harness
•
Solenoid harness
• Transfer case neutral position switch harness • Transfer case L4 position switch harness
holes are aligned,
the starter and then
install
Tighten to 47
bolts.
all
lbs.
ft.
case indicator switch
10.
Remove
1 1
Loosen the union nuts and disconnect the
(64 .
the bolts and clamps holding the
oil oil
cooler pipe. cooler
pipes.
Remove
the guide pin and
Tighten the bolts evenly to 20
4 cylinder engines and
to
30
ft.
ft.
install
the 6 converter bolts.
(27
lbs.
lbs. (41
Nm) on models with Nm) on those with the
12.
Disconnect the temperature sensor harness.
13.
Disconnect the neutral safety switch harness.
14.
Remove
15.
Unbolt the stabilizer bar bracket.
V6. 35.
Install
the engine under cover.
36.
Install
the rear support
16.
member and
tighten the 8 bolts a.
70
remove the snapring and
Remove Remove
will fall out.
Nm).
to
pliers,
7.
the transmission forward during installation; the
remaining transmission housing
34.
lever assembly.
lever from the transfer case.
• Transfer 33.
i
shift lever.
•
Never
shift
Unattach the harness then remove the 8 screws and
shift
^WARNING converter
knob.
the nut and washer, then disconnect the
Using snapring
6.
the converter
in
the screws and the front console box with the shift lever
Remove
g.
(26mm).
in.
a guide pin
Install
case
transmission
sure the distance
from the installed surface of the converter to the transmission
housing
assembly and trans-
the rear console box.
d.
f.
the torque converter into the transmission case.
Install
shift lever
Disconnect the harness wires.
e.
pilot
the transmission
lever as follows:
c.
of the converter with grease.
31.
cable by loosening the nut then
control knob.
transmission case. 30.
shift
transfer
in.
(0.20mm).
To
throttle
the fan shroud.
Remove Remove
a.
Zero the indicator needle and slowly rotate the flywheel.
29.
the engine under cover.
disconnecting the cable. Separate the cable from the clamp.
(0.30mm).
28.
the fluid level dipstick.
ft.
lbs.
(95 Nm).
Remove the torque converter clutch mounting bolt: On the 3RZ-FE engine, remove the 2 nuts and bolts,
then the 2 bolts and flywheel housing under cover.
37.
Connect the transfer case
38.
Connect the speedometer cable being sure
cooler lines.
oil
On
b.
washer and
felt
the starter.
dust protector are
still
that the
on the end.
Connect the
40.
Coat the cross shaft
shift
linkage using a joint with
new
cotter pin.
the 6 bolts.
grease and then
5VZ-FE engine remove
While turning the crankshaft
c.
39.
the
the 4 bolts and flywheel
housing under cover.
install
When
then the other
the shaft to the body. Connect the 2 transfer case linkages to
Remove
17.
to gain access,
installing first attach the
5.
remove
green colored
bolt
/
|
the front differential rear mounting cushion as
the cross shaft. follows:
41.
Connect the
cooler lines to the transmission case
oil
and a.
install
the bracket. lift
42.
Connect the exhaust pipe
to the tailpipe. Tighten the b.
connecting nuts and pipe clamp bolt to 32 43.
Install
ft.
lbs.
(43 Nm).
c.
44.
Engage the
five
connectors under the
air intake
18.
the upper starter mounting nut.
Install
46.
Connect and adjust the
47.
Connect the
truck.
careful not to touch the torque converter clutch differential
companion
flange.
Remove the 2 rear mounting cushion mounting bolts. Remove the crossmember, support the transmission rear
side with a suitable jack.
45.
tery cable.
Be
nut. then
front differential.
housing and front
the front and rear driveshafts.
chamber.
Using a hexagon wrench (12mm), remove the
up the
Fill
Check
air intake
throttle cable.
connector and the negative bat-
the transmission with fluid and road test the
for
any
leaks.
19.
Remove
the mounting bolts then the crossmember.
sure to support the transmission with a jack. 20.
Lower the transmission rear
21.
Separate the wire harness from the transmission.
side.
Be
:
DRIVE TRAIN On the 3RZ-FE engine remove On the 5VZ-FE engine, remove
22. sion.
the 4 bolts and transmisthe 6 bolts
c.
move
transmission.
To
23.
reverse the procedure. Always use
install
new
gas-
24.
Fill
the transfer case shift lever knob. the four screws holding the console and re-
the console.
Remove
d.
and O-rings.
kets
Remove Remove
b.
and
the unit with the correct
the vehicle and
fluid, start
Remove Remove
e. f.
T100
A340E AND A340F
the six bolts holding the transmission shift
Remove
g.
Pull out the pin
h.
Remove
1.
Remove
2.
Unbolt the engine under cover.
3.
Disconnect the
fluid level dipstick.
throttle
cable by loosening the nut then
8.
Disconnect the speedometer cable.
9.
Remove Remove Remove
Raise and safely support the vehicle.
5. 6.
Remove Remove
7.
Disconnect the front exhaust pipe.
12.
8.
Disconnect the speedometer cable and vehicle speed
13.
10.
the fluid level dipstick.
1 1
the front and rear driveshafts.
Remove the cross shaft as follows: Remove the clip and disconnect the
the undercover. the endplate hole plug. Turn the crankshaft to
the bolts.
(preferred) or a floor jack
Remove the nut, washer, 4 bolts and the cross shaft. Remove the oil cooler pipe. Remove the bolts and clamps holding the oil cooler pipe. oil
cooler
tension
fluid
temperature sensor
off
and remove
Use a
the bolts and nuts holding the
floor jack
Lower the
17.
rear
Disconnect the neutral safety switch harness.
15.
Disconnect the starter wire.
16. 17.
Remove Remove
18.
Disconnect the rear mounting insulator.
19.
Jack up the transmission.
20.
While turning the crankshaft to gain access to the 6
Set up a
remove them.
the torque converter.
Disconnect the harness and connectors from the
try to correct
21.
run-out.
the ring gear
if
is
dial indicator
it
If
Unbolt the transmission from the engine.
position
reverse the procedure. Always use
new
gas-
and O-rings. fluid, start
dial indicator
damaged, the
driveplate
is
the vehicle and
used
If
the
If
that the
is
Remove
the
completed.
To
install:
20.
With the torque converter installed on the transmission, a straightedge across the
installation with
lugs to the front of the case
the distance
See Figures 69 and 70
(0.30mm),
the misalignment cannot be
when measurement
front of the case. Correct distance
A440F
in.
make matchmarks so
at reinstallation.
check the converter
Land Cruiser
at the center of
run-out exceeds 0.0118
corrected, the torque converter must be replaced.
test the operation.
I
slide the unit
by repositioning the torque converter.
torque converter
the unit with the correct
pan.
and
run-out exceeds 0.0079
If
and measure run-out
repositioning corrects the error,
To
Fill
of the transmission
Temporarily mount the torque converter to the driveplate.
19.
23.
24.
support the
oil
must be replaced.
22.
kets
to
the engine.
(0.20mm) or
in.
transmission.
install
end
and measure the driveplate
the rear end plate nuts, bolts and plate.
crossmember
With the transmission removed, set up a
18.
the stabilizer bar.
of wood Do NOT bend the
and a piece
pan.
oil
14.
away from
to pro-
to take
it.
engine under the
harness.
wood
of
enough
just
the crossmember.
Remove
15.
and a broad piece
Tension the jack
tect the transmission.
16.
Disconnect the transmission
bolts,
oil
Support the transmission, either with a transmission jack
14.
pipes. 13.
and disconnect the
the two line clamps
Remove Remove
Remove No. 2 gear shifting
Loosen the union nuts and disconnect the
12.
the starter.
gain access to each of the six torque converter mounting bolts.
rod.
.
.
the front and rear propeller shafts.
cooler lines at the transmission.
sensor harness.
10.
shift
lever assembly.
Elevate and safely support the vehicle. Double check the
7.
4.
1 1
shift rod.
the four bolts holding the transfer case
supports for placement and security.
disconnecting the cable. Separate the cable from the clamp.
b.
the assembly.
and disconnect the
and remove the
lever
a.
case
transfer
the three bolts holding the console box.
lever assembly.
9.
remove the
the four bolts and
shift lever boot.
test the operation.
the
7-35
measured
is
is
from the surface of the bolt
0.618
in.
(1.57mm) or more.
less than specified,
If
check the con-
verter for improper installation. 1.
Disconnect the negative battery cable.
2.
Remove
Loosen the cooling fan shroud damage. 3.
Loosen the adjusting nuts
4.
21
the battery and the battery cover. bolts.
This
will
avoid fan
Disconnect the cable housing from the bracket; disconnect the
Unplug the
6.
Remove a.
connectors near the
starter.
the transfer case shift lever as follows:
Under the
control rod.
electrical
vehicle,
23.
remove the nut and transmission
the rear
Install
Install
to
mount ft.
lbs.
53
to the transmission. Tighten the
(59 Nm).
ft.
lbs.
ft.
lbs.
(59 Nm).
the torque converter mounting bolts, tightening
to 21
when
finished. Install
43
the nuts to 43
them 25.
place.
them
the crossmember. Tighten the bolts to 45
Install
Nm) and
24.
fully into
(72 Nm).
retaining bolts to
(61
it
the transmission retaining bolts and tighten
lbs.
ft.
22.
for the throttle control cable.
cable from the throttle linkage. 5.
Elevate the transmission and push
.
Install
ft.
lbs.
(28 Nm).
the undercover.
Install
the end plate hole plug
7-36
DRIVE TRAIN
Hold
Down Clamp
Cover
Battery
Fan Shroud
.
Oil Cooler Pipe
290 21 29 ) (
.
Transfer
Under Cover
Engine Under Cover
620 us,ei)~l
|kg-cm
(ft-lb,
N-mJ]
:
Specified torque
— Frame Crossmember 86827g56
Fig.
69 Exploded view of the A440F transmission and components to be removed
DRIVE TRAIN
27.
Install
the front and rear driveshafts.
28.
Install
the
29.
Install
the starter.
oil filler
30.
Connect the speedometer cable.
31
The
.
transfer
case
Nm).
tube.
shift lever is installed
removal sequence. The four
shift lever bolts
by reversing the
should be
tight-
32.
Engage the
33.
Connect and adjust the
34.
Tighten the fan shroud bolts.
35.
Connect the negative battery cable.
36.
Add
electrical
the correct
connectors near the
amount
throttle cable.
of fluid.
starter.
7-37
7-38
DRIVE TRAIN
A343F AND A442F >
See Figures
71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82,
83, 84, 85, 86, 87, 88, 1
.
Remove
89 and 90
the battery and battery tray. Always disconnect
the negative battery cable
first.
2.
Unbolt the fan shroud for the cooling fan.
3.
Disconnect the
throttle
cable by loosening the adjusting
nut and removing the cable from the bracket. 4.
Detach the cable from the linkage.
5.
Remove Remove
6.
the upper side starter mounting the
clip,
nect the transfer case 7.
Remove
shift lever link.
the nut and washer, then disconnect the trans-
mission select lever
86827g41 link.
8.
Unscrew the
9.
Unbolt the console and set aside.
10.
Remove
bolt.
washer and wave washer, then discon-
transfer
case
shift lever
knob.
the mounting screws for the transfer case
shift
Fig.
73 The upper side starter mounting bolt
is
located
lever boot. 1 1
.
Remove
at
the console box.
the arrow
l
j
(
(
Fig. 74 When removing the select lever and shift lever, always discard the old clip; it should not be reused
DRIVE TRAIN 12.
Disconnect the wiring harnesses.
13.
Remove
7-39
the 6 mounting screws for the transmission shift
lever assembly. 14.
Unbolt the transfer case
shift lever,
then remove the two
cushions. 15.
If
applicable, disconnect the following:
•
Vehicle speed sensors
•
Neutral safety switch
• Solenoid connector •
ATF
•
Center
•
L4 position switch
•
Bleeder hose from the transfer case
temperature sensor differential lock indicator switch
17.
Remove Remove
18.
Unbolt the upper side mounting.
19.
Remove
16.
the front and rear driveshafts. the
oil
level dipstick.
the bolt retaining the
filler
pipe. Discard the old
O-ring.
Fig.
77 The
shift lever
boot has 4 mounting screws
Fig. 78 The other console screws are on the top and deep inside
20.
Loosen the two
21.
Remove
oil
cooler pipe union nuts.
the 4 stabilizer bar bracket mounting bolts.
DRIVE TRAIN
7-40
84
Fig.
When removing
the stabilizer bar bolts, there
are two U-brackets holding the bar into place
22.
Separate the engine undercover from the vehicle.
23.
Take
the converter plug
off.
24. Turn the crankshaft to gain access to
each
hold the crankshaft pulley nut with a wrench and
bolt,
then
remove the 6
bolts.
26.
Remove Remove
27.
Support the transmission with a suitable jack.
25.
the front exhaust pipe, discard the gaskets. the starter.
Remove
the bolts and nuts retaining the crossmember. Lower the
crossmember.
Lower the rear end
28.
damage
of the transmission.
the cooling fan, brake booster
Be
careful not to
and brake
line.
Separate the wire harness from the transmission and
29.
transfer case.
Remove
30.
the cooler pipe mounting bolts from the torque
converter clutch housing, then disconnect the 2
cooler pipes
oil
from the elbows.
Remove
31.
the transmission mounting bolts.
To
install:
32.
Using calipers and a straightedge, measure from the
stalled surface of the transmission housing.
should be more than 0.618
53
sion, tighten to
33.
Attach the
lbs.
ft.
oil
in.
(15.7mm).
in-
The distance
Install
the transmis-
(72 Nm).
cooler pipe mounting with the bolts to the
converter housing, then attach the harness to the transfer case
and transmission. 34.
Attach the
bolts to
45
crossmember to the vehicle. Tighten the 8 Nm) and the 2 nuts to 54 ft. lbs. (74
lbs. (61
ft.
Nm). 35.
Install
the starter. Tighten the bolts to 29
lbs.
ft.
(39
Nm). Attach the harness. 36.
Using new gaskets and nuts, attach the
pipe. Tighten the support bracket to
clamp ft.
ft.
lbs. lbs.
37. to
Fig.
83
A
pipe wrench
union nuts on the
may be used
40
cooler line
14
ft.
lbs.
ft.
lbs.
front
exhaust
(24 Nm), the
(19 Nm), the front pipe-to-manifold 46
(62 Nm), and the front pipe-to-catalytic converter to 29 (39 Nm). Install ft.
lbs.
the torque converter clutch mounting
(55 Nm). First
install
bolt.
the gray colored
Tighten
bolt,
then
the other 5 bolts.
to separate the 38.
oil
bolts to
17
Install
(28 Nm).
the front engine undercover, tighten to 21
ft.
lbs.
DRIVE TRAIN
39.
Place the 4 stabilizer bar bracket mounting bolts into
position,
then tighten to 13
40.
Attach the 2
41.
With a
new
level dipstick into
oil
ft.
lbs.
cooler pipe union nuts. oil filler
pipe. Insert the
the pipe.
42.
Install
the front and rear driveshafts.
43.
Install
the following:
• Center differential lock indicator switch •
L4 position switch
•
Neutral safety switch and connector
•
Bleeder hose from the transfer case
• Vehicle
speed sensors
44.
ATF temperature sensor
Place the transfer case
the 4 bolts to 13 to
48 inch
lbs. (5
ft.
lbs.
Nm).
boot into position, then tighten the 4 screws. Slip the console
over the lever assembly and tighten the 4 screws. 46.
Screw on the
47.
Place the nut and washer on the select lever linkage.
48.
Install
shift
lever into position. Tighten
(18 Nm). Attach the 6 screws, tighten
the
transfer
case
shifter knob.
wave washer, washer and new
clip
onto the
shift lever linkage.
49.
• Solenoid connector •
45. Attach the connectors to the shift lever assembly. Install
the 3 mounting bolts on the console box. Place the shift lever
(18 Nm).
O-ring, install the
7-41
29
ft.
Attach the upper side starter mounting lbs.
bolt.
Tighten to
(39 Nm).
50.
Attach the throttle linkage.
51.
Install
the fan shroud for the cooling fan.
52.
Install
the battery tray and battery.
53.
Fill
54.
Start the vehicle. Test the operation of the unit.
the transmission.
7-42
DRIVE TRAIN
Hold
Down Clamp Battery
Battery Tray
Starter
Fan Shroud
Level
Gauge
r*> Front Propeller Shaft
Oil Filler Pipe
Gasket
- O-Ring 4 Gasket
Hole Plug
Engine Under Cover Stabilizer Bar
Crossmember with Transfer Under Cover
Non-reusable part 86827gb3
Fig.
87 Exploded view of components to be removed
— A343F transmission
DRIVE TRAIN
7-43
Transfer Shift Lever Boot
86827g32
Fig.
88 Exploded view of the A343F transmission and components to be removed (continued)
7-44
DRIVE TRAIN
Cover Hold
Down Clamp Battery
Fan Shroud
Front Propeller Shaft
Cooler Pipe
Oil
74 760 54 (
,
)
Speedometer Cable
Transfer Under Cover
28 ( 290 21 ,
)
Torque Converter Clutch Cover
28 290 21 (
,
61
)
Engine Under Cover
(
620 45 ,
)
59 600 43 (
,
)
Frame Crossmember
N-m
(kgf-cm,
ft
•
Ibf) |
:
Specified torque 86827g30
Fig.
89 Exploded view of components to be removed
— A442F transmission
DRIVE TRAIN
7-45
Rear Mounting Torque Converter Clutch
h
1
59 600 43 )] (
.
86827g31
Fig.
90 Exploded view of the A442F transmission and components to be removed (continued)
TRANSFER CASE Transfer Case Assembly
Applications Toyota Pick-Ups, 4Runners, TIOO’s and Tacomas use either the
RF1A
or
VF1A
transfer case.
The RF1A uses a
REMOVAL & INSTALLATION
countergear reduction scheme.
The VF1A is
found
in
transfer
case
is
a planetary gear reduction
unit.
The Land Cruiser employs the HF2A or HF2AV transfer A440F and A343F transmissions for full
case, used with the time
4WD
It
>
See Figure
91
the T100, Pick-Up, and 4Runner.
^•The transfer case
is
removed as an assembly with the
transmission.
application. 1
will
.
Remove
On some models remove the breather hose between the
the transmission assembly.
be necessary
to
it
transmission control retainer and the transfer case upper cover. 2.
the
Remove
the rear engine
dynamic damper 3.
Remove
if
one
is
mount from the case. Remove present.
the upper driveshaft dust cover.
DRIVE TRAIN
7-46
Remove
4.
then
pull
'"Be
the transfer case adapter rear mounting bolts,
the transfer case straight up
careful not to
damage
and remove
the adapter rear
it.
seal dur-
oil
ing removal.
To
install:
5.
Move
6.
Coat the adapter
the 2 shift forks into the oil
H4
position.
seal with grease
and
new
position a
gasket on the transfer case adapter. 7.
the transfer case to the transmission. Tighten the
Install
bolts to
29
lbs.
ft.
(39 Nm).
The longer
dust cover, the shorter ones are used Install
8. ft.
lbs.
the rear engine
bolts are
in all
used
at the
other locations.
mount and tighten the bolts damper one was
(25 Nm). Install the dynamic
19
to
if
removed. 9.
Install
the breather hose
if
one was removed.
the
Install
transmission assembly. Fig. 91
Place the shift fork shafts into the H4 position
as shown
DRIVELINE Front Driveshaft and Universal Joints
REMOVAL & INSTALLATION > See Figures 92, 93, 94, 95, 96, 97, 98, 99, 100 and 101 1
Jack up the
.
front of the vehicle
and support
with
jackstands.
Place matchmarks on the flanges.
2.
and
Remove
the 4 nuts
bolts.
Remove
3.
the front driveshaft dust cover.
equipped with 2
Remove
4.
bolts, while
others use
Some
types are
4.
The
the driveshaft dust cover subassembly.
three bolts are two different sizes.
»"The driveshaft dust cover portion of the U-joint.
is
located around the outer
On some models you may have an
upper and lower.
Suspend the front side of the driveshaft. Place matchmarks on the flanges. Remove the 4 nuts
5. 6.
and
bolts.
7.
To 8.
10.
Remove
11.
install:
Align the
matchmarks on the
rear flanges, then connect ft.
lbs.
(74
then connect
front flanges,
ft.
lbs.
(74
to
13 12.
Install ft.
lbs.
the front driveshaft dust cover. Tighten the bolts
(17
Nm) and
the nuts to 10
ft.
lbs.
(13 Nm).
Attach the rear driveshaft flange to the companion flange
on the transfer case. Align the matchmarks on the flanges,
Nm). Install
Tighten bolts
Nm).
matchmarks on the
Nm).
the front driveshaft.
the flanges with the nuts and/or bolts. Tighten to 54
9.
Align the
the flanges with the bolts and nuts. Tighten to 54
then connect the flanges with the bolts and nuts. Tighten to
the front driveshaft dust cover subassembly.
A
to
27
ft.
lbs.
(36
Nm) and B
to 17
54-56 ft.
lbs.
(23 13.
ft.
lbs.
(74-76 Nm).
Lower the vehicle and road
test
it.
DRIVE TRAIN
Fig.
93
Remove
the front dust cover retaining bolts
7-47
7-48
DRIVE TRAIN
[4WD] Others Front Propeller Shaft
1
74 (750.
74 (760, 54)
|
S4|~~|
Rear Propeller Shaft
I
|N-m (kgf-cm,
ft-lbf)
|
:
Specified torque
Non-reusable part 86827g71
Fig.
96 Exploded view of the front driveshaft
—
1
989-95
4WD
Pick-Up and 4Runner except with 3VZ-FE engine
DRIVE TRAIN
[4WD]
w/
Boot for 3VZ-FE
N -m
(kgf -cm,
ft
•
Ibf )
:
Specified torque
|
Non-reusable part 86827g70
Fig.
97 Exploded view of the front driveshaft
— 1989-95
4WD
Pick-Up and 4Runner with 3VZ-FE engine
7-49
7-50
DRIVE TRAIN Front Propeller Shaft
86827gvc
Fig.
98 Exploded view of the front driveshaft
— 4WD
Land Cruiser
DRIVE TRAIN
U-JOINT >
7-51
REPLACEMENT
See Figures 102, 103, 104, 105 and 106 1.
Raise and support the vehicle.
2.
Remove
3.
Matchmark the yoke and the
4.
Remove
the driveshaft.
9.
driveshaft.
the snaprings from the bearings. There are two
types of snaprings; Toyota and Dana. 5.
Position the
yoke on vise jaws. Using a bearing remover
and a hammer, gently tap the remover driven out of the yoke about 6.
Place the
the tool
until
tool in the vise
the bearing
is
in.
until
the bearing
is
(25mm).
and
drive the
yoke away from
removed.
7.
Repeat Steps 4 and 5
8.
Check
for
1
for the other bearings.
worn or damaged
parts. Inspect the bearing
journal surfaces for wear.
To assemble: Install
10. ings. 1 1
.
12.
the bearing cups, seals, and O-rings
Apply multi-purpose grease
Be
careful not to apply too
Start the bearings
If
in
Repeat
Be sure
Check the
^When
vibration
U-joint
will
assembly
is
will
that the snaprings are the
and
them
into
for the other bearings.
the axial play of the spider
driveshaft noise
greater than 0.0020
in.
provide the correct play.
same
size on both sides or
result.
for
smooth operation.
replacing the driveshaft U-joints on a
be sure that the grease joint is assembled. cle,
the spider.
grease.
the yoke, then press
(0.05mm), select snaprings which
14.
much
in
spider and bear-
Position the spider into the yoke.
place, using a vise. 13.
new
a
to
fitting is
4WD
vehi-
accessible after the
7-52
DRIVE TRAIN
Fig.
5.
To 6.
106 Check the axial play after reassembly
Remove
the driveshaft from under the truck.
install:
Apply multi-purpose grease
to the splined
end
of the
shaft. 7.
^•Be
Insert the driveshaft sleeve into the transmission.
careful not to
damage
the extension housing grease
seal. 8.
marks on the rear flange and replace
Align the mating
ft. lbs. (74 Nm) on all vehicles except models with 3VZ-E engines and manual transmissions. Tighten
the bolts. Tighten to 54
to
56
ft.
9.
Remove
lbs.
Nm) on these models.
(76
the jackstands and lower the vehicle.
TWO-PIECE DRIVESHAFT 1
.
Jack up the rear
of the truck
and support the rear axle
housing on jackstands. 2.
Before you begin to disassemble the driveshaft compo-
nents, you
must
mating flanges.
first
Do
marks on the
paint accurate alignment
this
on the rear universal
joint flange, the
center flange, and on the transmission flange. 3. 10.
Remove
the bolts attaching the rear universal joint flange
to the drive pinion flange. 4.
REMOVAL & INSTALLATION
5.
2WD
Models
6.
Jack up the rear
of the truck
and support the rear axle
housing with jackstands. 2.
Matchmark the two halves
4.
of the rear universal joint
the bolts which hold the rear flange together. the splined end of the driveshaft from the
transmission.
’•tPlug the
the center bearing support from the
Separate the transmission output flange and remove the
7.
install:
Connect the output flange
8.
Install
but do not
Remove Remove
the
end
9.
the center bearing support to the crossmember,
fully tighten
Install
of the transmission with a rag or other oil
loss.
the bolts.
the rear section of the shaft making sure that
mating marks are aligned. Tighten
device to prevent
of the transmission to the
flange on the front half of the shaft.
flange. 3.
pull
assembly.
To .
and
front half of the driveshaft together with the center bearing
See Figures 107 and 108 1
Remove
of the shaft slightly
bearing sleeve yoke.
crossmember.
ONE-PIECE DRIVESHAFT I
Drop the rear section
unit out of the center
all
flange bolts to 22-36
ft.
lbs.
(30-49 Nm).
all
DRIVE TRAIN
7-53
[2WD] 2-Joint
Type
TMC-made (DANA-made)
3-Joint
Type
Nut
Flange Yoke
Non-reusable part 86827gvd
Fig.
107 Exploded view of one and two-piece rear driveshaft
— 2WD Tacoma
DRIVE TRAIN
7-54 4WD
sure the marks
Models
EXCEPT LAND CRUISER
1 1
I
See Figures 109, 110 and 111 1
.
2.
all
line up,
then tighten the bolts to 54
ft.
r"
lbs.
(74 Nm). .
Connect the rear flange to the differential flange and 54 ft. lbs. (74 Nm). Connect the front flange to the transfer case flange and
tighten the bolts to
Raise and support the vehicle with jackstands. Matchmark all driveshaft flanges BEFORE removing any
12.
54 ft. lbs. (74 Nm). Mount the center bearing on the crossmember and tighten the mounting bolts to 27 ft. lbs. (36 Nm). 14. Lower the vehicle and road test. tighten the bolts to 13.
bolts. 3.
Disconnect the driveshaft flange at the companion flange
on the
differential.
Remove
4.
the center bearing from the frame
LAND CRUISER
crossmember. Disconnect the front flange at the companion flange on
5.
and remove the
the rear of the transfer case
Separate the
6.
driveshaft.
1
front portion of the shaft at the intermedi-
ate shaft flange. 7.
Disconnect the rear of the driveshaft at the center bear-
Using a
hammer and
chisel,
loosen the staked portion of
remove the
nut.
Matchmark the
flange to the intermediate shaft, then pull the bearing
off
the
nut,
all
equipped,
install
the center bearing on the intermediate
Tighten the nut to 134
and
retighten again to 51
Connect the
ft.
ft.
(181 Nm), then loosen the
lbs.
lbs.
(69 Nm). Stake the nut.
front portion of the driveshaft to the inter-
mediate shaft and the rear portion
with jackstands.
BEFORE
removing the
Unfasten the bolts which secure the universal
joint
flange
4.
Matchmark
all
of the flanges for the joint-to-transfer
case
flange bolts. 5.
ft
Withdraw the driveshaft from beneath the
vehicle.
install:
-
to the center flange.
Make
^Lubricate the U-joints and sliding pose grease before installation. 6.
Position the driveshaft so that
tighten the flange bolts to 7.
65
108 Exploded view of one-piece rear driveshaft
ft.
lbs.
Lower the vehicle and road
[2WD]
Fig.
it
driveshaft flanges
install: If
shaft.
3.
To
shaft.
9.
Raise the vehicle and support
Matchmark
to the differential pinion flange.
the center bearing nut, then
To
.
2.
bolts.
ing flange. 8. 10.
> See Figure 112
joints with multi-pur-
marks
all
(88 Nm).
test
it.
Flange
— 1989-95 2WD
Pick-Up and 4Runner
Yoke
line up,
then
-
DRIVE TRAIN
7-55
7-56
DRIVE TRAIN
DRIVE TRAIN U-JOINT
REPLACEMENT
10. ings. 1 1
>
See Figures 113, 114, 115, 116 and 117 1
.
2.
the driveshaft.
3.
Matchmark the yoke and the
4.
Remove
driveshaft.
the snaprings from the bearings. There are two
5. Position the yoke on vise jaws. Using a bearing remover and a hammer, gently tap the remover until the bearing is driven out of the yoke about 1 in. (25mm). 6.
Place the tool until
in
the vise and drive the yoke
the bearing
is
spider and bear-
grease.
Position the spider into the yoke.
them
into
13.
Repeat Step 5
14.
If
away from
for the other bearings.
the axle play of the spider
(0.05mm), select snaprings which
that the snaprings are the
driveshaft noise 15.
Check the
and
vibration
U-joint
is
will
greater than 0.0020
in.
provide the correct play.
same
size
on both sides or
will result.
assembly
for
smooth operation.
Center Bearing
removed.
7.
Repeat Steps 4 and 5
8.
Check
for
new
a
Start the bearings in the yoke, then press
Be sure
types of snaprings: Toyota and Dana.
the tool
to
much
careful not to apply too
place, using a vise.
Raise and support the vehicle.
Remove
.
12.
Apply multi-purpose grease
Be
7-57
for the other bearings.
worn or damaged
parts. Inspect the bearing
REMOVAL & INSTALLATION
journal surfaces for wear.
To assemble: 9.
Install
the bearing cups, seals, and O-rings
in
the spider.
The center support bearing
is
a sealed
unit
which requires
no periodic maintenance. The following procedure should be
DRIVE TRAIN
7-58
Remove
5.
the two bolts from the bearing housing and
remove the housing.
Remove the dust deflectors from both sides of the Remove the dust deflectors from either side
6.
bear-
ing cushion.
of the
bearing.
Remove
7.
This
easy
is
holes
in
the snaprings from each side of the bearing.
to
do
if
you have a snapring
the ring, and very
difficult
which
tool
otherwise.
the
fits
Remove
the
bearing.
To assemble: Install
8.
on each
ing
the .new bearing into the cushion and
fit
a snapr-
side.
86827g78
Apply a coat
9.
and put them
tors
the bearing.
The
goes on the rear
The water position
117 Check the axial play after reassembly
to the
dust deflec-
respective places on each side of
single deflector with a slightly larger diameter of the bearing.
Press the dust deflector onto each side
10.
Fig.
grease
of multi-purpose in their
drain holes
in
on each side
of the cushion.
the deflectors should be
The water
of the cushion.
the
in
same
drain holes
should face the bottom of the housing.
used
if
it
becomes necessary
does not supply
individual parts for the bearing
only the assembly. 1
Remove
.
to replace the bearing.
See your
local
jobber
if
replacement
joint
flange and the
Remove
the cotter pin and castle nut from the intermedi-
ate driveshaft; the nut joint
and
earlier,
the
install
on the intermediate shaft and tighten the nut
(181 Nm).
Loosen the nut and then
retighten
it
to
134
to 51
ft.
ft.
lbs.
lbs.
(69 Nm). Stake the nut.
intermediate driveshaft. 3.
inter-
front.
universal joint flange to the driveshaft. Install the center bearing
marks on the universal
Match the mating marks painted
12.
the intermediate driveshaft and the center sup-
Paint mating
Press the support bearing assembly firmly onto the
.
mediate driveshaft, with the seal facing
necessary.
port bearing assembly. 2.
1 1
Toyota
be staked. Remove the universal
will
^Check
to see if the center support bearing assembly smoothly around the driveshaft.
rotate
will
flange from the driveshaft using a press.
4.
Remove
When
13.
the center support bearing assembly from the
reinstalling the driveshaft,
be certain
to
match up
the marks on both the front transmission flange and the flange
driveshaft.
on the sleeve yoke
of the rear driveshaft.
FRONT DRIVE AXLE Manual Locking Hub
12.
Place a
13.
Install
new gasket
into position
on the cover.
the cover to the body with the follower pawl tabs
aligned with the non toothed portions of the body. 14.
REMOVAL & INSTALLATION
Tighten the cover mounting bolts to 7
ft.
lbs.
(10 Nm).
Front Axle, Bearing and Seal
> See Figures 118, 119, 120, 121, 122, 123, 124, 125, 126,
127 and 128
Remove the hub cover. Set the control handle to free. 2. Remove the cover mounting bolts, then pull off the cover. Remove and discard the gasket. 3. Remove the bolt with washer. 4. Remove the mounting nuts and washers. 1.
5.
Using a brass bar and hammer, tap on the
bolt ends,
then remove the cone washers. Pull off the
7.
Remove and
To 8. Install
See Figures 1
Raise the front
.
new gasket
into position
on the
front axle hub.
the free wheeling hub body with the cones washers and
23
ft.
and 132
of the vehicle
Remove the wheel. On models with ABS,
and support on safety
lbs. (31
disconnect the speed sensor from
4.
Remove Remove
5.
Disconnect and plug the brake
3.
Place a
129, 130, 131
4WD
the steering knuckle.
install:
Install
>
2.
discard the gasket.
nuts. Tighten the nuts to 9.
Pick-Up and 1989-95 4Runner
stands.
hub body.
6.
REMOVAL & INSTALLATION
Nm).
cure
the bolt with washer, tighten to 13
ft.
lbs.
(18
Nm). 10.
Apply multi-purpose grease
11.
Set the control handle and clutch to the free position.
to the inner
hub
splines.
it
the brake caliper. the hub. line at
the disc and se-
out of the way.
6. Pop off the axle nut lockwasher, then remove the nut, washer and adjusting nut. Remove the axle hub/brake rotor as an assembly along with the outer wheel bearing.
DRIVE TRAIN
7-59
31 (315, 23)
Gasket Free Wheeling
Hub Body 10 (100, 7)
Free Wheeling
Hub Body Gasket 18(185,13)
Tension Spring
Clutch
Snap Ring Steel Ball
Spring Follower Pawl
Free Wheeling
Hub Body
Control Handle
Nm
(kgf-cm,
ft
lbf)
:
Specified torque
Non-reusable part 86827gva
Fig.
118 Exploded view of the free wheeling hub
7-60
DRIVE TRAIN
86827pl9 86827pl2
Fig.
119 Turn the handle with your hand to the free Fig.
position
122 Pull the cover off
86827p20 86827pl3
Fig.
120 Note the directions
handle:
left
— free,
right
in
— lock
which you can turn the Fig.
86827pll
Fig. 121
the six
With the handle
hub cover
bolts
in
the free position, remove
123 Using the correct size wrench, loosen
.
DRIVE TRAIN
86827pl8
86827pl5
125 Next, remove the outside mounting nuts and
Fig.
washers
7-61
Fig.
128 The free wheeling body should
easily;
come
off
be sure to discard the old gaskets
86827pl6 86827p22
Fig.
126 Using a brass bar and hammer, tap on the bolt
ends
.
.
Fig.
.
129
Remove
the axle nut lockwasher
127
... then remove the cone washers
.
.
86827p23
86827pl7
Fig.
.
Fig.
130
... the nut
.
.
.
DRIVE TRAIN
7-62
Pry out the
7.
oil
seal and
remove the inner bearing from
14.
8.
Loosen the 6 axle
9.
Remove
shaft-to-differential
housing nuts.
the snapring and spacer from the end of the
Coat the outboard end
18. is
Insert the
12.
17.
of the axle shaft with lithium
grease.
outboard end of the shaft
knuckle and then
install
it
Hand
tighten the
20.
[-'•-WARNING
13.
Install
assembly on the
a
lbs.
ft.
nut,
(59
Nm)
then retighten
that the bearing preload
(28-56 N).
lbs.
new
locknut and washer, tighten to 35-58
Use a tension gauge and check (28-56 N).
lbs.
tions, adjust
the axle shaft boots.
the spacer
Use a tension gauge and check Install
steer-
the outer bearing.
Tighten the bearing adjusting nut to 43
6.4-12.6
21.
damage
in
ft.
lbs.
(47-78 Nm). Check that the bearing has no play.
is
not
and press
6.4-12.6 19.
into the steering
to the differential.
bolts.
Do
Position the axle hub/brake disc
and spin the hub a few times. Loosen the to 18 ft. lbs. (25 Nm).
install:
.
it
ing knuckle
gear shaft and then remove the shaft down and through the
To
(83 Nm).
hub. 16.
Separate the inboard axle shaft flange from the side
steering knuckle.
1 1
lbs.
ft.
into Pack the inner axle bearing with grease and press the hub. Coat a new oil seal with grease and press it into the
axle shaft. 10.
Tighten the inner mounting nuts to 61
15.
the hub.
it
If
that the bearing preload
the preload
is
not within specifica-
again with the adjusting nut.
Secure the locknut by bending one
washer teeth
of the
inward and another outward.
and a new snapring.
22.
Install
the hub.
23.
Install
the brake caliper
24.
If
25.
Install
26.
Road
T100, >
removed, attach the
and
line.
ABS speed
sensor
to the knuckle.
the wheel, lower the vehicle and bleed the brakes. test the truck.
Tacoma and 1996 4Runner
See Figure 133 1.
Loosen the
2.
Raise and support the vehicle.
3.
4.
Remove Remove
5.
Pull off the
6.
Disconnect the driveshaft.
lug nuts.
the front wheels. the shock absorber.
grease cap.
Remove
the cotter pin and
lock cap. 7.
With a helper applying the brakes, remove the locknut.
8.
On
vehicles with
ABS, remove the speed sensor and
harness from the steering knuckle. 9.
10.
11.
Remove Remove Remove
the brake line from the knuckle.
and
the caliper
rotor.
the bolts retaining the lower ball
joint,
separate
from the vehicle. 12.
Remove the SST
hub. Using a
and loosen the nut on the axle
cotter pin
remove the steering knuckle.
or equivalent,
To
install:
13.
Attach the steering knuckle with hub axle to the vehicle,
tighten the
hub nut
80
to
14.
Attach the lower
15.
Install
16.
Place the brake
tighten to 21
ft.
(108 Nm).
lbs.
ball joint, tighten to
59
ft.
lbs.
(80 Nm).
the disc and caliper.
ft.
lbs.
line
bracket on the steering knuckle,
(28 Nm).
ABS
sensor
equipped) and harness.
17.
Install
the
18.
Install
the driveshaft. Tighten the locknut to 174
(if
ft.
lbs.
(235 Nm). 19.
Install
the grease cap.
20.
Install
the shock absorber.
21.
Install
the wheel, lower the vehicle, tighten the lug nuts.
Land Cruiser 1989-91 1.
MODELS
Raise and support the vehicle securely and remove the
wheel assembly.
DRIVE TRAIN
„
7-63
Cotter Pin
Shock Absorber and Coil Spring
Grease Cap
4WD Oil
Seal
Bearing Spacer
w/ ABS ABS Speed Sensor Rotor
Brake Dust Cover
Snap Ring
Oil N
m
(kgf
cm,
ftlbf)
:
Seal
Specified torque
Non-reusable part 86827g95
Fig.
133 Exploded view of the front axle hub and components
— 1996
4Runner shown
DRIVE TRAIN
7-64
Remove
2.
move
Remove
3.
and then
the outer axle shaft flange cap,
re-
6.
the bolts retaining the outer axle shaft flange
remove the
Remove
4.
brake drum.
and
If
the brake
drum
shaft flange with
its
8.
equipped with disc brakes, remove the caliper
remove the
Straighten the lockwasher, and
Remove
the front axle hub together with
Remove
its
claw washer,
flat
bladed
tool,
release the lockwasher.
may
the locknut, this
require
SST
Remove' the lockwasher. Using SST 09607-60020
an equivalent socket,
or
Remove
e.
the clip and disconnect the brake flexible hose
the hub and rotor together with the outer
assembled
Tap the steering knuckle spindle lightly and remove the spindle with its gasket.
oil
seal
install:
10.
Pack the bearing hub also.
1 1
to the
backing plate. 9.
the
To
and inner bearing from the hub.
with multi-purpose grease.
Coat the
inside of the
the brake backing plate together wit the brake shoes, still
Remove
9.
Cut and remove the lock wire and remove the bolts
tension spring, and the wheel cylinder
with a soft mal-
Place the inner bearing into the hub.
.
the steering knuckle spindle on a vehiequipped with the ball joint type axle shaft joint, be prepared for the disconnection of the outer axle shaft from the joint. The joint ball will fall from the joint. Try to cushion its fall or catch it if you can.
new
the
seal into the hub.
12.
Install
13.
Place the axle hub with the rotor to the spindle.
oil
Install
the outer bearing and thrust washer.
Adjust the preload, tighten the adjusting nut to 43
14.
**When removing
(59 Nm). Turn the hub right and then the adjusting nut again to 43 until
ft.
(59 Nm). Loosen the nut
lbs.
can be turned by hand. Tighten the nut again
it
inch lbs. (5 Nm).
6.4-12.6 15.
On
those models equipped with the
the inner front axle shaft out of the axle housing.
joint, slide
On
type axle shaft
ball
those models equipped with the constant velocity
remove the
of axle,
joint
Remove bushing from inside bearing puller. Install new bushing 11.
knuckle spindle with a
of
the axle housing
oil
the axle shaft
Install
in
the inner axle with fully
proper spacer
meshed
joint ball
and the
spindle
its
ball joint in
type axle
should be 6.4-12.6
and
On
shaft until
full
on the inner shaft end. spacer
joint,
15.
install
the spindle with
its
Install
its
(28-56 N).
the preload
If
is
Check play. It
not within
removing the
Install
of
the flange as follows:
new gasket
On
c.
Install
install
d.
Place the cone washers, plate washers and nuts
into position
the flange to the axle hub.
position, tighten the nuts to e.
move
knuckle
g.
gasket onto the steering
Install
the bolt
in
26
ft.
lbs.
mesh
with the splines
in
install
a
it
new
out.
snapring. Re-
the bolts.
Coat the inside
of the
cap with grease.
Install
the cap
to the flange.
the differential. full
the caliper and front wheel.
18.
Install
19.
Bleed the brake system.
Pinion Seal
with grease
REMOVAL & INSTALLATION
MODELS
3.
Using a
the front wheel.
Pick-Up and 4Runner
the front brake caliper.
>
flat
See Figures 134, 135, 136, 137 and 138
bladed too and a hammer, remove the
grease cap from the flange. Using a snapring expander, remove the snapring.
1
.
into
(35 Nm).
the axle shaft and pull
Using a snapring expander,
f.
on the axle hub.
the steering knuckle spindle.
Remove Remove
4.
lbs.
the axle into the housing and rotate the axle
splines
2.
1.
SST
(64 Nm).
Apply multi-purpose grease to the inner flange splines.
the outer
Adjust the wheel bearing preload.
1992-96
lbs.
b.
with grease
into the steering
the steering knuckle housing three quarters
and
ft.
Place a
those models equipped with the constant velocity
joint axle, install
Fill
47
a.
with the differential side gear splines.
front axle shaft
install
17.
knuckle. 14.
lock nut. Using
to
lockwasher and locknut. Secure the locknut by hand one
position until the
the steering knuckle three quarters
and place the shaft
washer and
lock
Using a spring tension gauge, measure the preload.
16.
tool.
the reverse order of removal.
those models equipped with the
fill
48
hub turns smoothly and the bearing has no
that the axle
seal with a bearing puller.
To install, use a metal tube as a seating To install:
Next,
to
should be
outward.
Remove
splines are
It
the lockwasher teeth inward and the other lockwasher teeth
using a metal tube as a
seating tool.
13.
new
specifications, adjust with the nut after
housing.
12.
a
09607-60020, tighten the lock nut
type
assembly from the axle
entire axle shaft
the preload again.
(28-56 N).
lbs.
Install
Remeasure
lbs.
ft.
2 or 3 times. Tighten
left
cle
10.
re-
the adjusting nut and thrust washer.
bearing.
seal.
oil
retaining the brake backing plate onto the steering knuckle.
let,
Remove
c.
from the brake tube.
Remove
b.
move
bearings, and
8.
With a
d.
similar tool.
7.
the axle hub and disc as follows:
a.
wheel
front
bearing adjusting nuts with front wheel adjusting nut wrench or
6.
the flange and gasket.
09607-60020 or an equivalent socket.
disc.
5.
Remove Remove
7.
gasket.
and remove the
set screws
heads,
bolt
then remove the 6 cone washers, plate washers and nuts.
onto the front axle hub, then screw service bolts into the shaft flange alternately, and
Loosen the 6 mounting nuts. Using a brass bar and a hammer, tap on the
5.
the shaft snapring on the outer shaft.
Elevate and safely support the vehicle.
2.
Drain the differential
3.
Make matchmarks and remove
oil.
the propeller shaft.
DRIVE TRAIN
7-65
[2WD] 2 -Joint Type
3 -Joint Typ« Flange
Nut
1
kg-c
m
(It lb,
Non
N m)|
Specified torque
reusable part
86827g80
Fig.
— 1989-95
134 Exploded view of the front differential axle seal components
models
4. Loosen the staked part of the companion flange nut. Use a counterhold tool on the flange and remove the nut. 5. Use a screw-type extractor to remove the companion
flange. 6.
Use an
7.
Remove
To 8.
extractor to
remove the
oil
seal
the bearing spacer, bearing
and
and
oil
oil
slinger.
slinger.
install: Install
the
new
bearing spacer, rear bearing and
the
new
oil
oil
slinger. 9. install
Install
the seal. Drive
below the 10.
seal. in to
Use
the correct size driver to
a depth of 0.059
in.
(1.5mm)
lip.
Apply a coat of multi-purpose grease
the seal. Install the 11.
it
companion
Coat the threads
of
a
to the inner
lip
flange.
NEW
nut with multi-purpose
grease. Counterhold the flange and tighten the nut to 89 lbs.
(120 Nm).
ft.
of
7-66
DRIVE TRAIN Use a torque wrench
12.
measure
to
Correct preload on a used bearing
Nm) and on a new ^If preload
bearing
is
panion flange nut
in
If
correct preload
165
lbs.
ft.
pinion bearing preload.
5-9 inch
10-17 inch
is
lbs. (0.6-1 .0
lbs. (1-2
Nm).
greater than specified, replace the bearing
is
preload
spacer.
is
is
com-
less than specified, tighten the
Nm) increments achieved. Maximum torque for 9
(223 Nm).
If
(13
lb.
ft.
the nut
is
exceeded, the bearing
this value is
NOT back
spacer must be replaced; do
the
until
off the flange nut
to lower the torque or preload.
Check the
13.
companion
run-out at the
allowable run-out
is
0.003
14.
Stake the pinion flange
15.
Fill
16.
Install
17.
Lower the vehicle
flange;
maximum
(0.10mm).
in.
nut.
amount
the differential with the correct
of fluid.
the front propeller shaft. to the ground.
T100 and Tacoma 1.
Remove
2.
Drain the differential
3.
Remove
4.
Using a chisel and hammer, loosen the staked part
the engine undercover. fluid.
the front driveshaft.
the nut. Hold the flange and 5.
With a seal extractor,
6.
Pull the
of
remove the nut, then the flange. remove the oil seal and slinger.
bearing from from the drive pinion, then extract
the spacer.
To 7.
install: Install
the
new
bearing spacer, rear bearing and
the
new
oil
oil
slinger. Install
8.
the seal. Drive
install
below the
the seal. Install the 10.
correct size driver to
a depth of 0.059
in.
(1
,5mm)
lip.
Apply a coat
9.
Use the
seal. in to
it
grease
of multi-purpose
companion
Coat the threads
NEW
of a
to the inner
lip
nut with multi-purpose
grease. Counterhold the flange and tighten the nut to 89 Fig.
137 This
is
a screw-type extractor from
Toyota —
ft.
(120 Nm).
lbs.
11.
Tool 09950-30010
of
flange.
Use a torque wrench
measure
to
Correct preload on a used bearing
Nm) and on a new 'Hf preload
is
bearing
is
pinion bearing preload.
5-9 inch
10-17 inch
is
lbs. (0.6-1.
lbs. (1-2
Nm).
greater than specified, replace the bearing
preload
is
less than specified, tighten the
panion flange nut
in
9
correct preload
achieved.
spacer.
173
ft.
If
lbs.
is
(235 Nm).
If
ft.
(13
lb.
Nm) increments
Maximum
this value is
the
torque for the nut off the flange
nut
to lower the torque or preload. 12.
Check
the run-out at the
allowable run-out
is
0.003
in.
13.
Stake the pinion flange
14.
Install
15.
Fill
16.
Install
17.
Lower the vehicle
companion
flange;
maximum
(0.10mm). nut.
the front driveshaft.
the differential with the correct
amount
of fluid.
the front propeller shaft. to the
ground.
Land Cruiser Fig. 138 The extractor 09308-10010 as shown
fits
into Seal
Removal Tool
1.
Elevate and safely support the vehicle.
2.
Make matchmarks and disconnect
shaft.
is
exceeded, the bearing
NOT back
spacer must be replaced; do
com-
until
the front propeller
DRIVE TRAIN matchmarks and
3. Loosen the staked part of the companion flange nut. Use a counterhold tool on the flange and remove the nut. 4. Use screw type extractor to remove the companion
the
flange.
tightness. Install the correct
Use an
5.
To
install:
6.
Install
remove the
extractor to
slinger
oil
.0mm) below the
and a new
seal.
in to
it
slinger.
Use the
1996
measure
to
greater than specified, replace the bearing
9
in
preload
achieved. If
Disconnect the front driveshaft.
(13 Nm.) increments
lb.
ft.
Maximum
value
this
NOT
be replaced; do
Check
until
companion 253
ft.
ness and
lbs.
the flange nut to lower torque or
off
companion
is
0.02
in.
flange;
maximum
13.
Fill
14.
Install
15.
Lower the vehicle
amount
of fluid.
the front propeller shaft. to the
ADD
ADD, disconnect
Without
switch har-
sensor connector with 2-4 selector.
Remove
the breather hose.
Support the front
Remove
8.
Lower the
a suitable jack.
differential with
the rear mounting nut and front mounting bolts.
remove the
jack, then
front differential
assembly.
nut.
the differential with the correct
TEMP
6.
9.
Stake the pinion flange
oil
7.
(0.10mm).
12.
Disconnect the driveshaft.
the 2 bolts and tube from the differential.
exceeded, the bearing spacer must
is
back
bolts.
the front differential as follows:
With Automatic Disconnecting Differential (ADD), dis-
b. is
oil.
connect the vacuum hoses, breather hose,
the correct
torque for the nut
the run-out at the
allowable run-out
noise and/or leaks.
Place matchmarks on the driveshaft, then remove the 4
Remove
preload. 11.
for
the engine undercover.
washers and
a.
less than specified, tighten the
is
flange nut
(343 Nm).
3.
5.
4.3-6.9 inch lbs. (0.5-0.8 Nm).
is
Drain the differential
pinion bearing preload.
is
preload
checking
Remove
4.
is
If
test the vehicle,
1.
ft.
preload
spacer.
its
Lower the
of lubricant.
2.
nut with multi-purpose
Correct preload If
amount
MODELS
of
lip
nuts,
Use a torque wrench
10.
(74 Nm).
lbs.
ft.
in.
(196 Nm).
9.
Road
flange.
NEW
of a
to the inner
grease. Counterhold the flange and tighten the nut to 145 lbs.
54
removed or double check
if
I See Figure 139
companion
Coat the threads
the drain plug
Install
the propeller shaft to
install
flange. Tighten the nuts to
vehicle to the ground.
correct
lip.
the seal. Install the 8.
13.
a depth of 0.04
Apply a coat of multi-purpose grease
7.
oil
companion
14.
the
size driver to install the seal; drive (1
and
seal
oil
Align the
12.
7-67
Remove install:
10.
Attach the front and rear mounting cushions, tighten the
rear to
ground.
the front and rear mounting cushions.
To
80
ft.
lbs.
(108
Nm) and
the front to 116
lbs.
ft.
(157
Nm). 1 1
Differential Carrier
.
12.
Raise and support the Install
Tighten the nuts to 64 lbs.
REMOVAL & INSTALLATION
into position.
ft.
(87
lbs.
Nm) and
the bolts to 101
ft.
(137 Nm).
13. tial,
assembly
differential
the rear mounting nut and front mounting bolts.
On
vehicles without
tighten the
ADD,
mounting bolts
attach the tube to the differen-
to 9
ft.
lbs.
(13 Nm).
Install
the
breather hose.
Pick-Up and 1989-95 4Runner
14.
Elevate and support the front of the truck. Double check
1.
and
the placement
Place matchmarks on the flanges and disconnect the
oil.
propeller shaft.
Matchmark the driveshafts and side gear and disconnect the front driveshafts.
shafts.
Remove
the 6 nuts If
ADD
ADD,
vacuum hoses,
attach the
switch harness and
then tighten the mounting bolts to 9
Drain the differential
3.
5.
vehicles with
TEMP
oil
sensor con-
nector with 2-4 selector. Attach the tube to the differential,
security of the jackstands.
2.
4.
On
breather hose,
Differential
4WD
indicator
lbs.
(13 Nm).
Attach the front driveshaft, tighten to 54
16.
Install
the driveshafts.
17.
Install
the drain plug
its
equipped with Automatic Disconnecting
(ADD), disconnect the vacuum hoses and the
ft.
15.
if
it
tightness. Install the proper
ft.
lbs.
(74 Nm).
was removed or double check amount of gear oil.
the engine undercover.
18.
Install
19.
Test drive the vehicle.
switch connector.
Remove
6.
Support the
7.
and
right rear
To
Support the
8.
the
left
lbs.
ft.
9.
differential with
a
Remove
floor jack.
mounting bolts and remove the
the
left
front differential.
install:
Install
123
T100
the front mounting bolt and nut.
Install
and
differential right rear
and place mounting
it
under the vehicle.
bolts, tightening
them
to
(167 Nm).
If
the front mounting
bolt,
tightening
equipped with Automatic Disconnecting
Align the
the nuts to 61
3.
Disconnect the front driveshaft.
4.
Place matchmarks on the driveshaft and remove the 6
the engine undercover. oil.
nuts holding the driveshaft and side gear shaft.
Remove
the
it
to
108
ft.
lbs.
5.
Disconnect the vacuum hoses and the
4WD
indicator
switch harness.
(ADD), attach the hoses and the 11.
Remove
Drain the differential
driveshaft nuts.
(147 Nm.) 10.
1.
2.
matchmarks and ft.
lbs.
(83 Nm).
4WD install
Differential
switch harness.
the driveshafts. Tighten
6.
Remove
7.
Loosen and remove the mounting
the crossmember. bolt
and nut
for the
differential. 8.
Support the front
differential with
a suitable jack.
7-68
DRIVE TRAIN
w/ A.D.D. A.D.D. Switch Connector-
RH
Drive Shaft
w/ A.D.D. Vacuum Hose
Front Propeller Shaft
Differential
Front (RH) j
^
Mounting Cushion
LH
N m (kgfcm,
ft lbf)
:
Drive Shaft
Specified torque
Non-reusable part 86827g96
Fig.
139 Exploded view of the front
differential
assembly
— 4Runner
DRIVE TRAIN
7-69
9.
Remove jack, then
To
Lower the
assembly.
and
a jack and raise and left mounting
into posi-
differential with
tighten the right
ft.
and attach the crossmember, tighten
to
93
ft.
lbs.
(126 Nm). Attach the
13.
vacuum hoses and
the
4WD
indicator
and
Install
mounting bolts
On
vehicles with
ADD
breather hose,
attach the tube to the differen-
to 9
lbs.
ft.
ADD,
(13 Nm). Install the
vacuum hoses,
attach the
switch harness and
tighten the driveshaft nuts to 61
ft.
then tighten the mounting bolts to 9
oil
TEMP
(83
lbs.
ft.
lbs.
sensor con-
(13 Nm).
15.
Attach the front driveshaft, tighten to 54
16.
Install
the driveshafts.
17.
Install
the drain plug
its
harness. 14.
ADD,
vehicles without
nector with 2-4 selector. Attach the tube to the differential,
Attach the front mounting bolt and nut, tighten to 108
Install
On
tighten the
14.
123
bolts to
(147 Nm).
12.
13. tial,
(167 Nm).
11. lbs.
rear mounting bolts.
breather hose.
Support the Install
lbs.
ft.
left
differential
install:
10. tion.
the right and
remove the
if
it
tightness. Install the proper
ft.
lbs.
(74 Nm).
was removed or double check amount of gear oil.
the engine undercover.
18.
Install
19.
Test drive the vehicle.
Nm). 15.
Attach the front driveshaft.
16.
Install
its
the drain plug
if
it
tightness. Install the proper
17.
Land Cruiser
was removed or double check amount of gear oil.
I See Figures 141 and 142 Before removal on vehicles with a
the engine undercover.
Install
ON
ignition switch to the
Test drive the vehicle.
18.
FR/RR 1.
See Figure 140
position, then lock the front differential.
Remove
.
the engine undercover.
2.
Drain the differential
3.
Disconnect the front driveshaft.
4.
Place matchmarks on the driveshaft, then remove the 4
washers and
nuts,
Remove
5.
bolts.
oil.
oil
TEMP
6.
Support the front
ADD
7.
Remove
8.
Lower the
switch har-
remove the
6.
Remove
To
a suitable jack.
7.
18-20
front differential
the front and rear mounting cushions.
To
install:
Attach the front and rear mounting cushions, tighten the
80
ft.
9.
lbs.
(108 Nm). and the front to 116
ft.
lbs.
(157
Nm). 11.
Raise and support the
12.
Install
assembly
into position.
the rear mounting nut and front mounting bolts.
Tighten the nuts to 64 lbs.
differential
(137 Nm).
ft.
lbs.
(87
Nm) and
ball joint
separator
to separate the tie rod joints;
end
(NEVER
remove the
Make matchmarks
tie
of
a rod.
first.
On
Remove
the ring of nuts holding the carrier
Do
not scratch the
and remove
machined surfaces
install:
Place a
new gasket
ft.
On
lbs.
and
in
position
install
on the housing.
Fit
the
the nuts. Tighten the nuts to
(25-27 Nm).
vehicles with differential lock, attach the harness
and
tube.
10.
rear to
Use a
Disconnect the front shaft.
carrier into the axle
8.
Remove
the cotter pin and castle nut from each
tie rod.
during removal.
assembly. 9.
the front axle shafts.
the carrier assembly.
the rear mounting nut and front mounting bolts. jack, then
of the stands.
oil.
vehicles with differential lock, disconnect the harness and tube.
differential.
differential with
Remove Remove
5.
sensor connector with 2-4 selector.
and tube from the
3.
hammer)
Disconnect the driveshaft.
Without ADD, disconnect the breather hose.
b.
the 2 bolts
Drain the differential
the steering
the front differential as follows:
connect the vacuum hoses, breather hose,
ness and
2.
4.
With Automatic Disconnecting Differential (ADD), dis-
a.
to the
Disconnect the
Elevate and safely support the vehicle on stands. Double
check the security and placement 1
differential lock, turn the
Turn the lock switch
negative battery cable.
Tacoma >
position.
the bolts to 101
Connect the
front driveshaft.
10.
Install
the
11.
Install
the front driveshafts.
12.
Install
the drain plug
its
tie rod.
if
it
tightness. Install the proper
was removed or double check amount of gear oil. Lower the
vehicle to the ground. ft.
13.
Test drive the vehicle.
14.
Check
that the bleeder plug at the point of the bleeder
(inside the engine area)
is
not
damaged
or worn.
7-70
DRIVE TRAIN
w/A.D.D. 2-4 Selector: Oil TEMP. Sensor Connector
RH
w/A.D.D:
ADD.
Switch Connector
Drive Shaft
w/A.D.D:
Vacuum Hose
+ Snap
Ring
Differential
i
LH
Rear Mounting Cushion
Drive Shaft
Front (LH)
Mounting Cshion
& Non-reusable part 8682 7g88
Fig.
140 Exploded view of the front differential assembly
— Tacoma
DRIVE TRAIN
Fig. 141
If
your vehicle has a
differential lock, turn the lock
7-71
switch to the FR/RR position, then lock the front differential
DRIVE TRAIN
7-72
REAR DRIVE AXLE Axle Shaft, Bearing and Seal
Understanding Drive Axles The
drive axle
a special type of transmission that reduces
is
the speed of the drive from the engine and transmission and
wheels. Power enters the axle from companion flange. The flange is mounted on the drive pinion shaft. The drive pinion shaft and gear which carry the power into the differential turn at the speed of the transmission output shaft. The gear on the end of the
power
divides the
REMOVAL & INSTALLATION
to the
the driveshaft via the
whose axis of rotation is The pinion and gear reduce the gear ratio of the axle, and change the direction of rotation to turn the axle shafts which drive both wheels. The axle gear ratio is found by dividing the number of pinion gear teeth into the number of ring gear teeth. The ring gear drives the differential case. The case provides
Pick-Ups, 4Runner, T100 and
1989-95
Tacoma
MODELS
> See Figures 143, 144, 145 and 146
pinion shaft drives a large ring gear
90 degrees away from the
of the pinion.
1
.
Loosen the
and support
it
lug nuts
on the wheel, then raise the truck
on jackstands.
2.
Drain the axle housing.
3.
Remove
the lug nuts
and remove the wheel.
the two mounting points for the ends of a pinion shaft on
which are mounted two pinion gears. The pinion gears drive
one
the two side gears, of
each axle
By
of
which
is
located on the inner end
shaft.
driving the axle shafts through this
ferential allows the outer drive
inner drive wheel
The main
in
a
arrangement, the
to turn faster
dif-
than the
turn.
drive pinion
weight of the
wheel
differential
and the side bearings, which bear the case, are
shimmed
to provide
proper
bearing preload, and to position the pinion and ring gears properly.
-•--•-WARNING The proper adjustment
of the relationship of the ring
and
should be attempted only by those with extensive equipment and/or experience. Doing pinion gears
it
is critical.
incorrectly is noisy
It
86827p27
and expensive. Fig.
143
Remove
the 4 bolts from the backing plate
Determining Axle Ratio The ratio.
drive axle of a vehicle
number
This
fraction)
(usually
said to have a certain axle
comparison
actually a
is
is
a whole number and a decimal
on the
ring
means
that, in theory,
number
of
gear teeth
there are 4.11 teeth on the ring gear
and one tooth on the pinion gear driveshaft
of the
gear and the pinion gear. For example, a 4.11 rear
must
put another way, the
or,
turn 4.11 times to turn the
wheels once. There
might be 37 teeth on the ring gear and 9 teeth on the pinion gear.
By
dividing the
numerical axle
number
ratio (4.11) is
of teeth
on the
ring gear, the
obtained.
Another method of determining gear
ratio is to jack
support the truck so that both rear wheels are
Make a
off
up and
the ground.
chalk mark on the rear wheel and the driveshaft. Put
the transmission
in neutral. Turn the rear wheel one complete and count the number of turns that the driveshaft makes. The number of turns that the driveshaft makes in one com-
turn
plete revolution of the rear
rear axle ratio.
wheel
is
an approximation
86827p28
of the
Fig.
144 Slide the axle shaft from the housing
DRIVE TRAIN 14.
the brake shoes
Install
and
lever assembly.
7-73
Connect the
parking brake cable and the brake shoe springs. After installing the brake drum, bleed the brakes
15.
16.
Refill
1996
and
shoe clearance.
adjust the brake
the axle housing with lubricant.
MODELS
I See Figures 147, 148 and 149 1
Loosen the
.
lug nuts
on the rear wheel.
Raise and support the vehicle, then remove the wheel.
2. 3.
Remove
4.
Check the bearing backlash and
the brake drum. axle shaft deviation as
4.
follows:
Using a
a.
dial indicator,
check
that the backlash in the
The maximum is 0.027 in. (0.7mm). backlash exceeds the maximum, repiace the
bearing shaft direction. b.
If
the
bearing. 86827p29
Using a
c.
Fig.
145 Pull the O-ring from the outside of the housing
0.0039
Remove
the brake
dial indicator,
check the deviation
face of the axle shaft outside the hub
drum securing screw, then the drum.
d.
If
at the sur-
Maximum
bolt.
is
(0.1mm).
in.
the deviation exceeds the
maximum, replace
the axle
shaft.
i-CAUTION
5.
Brake pads and shoes may contain asbestos which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air. Avoid inhal-
any dust from brake surfaces. When cleaning brakes, use commercially available brake cleaning fluids.
On models
6.
Remove
7.
Remove On ABS
ential side)
Remove the brake springs and the retracting spring bolt. Remove the lower springs and shoe strut. Remove
the brake shoes, screws, and the parking brake lever. Disen-
gage the parking brake cable from the lever and the backing
9.
10.
line
.
from the wheel cylinder, being tool,
damage
careful not to 7.
Remove
to the axle
To
Plug the brake
line.
the snapring and then press the axle shaft out
backing plate and slide the assembly out of the housing.
Remove
9.
fitting.
the
oil
seal
and press out the axle bearing.
replace the 11. 12.
oil
Install Install
into the axle
a
new
Be
careful not to
shaft splines
lbs.
Install
(69
Nm)
mesh
damage
back and
the
oil
Install
a
Install
a
14.
Replace the inner side
install
forth until the
with the differential gear splines.
a
new
new new
bearing to the axle shaft. outer seal onto the axle shaft. oil
seal.
Apply multi-purpose grease to the
On ABS
17.
Attach a
18.
Install
models,
install
Install
the
a
oil
seal
new
ABS speed
lip.
Press the
snapring.
sensor rotor and
new
O-ring on the axle housing.
the axle assembly attach the 4 mounting bolts to
the backing plate. Tighten to 48
seal
the brake backing plate nuts and tighten to 51
the outer seal. Using a suitable bearing removal
13.
15.
in.
(0.1mm).
bearing retainer on the differential side.
the axle shaft and brake backing plate assembly
with the axle splines. Rotate the axle
13.
Remove
in.
separate the bearing from the axle shaft.
O-ring into the axle housing.
housing.
the rear axle shaft from the backing plate. In-
axle shaft into the backing plate.
bearing into the brake backing plate and
(differ-
rotor.
the snapring from the axle shaft.
install:
seal.
new
sensor
To
install:
Press a
ABS speed
12.
16. 10.
Remove Remove
housing.
Remove
8.
of the
the
the four nuts retaining the brake backing plate
models, remove the bearing and retainer
and
(2.0mm) and the flange run-out should be 0.004 1 1
Disconnect the brake
the O-ring from the axle housing.
spect the axle shaft run-out. Shaft run-out should be 0.079
plate. 6.
the axle shaft assembly by unfastening the 4
the rear axle housing.
8.
5.
ABS, remove the ABS speed sensor
nuts from the backing plate. Pull out the shaft assembly from
ing
clamp
with
from the axle housing.
19.
Install
20.
On
ft.
lbs.
vehicles with
ABS,
install
the sensor to the rear
housing assembly, tighten to 71 inch ft.
21.
snapring. 22. 23.
(66 Nm).
the rear brake assembly.
lbs. (8
drum and wheel. Bleed the brake system and check Lower the vehicle and test drive. Install
Nm).
the rear
for leaks.
DRIVE TRAIN
7-74
Parking Brake Cable
[4WD]
Rear Brake Assembly
Snap Ring
Retainer
Bearing
N-m
(kgf-cm,
ft
-
Ibf
Specified torque
Non-reusable part 86827g94
Fig.
146 Exploded view of the rear axle shaft and components
— 1989-95
Pick-Up and 4Runner
DRIVE TRAIN
7-75
Brake Line
ABS Speed Sensor 8 (82, 71 In.-lbf)
Bellcrank
^
Hub
Bolt
Rear Brake
13(130,
9)
66 (670, 48)
Gasket
w/
ABS
Bearing Retainer
ABS Speed Sensor Rotor
Bearing
Case
Brake Drum
Backing Plate Bearing Retainer Serration Bolt
Oil
Seal
6.
.
DRUM BRAKES Remove
move
the wheel cover,
if
any,
and loosen the wheel
nuts. 2.
Raise the rear axle housing with a jack and support the
rear of the vehicle with jackstands. 3.
Drain the
4.
Remove Remove
5.
oil
from the
differential.
the wheel nuts and take off the wheels.
the brake
(continued)
On some models
it
will
be necessary
remove the load
drum and
related parts.
the cover from the back of the differential housing.
7.
Remove
8.
Withdraw the pinion shaft and
9.
Press the rear shaft toward the
removal
the pin from the differential pinion shaft.
•'CAUTION Brake pads and shoes may contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air. Avoid inhal-
any dust from brake surfaces. When cleaning brakes, use commercially available brake cleaning fluids.
its
spacer from the case.
differential, to aid in
10.
Remove
1 1
Withdraw the axle shaft from the housing.
.
the
of the axle shaft C-clip or axle shaft lock.
the C-clip.
12.
Repeat the removal procedure
13.
To remove
oil
seal
for the
oil
seal together.
use a metal tube to drive bearing and seal
r»Do not mix
opposite side.
and bearing, use a bearing
and remove the axle bearing and
ing
to
sensing proportioning valve bracket from the rear cover. Re-
See Figure 150 1
— 1996 Tacoma
the parts of the
left
puller
To
replace,
into seat.
and the
right axle shaft
assemblies.
and pinion measure the clearance between the axle shaft and the pinion shaft spacer with a feeler gauge. The clearance should be no more than 0.0181 in. (5mm). If the clearance is not 14.
shaft,
After installing the axle shaft, C-lock, spacer
DRIVE TRAIN
7-78
Pinion Shaft Pin
N-m
(kgf-cm,
Specified torque
ft-lbf)
Non-reusable part 86827g93
Fig.
150 Exploded view of the rear axle shaft and components
within 'specifications, the following just
spacers are available
— Land
to ad-
it;
15.
5.
Remove
6.
Disconnect the
7.
Remove
sensor.
(29.00mm)
•
1.157
in.
(29.39mm)
bearing locknut.
•
1.173
in.
(29.80mm)
an equivalent socket may be used.
•
1.189
in.
(30.20mm)
•
1..205
Fill
in.
lug nuts
Remove Remove
oil
seal
on the rear wheel. Raise and sup-
the 6 nuts and plate washers. Using a brass
remove the cone washers.
the shaft.
Remove
or
and outer bear-
with a seal puller,
and inner bearing from the
remove the
unit.
Using a brass bar and hammer, tap out the outer bear-
To
install:
Using a special
.
tool
and a press,
install
the
new
outer
races.
the wheel.
into the axle holes.
bolts evenly, then pull the axle shaft.
SST 09509-2501 1
ing races.
1 1
2 bolts
the locknut, a
Remove the axle hub. 9. Once the hub is removed,
bar and hammer, strike the center part of the axle shaft to
Install
Remove
ing.
the axle with the proper lubricant.
Loosen the
the two mounting screws from the rear axle
Pull out the rear axle hub, locknut plate
8.
(30.60mm)
port the vehicle.
4.
ABS speed
in.
10.
3.
the brake caliper and rotor.
1.142
I See Figures 151, 152, 153 and 154
2.
drum brakes
•
WITH DISC BRAKES
1.
Cruiser with
Gradually tighten the
Remove
the bolts from
the shaft and discard the gasket.
Pack multi-purpose grease
12.
into the
bearing
until
out from the other side. 13.
Coat the inside
14.
Install
of the
hub with grease.
the inner bearing and
a.
Place the inner bearing
b.
Tap
c.
Apply multi-purpose grease
oil
seal as follows:
into the
hub.
the seal into place with the seal installer. to the
oil
seal
lip.
it
oozes
DRIVE TRAIN
7-79
Non-reusable part 8682 7g89
Fig. 151
Exploded view of the rear axle hub and components
— Land
Cruiser with disc brakes
Non-reusable part 8682 7g90
Fig.
152 Exploded view of the rear axle shaft and components
— Land
Cruiser with disc brakes
DRIVE TRAIN
7-80
Check the distance between the top surface of the axle housing and the locknut. It should be 0.0079-0.0354 in. e.
(0.2-0. 9mm)
distance
below the surface
of the axle housing.
If
the
.
greater than specified, reassemble the locknut
is
plate.
Check
f.
that the
hub with the
rotor rotates
smoothly and
the hub has no axle play. 21.
the bearing locknut screw, tighten to 48 inch
Install
lbs.
Nm).
(5
22.
Attach the
ABS speed
sensor, tighten to 13
ft.
lbs.
(18
ft.
lbs.
(147
Nm).
and wheel.
the caliper, rear axle shaft
23.
Install
24.
Tighten the lug nuts on steel wheels to 109
Nm) and on aluminum wheels
to
76
ft.
(103 Nm).
lbs.
Differential Carrier
REMOVAL >
& INSTALLATION
See Figures 155, 156, 157 and 158 1
.
Raise the rear
of the truck
3.
Remove Remove
4.
Disconnect the driveshaft
2.
and support
it
on jackstands.
the drain plug and drain the differential
oil.
the rear axle shafts.
On
at the differential.
vehicles
remove the rear speed sensor from the housing and disconnect the wiring harness clip from
with anti-lock brakes, differential
the housing. 5.
On
vehicles with differential lock, disconnect the harness
and tube. 6.
Remove
the mounting bolts
and
lift
out the differential
assembly.
carrier
To install: 10. 7.
Install
a
•
lock• lock
tial
15.
Clean the hub
and apply clean
installation position of the axle
lubricant (thinly).
damage
Place the hub into position Be careful not to
16.
housing
the
install
the outer bearing.
17.
Install
18.
Place the locknut plate on the axle housing, making sure
the tongue lines up with the key groove. Temporarily
Install
Adjust the preload as follows:
Use a torque wrench
lbs.
(25
Tacoma and T100
Tacoma and T100 Nm)
Pick-Up, 4Runner,
— 54
ft.
lbs.
with differential
Nm) (73
•
1989-91 Land Cruiser
•
1992-96 Land Cruiser
Connect the driveshaft
— 34 — 54
to the
without differen-
ft.
lbs.
(47
ft.
lbs.
(73
Nm) Nm)
companion flange on the
the rear speed sensor
if
it
was removed;
the wire harness clips. Install
the rear axle shafts.
Lower the truck and
fill
the differential with gear
oil.
Pinion Seal
tighten the bearing locknut to
43
(59 Nm).
Make
REMOVAL & INSTALLATION
the bearing snug by turning the hub several
times. Retighten the locknut to
43
ft.
lbs.
(59 Nm).
Using the torque wrench, loosen the nut
until
can be
it
1
turned by hand. Using a spring tension gauge, check that the preload, then tighten the nut
until
the preload
is
6-13
Align the
lbs.
.
2.
Elevate and safely support the vehicle. Matchmark the flanges on the driveshaft and
connect the driveshaft from the
(26-57 N). d.
lbs.
ft.
assembly
to:
the rotor to the hub.
19.
c.
position the carrier
Drive the truck and check for any leaks.
20.
b.
9.
the
install
locknut.
ft.
Pick-Up, 4Runner,
18
differential. Install
axle seal.
a.
8.
new gasket and
housing. Tighten the mounting bolts
into the axle
mark on the bearing locknut and
axle housing under the above preload range.
tip of
the
3.
Use a hammer and
the companion flange
bolt.
pinion. Dis-
differential.
small chisel to loosen the staking on
Attach a counterholding tool to the
DRIVE TRAIN 9.
companion flange and remove the nut. Use the proper threaded extractor to remove the companion flange.
Use an
4.
extractor to
remove the
oil
and
seal
oil
slinger
Make certain the new seal faces in the correct direction. Install the new seal with a driver or seal installation tool of the is recessed correct diameter. Drive the new seal in until it
(1.0mm)
in.
in
Coat the inner
6. Install
the
7.
lip
of the seal with multi-purpose grease.
companion flange (and washer, if removed). Apply a oil to the threads of a NEW companion flange nut.
Set up the counterholding tool and
flange nut. For Pick-Ups, 4Runners,
On Land Cruisers, Nm). On Tacoma tighten to 109 lbs.
(196 Nm).
Check the
lbs.
Nm)
tighten ft.
companion it
to
lbs.
145
ft.
(245
units.
Land Cruisers should be
Nm).
greater than specified, the bearing
is
Do NOT back
for 2-spider
gear
is
differentials
8-1
1
off
lbs.
(13
lbs.
Nm)
the companion flange nut to relieve the
the preload
until
is
less than specified (the usual
companion flange nut
in
increments of 9
the correct specification
is
reached. Maxi-
case), retighten the
allowable torque on the nut under any condition
(441
Nm) on Land
Cruiser and Tacoma, 253
ft.
is
lbs.
325
ft.
ft.
(343
Nm) on Pick-Ups and 4Runner, and 109 ft. lbs. 333 ft. lbs. (451 Nm) on T100. Take great care not to exceed either the preload limit or the maximum torque on the nut. 10.
Stake the drive pinion
1 1
Connect the rear propeller
.
12.
Lower the vehicle
the axle.
inch lbs.
and 4-7 inch
If
nut.
shaft, aligning the
matchmarks.
(147 Nm).
drive pinion preload with a torque wrench. For
Pick-Ups and 4Runners, correct torque (0.9-1. 2
the
install
T 1 00s
tighten to 181
ft.
8.
gear
lbs. (0.6-1 .0
the preload
pressure.
mum
the housing,
coat of
light
If
ing.
install:
5.
0.039
for 4-spider
spacer must be removed and replaced inside the pinion hous-
from the housing.
To
Nm/
(0.4-0. 8
between 6-9 inch
7-81
lbs.
to the ground; inspect the fluid level in
7-82
DRIVE TRAIN
Non-reusable part 86827ga0
Fig.
156 Exploded view of the rear differential
— 1996
Land Cruiser shown
DRIVE TRAIN
ABS Speed Sensor |
Q
O-Ring
j
8
82 7i
(
,
in. ibf) |
F "' e,P U9 '
£
49 (500,39)
Gasket Parking Brake Cable
^
Brake Line
ABS Speed Sensor «« Brake Drum
Gasket
g— Drain |
Plug
49(500,39)
8 (82, 71
®
In.-lbf)
Yo
|
68 (700, 50)
O-Ring Gasket ''I
See Figure 23
the retaining nut from the front of the bar.
1.
the nuts holding the bar to the lower control
2.
Remove Remove
3.
Compress
out the strut bar.
the front wheel. the shock absorber. the spring using a spring compressor, accord-
ing to the tool manufacturer's instructions.
8-12
SUSPENSION AND STEERING
SUSPENSION AND STEERING To
Disconnect the stabilizer bar as follows:
4.
Remove
a.
the nut
and
stabilizer bar link
from the lower
control arm.
Remove the 2 stabilizer bar bracket set bolts. Remove the lower control arm and strut bar as
b.
5.
Support the upper control arm and steering knuckle
c.
d.
Remove
the cotter pin and nut.
Using a
ball joint extractor,
disconnect the lower
ball
Loosen the lower
e.
control
the 2 center bush-
lbs.
ft.
arms on each
side.
Use
(13 Nm).
Tighten the center bracket bolts to 9
ft.
lbs.
Nm) and
(13
the torsion bar. the wheels and lower the truck.
8.
Install
9.
Have the alignment checked
at
a reputable repair
facility.
Tacoma I See Figure 24
from the lower control arm.
joint
install
to the control
nuts and tighten to 9
install
assembly.
and
to the frame. Finger-tighten the bolts.
Connect the bar
new 7.
securely. b.
Position the stabilizer bar
and brackets
6.
follows:
Support the upper control arm and steering knuckle
a.
install:
5.
ings
8-13
arm
set bolt
and remove the 1.
Remove
2.
Hold the bolt with a wrench, then remove the nut,
the front wheels.
nut.
Loosen the
f.
strut
bar front set
then remove the
bolt,
and cushion from the lower
tainer, collar
re-
control arm.
nut. Pull out the bolts
g.
along with the
and remove the lower
control
strut bar.
the lower control
Install
arm and
Attach the strut bar front set
a.
(300
Nm) make
strut
bar as follows:
bolt, tighten to
sure the suspension
221
ft.
To
148
(200 Nm).
lbs.
ft.
5. is
Make
arm
set bolt
and
ft.
sure the suspension
Tighten the nut holding the lower control arm compo-
6. is
stabilized
nents to 29
the nut and cotter pin. Tighten the nut to 80
ft.
(39 Nm).
the wheel, lower the vehicle.
Install
8.
Tighten the lug nuts.
9.
Have
the alignment checked at a reputable repair
facility.
4Runner
(29 Nm). the stabilizer link to the lower control arm, tighten
8.
Install
29
ft.
9.
Remove
lbs.
>
See Figure 25
(39 Nm).
1
the spring compressing tool.
Remove
.
Install
the shock absorber.
1 1
Install
the wheel, lower the truck and tighten the lug
a.
b.
the alignment checked at a reputable repair
facility.
Bar (Sway Bar)
4.
REMOVAL & INSTALLATION
5.
Pick-Up
link
it
on safety stands. Remove
Remove one torsion bar spring. Remove the nuts and cushions
3.
stabilizer
bar where
it
"Examine
with a wrench, then
Remove
remove the
the bolts and stabilizer bar with cushions and
install:
Place the stabilizer bar
into position,
then
install
to
Tighten to 19-22
ft.
lbs.
Hold the stabilizer bar
14-19
ft.
lbs.
mem-
the rubber bushings very carefully for any
the
(25-29 Nm).
link with
a wrench, then
new
nut.
install
the
Tighten the nut
(19-25 Nm).
Using a hexagon wrench, connect the stabilizer bar on
new
nuts, tighten to
55-70
deformation. Clean the inner and outer surfaces bushings before reinstallation. Failed or dirty bushings can create a chorus of odd noises under the vehicle,
7.
Install
8.
Have
ft.
lbs.
the front wheels. the alignment checked at a reputable repair
Upper Control Arm
splits or
of the
the both
install
(69-95 Nm).
at both sides of the
brackets at the frame
nut, re-
link.
both sides to the links with
attaches to the control arms.
Remove the 2 bushings and Remove the stabilizer bar.
link
cushions and
onto the lower control arm with a
6.
the wheels. 2.
as follows:
bar cushions and brackets to the frame. Temporarily bolts.
Raise the truck and support
links
the nuts and disconnect the stabilizer bar links
brackets.
To
.
Hold the
tainers, 3.
Stabilizer
Remove
from the lower control arm.
nuts.
Have
the front wheels.
Disconnect the stabilizer bar
2.
10.
ber.
lbs.
ft.
7.
lbs.
Attach the stabilizer bar bracket set bolts, tighten to 22
lbs.
4.
(29 Nm).
lbs.
nut, tighten to
(110 Nm). 7.
the cushions to the inside of the paint mark. At-
Install
stabilized prior to
the lower ball joint with a ball joint installer tool.
Install
c.
Install
install:
lbs.
prior to tightening the bolt.
1
stabilizer
tach the bar with the brackets, tighten the bracket bolts to 22
the lower control
Install
b.
12.
and cushions from the
the brackets
bar.
tightening the bolt.
.
Remove
install:
6.
to
the bolts and stabilizer bar with the cushions
and brackets. 4.
To
ft.
Remove
3.
arm
REMOVAL & INSTALLATION
particularly during cornering.
Pick-Up 1.
Raise and support the truck under the frame.
facility.
SUSPENSION AND STEERING
8-14
Non-reusable part 86828gl8
Fig. 1.
24 Exploded view of the stabilizer bar and associated components
Remove
2.
the wheel.
Remove
4.
the 4 nuts from the upper ball joint
nect the joint from the upper arm.
Unbolt and remove the upper arm at the 2 bolts holding
5.
the inner shaft to the frame, taking note of the number, size
and 6.
same
the upper
position
7.
Install
23
arm
with the adjusting
ft.
lbs.
the upper ball joint to the ft.
lbs. (31
shims
in
the
(96 Nm).
bolts,
m
joint.
then remove the front and rear
Make
not of the
number and thickness
of the front
and
arm and
tighten the
the wheel.
Install
9.
Lower the truck and bounce
Unbolt the upper control arm.
9.
Remove
the bolts, nuts and upper ball joint from the
To
install:
10.
Attach the
ball joint to
the arm, tighten to 29
ft.
lbs.
(39
Nm). it
several times to set the
suspension. Tighten the upper control arm shaft bolts
to
93
^Do
not lose the camber adjusting shims. Record the
ft.
camber shims so that these can be reinstalled to there original locations. Install the equal number and thickness of shims into there locations. position and thickness of the
(126 Nm).
Have the alignment checked
8.
arm.
Nm).
8.
lbs.
Loosen the 2
7.
and the same number as they were before
removal. Tighten the bolts to 71
bolts to
Disconnect the steering knuckle from the upper bar
6.
rear shims.
install: Install
5.
wire harness.
alignment adjusting shims.
position of the aligning shim.
To
4.
3.
and discon-
shown
Remove the front wheel. Removed the ABS sped sensor and Remove the stabilizer bar link.
2.
Raise the lower control arm with a floor jack.
3. 10.
— Tacoma
at
a reputable repair
facility.
Tacoma 11.
Raise and support the vehicle.
Install
tighten the
the
arm
to the vehicle, with the shims, then
mounting bolts
to
94
ft.
lbs.
(130 Nm).
SUSPENSION AND STEERING
8-15
25 ( 260 19 ) ,
&
©
-Stabilizer Bar Link
Nm
(kgf-cm,
ft-lbf)
Specified torque
: |
Non -reusable
part 86828gl6
Fig.
25 Exploded view of the front stabilizer bar components
12.
Attach the steering knuckle to the upper
13.
Install
the stabilizer bar
14.
Install
the
ABS speed
ball joint.
6.
Remove
the upper control arm.
Place the wheel into position, hand tighten the lug nuts.
Lower the
vehicle, tighten the lug nuts to
83
lose the camber adjusting shims. Record the and thickness of the camber shims so that these
1
the wheel(s) and lower the vehicle.
2.
Remove Remove
3.
Compress the
to stabilize the
Bounce the
suspension. ft.
lbs.
(226
**WARNING
.
the bolts are tightened with the control
arm(s) hanging, excessive bushing wear
5.
a.
will result.
at
a reputable repair
facility.
3. joint.
MODELS
the front wheel. the shock absorber.
Remove
the nut and stabilizer bar link from the lower
Discard the old cotter
pin.
A
Remove the 2 stabilizer bar bracket set bolts. Remove the lower control arm and strut bar as
follows:
Support the upper control arm and steering knuckle Support the upper control arm and steering knuckle
c.
Remove
the cotter pin and nut.
Using a
ball joint extractor,
disconnect the lower
ball
from the lower control arm.
Loosen the lower control arm set
bolt
and remove the
nut.
Disconnect the stabilizer bar from the lower control arm. Disconnect the lower control arm from the lower ball ball joint
separator
will
f.
Loosen the
g.
Pull out the bolts
along with the
4.
Place matchmarks on the front and rear adjusting cams.
5.
Remove
and adjusting cams, then remove the
strut
bar front set
bolt,
then remove the
nut.
be
needed.
lower control arm.
spring using a spring compressor, follow-
d.
joint
the shock absorber.
the nuts
(130
lbs.
assembly.
e.
2.
ft.
(142 Nm).
securely.
4Runner
Remove
96
to
lbs.
Disconnect the stabilizer bar as follows:
b.
Have the alignment checked
.
ft.
ing the manufacturer’s instructions.
b.
1
arm
control arm.
not tighten the control arm bolt fully until the vehicle If
105
See Figure 26
4.
1989-95
ball joint nut to
the torsion bar.
Tighten the lower suspension nut to 166
lowered.
the reverse order. Tighten the spring bumpers
(23 Nm), the lower control
Tacoma
a.
is
lbs.
ft.
cotter pin to secure the nut.
Nm.)
Do
control arm.
remove the 2
to
(25 Nm).
rod to the knuckle. Tighten the nut to 67
end several times
front
mount
or equivalent,
spring bumpers.
Nm), and the lower
the upper
cams and lower
SST 09922-10010
tool
Install in
arm and connect the
arm.
Nm) and
the bolts, nuts, adjusting
Using
(127 Nm).
the shock absorber. Tighten the lower
(18
Attach the
14. 18.
the suspension arm. Tighten
ball joint to
lbs.
joint.
ball joint
Place matchmarks on the front and rear adjusting cams.
9.
the strut bar to the lower
stabilizer bar to the
13
tighten the
remover, disconnect the lower
from the control arm.
much beyond snug.
12.
link.
7.
8.
11.
the steering gear assembly.
6.
Remove
nut
the front wheel.
Support the upper control arm and the steering knuckle
and then remove the torque arm. Do not
bolts
(196 Nm).
lbs.
3.
lower arm shaft and the torque arm. Finger-tighten the lower
arm
ft.
securely.
torque arm on the lower shaft. 10.
145
Remove Remove
5. 10.
install:
to
wheel alignment.
2.
1.
i-Mf the lower ball joint is not to
front
to stabilize the suspension. Align the
MODELS
1996
ball joint.
with
(25
remove the stands and bounce
matchmarks, then tighten the nuts
Unbolt and remove lower
Install
down
the shock absorber.
Disconnect the
arm
lbs.
ft.
(137 Nm).
lbs.
ft.
the wheel, then
the vehicle up and
Disconnect the stabilizer bar from the lower arm.
To
nuts. Tighten to 19
the torsion bar spring.
7.
ball joint,
the shock absorber to the lower control arm,
tighten to 101
rod end.
6.
lower
to the
(142 Nm).
lbs.
Nm).
the wheels. 2.
ft.
stabilizer bar link to lower control
the cushions, retainers 1.
frame with the adjust-
to the
7.
then tighten the nut to 105
Pick-Up
arm
the lower control
cams.
6. 7.
Remove Remove
and remove the lower
control
arm
strut bar.
the coil spring compressor tool
and
coil.
the nuts and strut bar from the lower control
arm. Separate the nut and spring bumper.
SUSPENSION AND STEERING
8-17
86828g01
Fig.
26 Exploded view of the lower control arm and related front suspension components
— Tacoma
SUSPENSION AND STEERING
8-18
Remove
8.
To
arm No.
the lower suspension
3.
Knuckle and Spindle
install:
arm No. 3
Attach the lower suspension
9.
tighten the mounting bolts to 111 10.
the spring bumper, tighten to 32
Install
and the
to the vehicle,
(150 Nm).
lbs.
ft.
ft.
bar to the lower control arm 111
strut
REMOVAL & INSTALLATION (43
lbs.
(150
lbs.
ft.
Nm)
Nm).
Pick-Up Place each end of the
11.
seat
when
contact
in
12.
Install
coil
spring
applying the
the lower control
Nm) make
(300
tightening the
ft.
strut
bolt,
sure the suspension
1
tighten to 221
ft.
Make
arm
set bolt
and
Install
the nut and cotter pin. Tighten the nut to 80
ft.
lbs.
ft.
14.
lbs.
Remove
Install ft.
lbs.
the stabilizer
link to
Install
wire to support the caliper
the brake rotor and hub.
When
cleaning brakes, fluids.
Install
Remove
the 2 cotter pins
and
bolts
and remove the dust
cover.
the spring compressing tool. 4.
Disconnect the knuckle arm from the steering knuckle.
5.
Position a floor jack under the lower control
the shock absorber. the wheel, lower the truck and tighten the lug
disconnect the
nuts. 6.
Have the alignment checked
a reputable repair
at
facility.
T100
Remove
To
install:
7.
Install
3.
Remove Remove Remove
4.
Disconnect the shock absorber from the lower control
the wheel.
nut to 105
the engine under cover.
the steering knuckle.
the steering knuckle into the 2 ball joints and
the torsion bar spring.
to
arm.
lbs.
ft.
8.
Install
80
ft.
9.
Install
lbs.
arm and
ball joints.
tighten the upper nut to
2.
from the mount but do not
stiff
use commercially available brake cleaning
the lower control arm, tighten
(39 Nm).
Remove
1.
Use
(29 Nm).
16.
18.
line.
ing any dust from brake surfaces.
Attach the stabilizer bar bracket set bolts, tighten to 22
15.
17.
and support with safety
Brake pads and shoes may contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air. Avoid inhal-
3.
29
to
of the truck
i-*CAUTION
stabilized
is
(110 Nm). 13.
disconnect the brake
nut, tighten to
sure the suspension
the lower ball joint with a ball joint installer tool.
Install
Raise the front
Remove the wheels. Remove the brake caliper
2.
lbs.
is stabilized prior to
prior to tightening the bolt. c.
.
stands.
bar as follows:
out of the way.
(200 Nm).
lbs.
arm
bolt.
the lower control
Install
b.
148
control
spring expander.
coil
arm and
Attach the strut bar front set
a.
and lower
80
(108 Nm). Tighten the lower
lbs.
ft.
(142 Nm).
Install
new
cotter pins.
arm and dust cover. Tighten the bolts (108 Nm) and secure them with new cotter pins. the brake disc and hub and install the brake
the knuckle
caliper.
5.
Separate the
stabilizer bar
6.
Separate the
strut
7.
Disconnect the lower
from the control arm.
10.
bar from the lower control arm. ball joint
Install
the wheels, lower the truck
and check the
alignment.
from the lower control
11.
Bleed the brake system.
arm. 8.
To 9.
10.
Remove
the nut
and lower the
4Runner
control arm.
install:
arm but do not joint, strut bar and
1989-95
Attach the lower control
tighten yet.
Attach the lower
stabilizer bar to
ball
the control arm. 11.
Tighten the lower control arm bolt to 152
ft.
lbs.
(206
the shock to the control arm.
Install
13.
Attach the torsion spring bar.
14.
Install
the engine under cover.
Install
the wheel, lower the truck and tighten the lug nuts
76 16.
Raise the front
ft.
lbs.
2.
out of the way. 3.
and support
with safety
at
Remove
line.
Remove
Use
stiff
the
mount but do not
wire to support the caliper
the brake rotor and hub.
the 2 cotter pins and bolts and
remove the dust
cover.
(103 Nm).
Have the alignment checked
of the truck
Remove the wheels. Remove the brake caliper from
disconnect the brake
12.
15.
.
stands.
Nm).
to
1
MODELS
a reputable repair
facility.
4.
Disconnect the knuckle arm from the steering knuckle.
5.
Disconnect the shock absorber from the lower control
arm. 6.
Disconnect the stabilizer bar from the lower control arm
by removing the nut and cushion. Disconnect the stabilizer bar link
from the suspension arm.
7.
Remove
8.
With a
the cotter pin and nut from the upper ball
ball joint
knuckle from the upper 9.
Remove
ball joint.
the bolts from the lower ball
the steering knuckle from the
down and remove
joint.
separator, disconnect the steering
joint.
the knuckle.
joint.
Disconnect
Push the lower
control
arm
SUSPENSION AND STEERING To
19.
install:
Push the lower control arm down and install the steering knuckle. Connect the lower ball joint to the steering knuckle, then tighten the bolts to 43 ft. lbs. (58 Nm). 10.
1 1
Attach the upper
.
the nut to 105
lbs.
ft.
new
the knuckle, then tighten
ball joint to
(142 Nm).
cotter pins.
12.
Install all
13.
Connect the knuckle arm
to the steering
knuckle as
follows: a.
Clean the threads
of the bolts
and steering knuckle
Apply sealant
threads such as Three Bond
to the bolt
1324 or equivalent. Tighten the
135
bolts to
lbs.
ft.
(183
Nm). 14.
Install
the dust cover, tighten the bolts to 14
lbs.
ft.
(19
Nm).
Pack the bearings
15.
with multi-purpose grease
Install
the inner bearing and
17.
Install
the hub and rotor assembly.
18.
Bleed the brake system.
19.
Have the alignment checked
oil
seal.
at
a reputable repair
facility.
Install
the inner bearing
22.
Install
the hub and rotor assembly.
23.
Adjust the preload. Install
25.
Attach the brake caliper.
26.
On models
29. 30.
On ABS
31.
Bleed the brake system.
and grease cap.
near the center of the axle hub
0.0020
front
end alignment.
vehicles,
3.
Remove
4.
Check the
check the
ABS speed
sensor
the speed sensor from the
Remove
b.
Place a
in.
(0.05mm).
If
the backlash
axle hub bearing backlash as follows:
the cap, cotter pin and lock cap. dial indicator
The maximum
c.
near the center of the axle hub
that the backlash in the bearing shaft direction.
0.0020
is
(0.05mm).
in.
If
Remove Remove Remove
the hub with the rotor. the
oil
seal
and inner bearing.
the dust cover.
8.
remove the
9.
Support the lower control arm with a jack.
stabilizer bar link.
10. Loosen the ball joint set bolts. Remove the cotter and discard then loosen the nut. 11. With a special tool 09628-62011 or its equivalent,
7. 8.
Unbolt the knuckle arm from the steering knuckle.
9.
Support the lower control arm with a suitable jack.
To
install:
Remove Remove
13.
Support the lower control arm with a jack.
10. 1 1
.
12.
With a
oil
Remove
Remove
the ball joint set bolts, then the nut and steering
knuckle.
the upper and lower cotter pins.
Install the steering knuckle to the upper ball joint and Push down the upper control arm and steering knuckle the lower ball joint and nut. Tighten the upper ball joint nut 80 ft. lbs. (110 Nm).
14.
the upper and lower nuts.
ball joint
remover, separate the steering knuckle ball joints.
the knuckle.
nut.
To
install:
15.
Tighten the lower
14.
Support thew lower control arm with a jack.
16.
Install
new
17.
Install
the dust cover, tighten the bolts to 14
18.
Install
the stabilizer bar
19.
Pack the bearings
Install the steering knuckle to the upper ball joint and Push down the upper control arm and steering knuckle the lower ball joint and nut. Tighten the upper ball joint nut 80 ft. lbs. (108 Nm).
15.
nut.
16.
Tighten the lower
17.
Install
new
ball joint nut to
105
ft.
lbs.
to to
(142 Nm).
cotter pins.
Attach the knuckle arm to the steering knuckle as
18.
Clean the threads
of the bolts
ft.
lbs.
(160 Nm).
cotter pins. ft.
lbs.
(19
Nm). link.
with multi-purpose grease
and coat
the inside of the hub and cap.
the inner bearing and
20.
Install
21
Attach the knuckle arm to the steering knuckle as
.
Apply sealant
to the bolt
Clean the threads
a.
and steering knuckle
oil
seal.
of the bolts
and steering knuckle
with trichloroethylene.
with trichloroethylene. b.
nut to 116
ball joint
to to
follows:
follows: a.
re-
the ball joint from the steering knuckle.
12.
the dust cover.
from the upper and lower 13.
move
and inner bearing.
seal
pin
it,
the hub with the rotor. the
the backlash
not within specifications, replace the bearing.
Remove Remove Remove
6.
signal.
„
the caliper.
a.
7.
not within specifications, replace the bearing.
5.
to
vehicle, tighten the lug nuts.
Remove the front wheel. On models with ABS, remove
6.
that the backlash in the bearing shaft direction. is
seal.
the front wheel.
Install
Lower the Check the
5.
dial indicator
The maximum
c. is
and coat
ABS, connect the ABS speed sensor
28.
is
Check the axle hub bearing backlash as follows: Remove the cap, cotter pin and lock cap.
and check
with
27.
the speed sensor from the
the caliper.
Place a
oil
the lock cap, cotter pin
24.
and check
a. b.
and
21.
1.
steering knuckle.
4.
with multi-purpose grease
steering knuckle.
Remove the front wheel. On models with ABS, remove Remove
Pack the bearings
20.
See Figure 27
3.
(19
the inside of the hub and cap.
2.
T100
2.
lbs.
Tacoma
16.
1.
ft.
and coat
the inside of the hub and cap.
>
the dust cover, tighten the bolts to 14
Nm).
steering knuckle, tighten to 71 inch lbs. (8 Nm).
with trichloroethylene. b.
Install
8-19
bolts to
135
ft.
lbs.
(183
Apply sealant
b.
threads such as Three Bond
1324 or equivalent. Tighten the Nm).
to the bolt
threads such as Three Bond
1324 or equivalent. Tighten the
bolts to
Nm). 22.
Install
the hub and rotor assembly.
135
ft.
lbs.
(183
8-20
SUSPENSION AND STEERING
i
Non-reusable part 86828g23
Fig.
27 Exploded view of the front hub and steering knuckle and other suspension components
— T1 00
SUSPENSION AND STEERING
sures to the correct level and take the truck to a reputable
23.
Adjust the preload.
24.
Install
25.
Attach the brake caliper.
26.
On models
the lock cap, cotter pin and grease cap.
alignment
to
steering knuckle, tighten to 71 inch lbs. (8 Nm).
owner/mechanic
Lower the
vehicle, tighten the lug nuts.
29.
Check the
front
30.
On ABS
31.
Bleed the brake system.
end alignment.
Hub and Bearing
REMOVAL & INSTALLATION Raise the front
and support
of the truck
with safety
Remove the wheels. with wire, out 2. Remove the brake caliper and suspend the way. Remove the caliper mount bracket (torque plate). 3. Remove the axle end cap and then remove the cotter
stands.
and
pin, nut lock
let
assembly
the bearing
Pry the inner
5.
6.
To
oil
fall
seal out
off
Camber
and remove the inner bearing
Clean the bearings and outer races and inspect them
in
and a hammer, drive out the bearing
new one
into position. until
it
and press
it
oil
seal
into the hub.
the correct direction.
the wheels
install
the
then loosen the nut
(0.5mm)
check that the preload
play. is
as
camber
of
measurement
tilt
is
and
tire
wear.
Many
on the road surface cornering.
Changes
ride qualities of the truck
wear patterns
tire
as
camber
indicate
problems from misalignment, overloading or poor
related
said
is
measured in degrees from called camber angle. is
movement and
affect the handling
the
said to be posi-
is
inward at the top the camber
affects the position of the tire
camber
Camber use
the hub nut and tighten. Turn the hub a few times
to seat the bearings,
tilt
When
the front of the vehicle.
at the top, the
driv-
ing habits.
Press the hub assembly onto the spindle and
in.
in
the wheels from the vertical (leaning
be negative. The amount
well
outer bearing and thrust washer.
than 0.02
outward
tiit
Camber
oozes out the
Position the inner bearing into the hub, coat the
Install
tilting of
during vertical suspension
other side. Coat the inside of the hub and cap with grease.
11.
the
the vertical. This drift
in
10.
is
When
tive.
to
Pack the bearings with grease
9.
adjustable through the use of shims, which reposi-
when viewed from
or out)
for
install:
with grease
is
suspension components
the spindle with the outer
out.
or cracks.
outer race. Press a 8.
tilt
CAMBER
wheels
Using a brass
7.
the side of the
said to be positive and a forward
is
tilt
said to be negative.
tion the
from the hub.
wear
when viewed from
vertical,
nut.
Pull the hub/disc
4.
bearing. Don’t
the steering axis either forward or
tilting of
A backward
Caster
it
of
toe.
Changes in caster affect the straight line tendency of the vehicle and the “return to center” of the steering after a turn. If the camber is radically different between the left and right wheels (such as after hitting a major pothole), the truck will exhibit a nasty pull to one side. is
.
the
is
backward from the vehicle.
1
camber and
sensor signal.
Caster
Front Axle
determine the settings. The ex-
CASTER
ABS speed
check the
in
for the
help you understand the three dimen-
will
sions of alignment: caster,
Install
28.
almost impossible
is
it
to accurately
planations that follow
the front wheel.
27.
vehicles,
Since the alignment settings are measured
facility.
very small increments,
ABS, connect the ABS speed sensor
with
8-21
until
there
is
is
adjustable on Pick-Ups and 4Runners through the
of shims;
if
measurement
the
is
out of specification, the
damaged component(s) must be
bent or
replaced.
no more
Using a spring tension gauge,
TOE-IN
1. 3-4.0 lbs.
new
and hub grease cap.
12.
Install
the locknut,
13.
Install
the brake torque plate to the knuckle. Install the
cotter pin
Toe
brake caliper. 14.
Bleed the brake system.
15.
Install
the turning
is
in
amount of toe The purpose of
actual inch.
the wheels and lower the vehicle.
parallel rolling of the
or out (parallelism) of the wheels.
setting
is
The
normally only a fraction of an
toe-in (or out) specification
is
to insure
wheels. Toe-in also serves to offset the
small deflections of the steering support system which occur
Front End Alignment
when
the vehicle
is
rolling
forward or subjected to hard
braking.
Alignment go, stop
of the front
and
collision, overloading, If
wheels
is
essential
turn as designed. Alignment
if
your vehicle
is
to
can be altered by
poor repair or bent components.
wear and
you are diagnosing bizarre handling and/or poor road man-
ners, the
first
wear as a
place to look
result of
inflated tires
is
the
tires.
Although the
tires
may
an alignment problem, worn or poorly
can make you chase alignment problems which
don’t exist.
Once you have
Changing the toe of the steering,
all
other causes, unload every-
thing from the trunk except the spare
tire,
set the
tire
pres-
economy. Excessive toe
cessive drag or scrubbing on the
Toe and
is
is
adjustable on
generally
all
measured
until
in
the correct reading
rods must remain equal
in
(in
ability, tire
or out)
causes ex-
tires.
vehicles covered by this manual,
inches or degrees.
by loosening the locknut on each rod
eliminated
fuel
setting will radically affect the overall “feel”
as well as the vehicle’s braking
is
tie
It
is
adjusted
rod end and turning the
achieved. The
length during
all
left
and
right
adjustments.
SUSPENSION AND STEERING
8-22
9.
4WD FRONT SUSPENSION 10.
After
you work on the suspension
of
your truck,
is
it
ble to have the alignment checked at a reputable repair
This
ensure that your
will
end
front
is
in
Attach the shock to the lower control arm, tighten to 101
advisafacility.
ft.
(135 Nm).
lbs.
Install
order after repairs.
the wheel, tighten the lug nuts to 83
(110
lbs.
ft.
Nm).
Coil Springs
Tacoma I See Figures 30, 31 and 32
REMOVAL & INSTALLATION
1
Loosen the
.
lug nuts.
Make
Elevate and safely support the vehicle.
2.
jackstands are securely placed under the frame
Land Cruiser
Use a
3.
I
See Figure 28 1
Make
jackstands are securely placed under the frame
Use a
2.
floor jack to slightly jack
certain the
rails.
and support the
front
Remove
5.
Disconnect the shock absorber from the lower control
arm as
remove the upper mounting 3.
4.
Lower the jack holding the
pressor to compress the spring.
front axle.
Remove
Use a
the spring,
pressed, from the vehicle. Place the spring, facing
still
com-
the spring
is fully
extended, remove the
Remove install:
5.
6.
Install
the follow spring nuts
and
82 inch
lbs.
Compress
7.
cle. Align
the spring
and
fit
it
into position in the vehi-
the end with the lower spring seat; slowly release
the compressor, allowing the spring to expand into place. Install
8.
Install
9.
nut to 51
same
Match the
ft.
the stabilizer bar.
the shock absorber. Tighten the lower mounting lbs.
(69
Nm) and
then the upper mount to the
the shock.
bolt of the
Install
Fit
that the line
the lower end of the
coil
bolts
would be
parallel to
the direction of the lower bushing.
Remove
Lower the vehicle
13.
Check
14.
the compressor tool.
that the direction of the support again. Tighten
Attach the
coil
ft.
lbs.
(29 Nm).
and shock assembly
to the top portion of
the engine compartment. Tighten the nuts to
See Figure 29
spring into the
center nut. Position the support so
drawn between the 2
the center nut to 22
>
the insulator to the support.
the suspension support rod. Temporarily tighten
12.
4Runner
suspension support with the cut
install
new suspension support
value. to the ground.
support.
of the spring seat of the shock.
11.
the
coil spring.
Using the spring compressor, compress the spring and
install
gap
there
install:
out part of the insulator, 10.
Nm).
coil until
the suspension support
Remove the suspension support and Remove the insulator from the suspension
9.
the follow spring, tighten the nuts to
spring as an
coil
center nut.
To
spring.
Remove
a clearance at both ends.
8.
To
the shock mounting nuts and
Using a spring compressor, compress the
7. is
tool.
(9
Remove
6.
assembly.
away from
you, on the work bench and slowly release the tension on the
When
bolt
then disconnect the shock.
com-
spring
then remove the shock absorber lower
bolt,
While lowering the lower control arm, remove the
b.
Disconnect the stabilizer bar from the axle housing.
follows:
nut.
Hold the shock and remove
nut.
the front wheel.
Loosen the
a.
the lower mounting nut, the cushions and the retainer.
10.
front
4.
axle housing. Hold the piston rod of the shock absorber and
compressor.
and support the
axle housing.
Elevate and safely support the vehicle.
.
floor jack to slightly jack
certain the
rails.
47
ft.
lbs.
(64
Nm). 1.
Remove
2.
Disconnect the shock absorber from the the lower con-
When you
arm.
trol
the front wheel.
15.
lower the arm, remove the bolt and dis-
connect the shock absorber.
Remove
3.
the shock and
coil
is
ft.
lbs.
(135 Nm).
16.
Attach the wheel, hand tighten the lug nuts.
17.
Lower the
vehicle, tighten the lug nuts.
spring as an assembly.
Using a spring compressor, compress the spring
4.
there
Attach the shock to the lower control arm, then tighten
the mounting bolt to 101
a clearance on both ends.
Remove
until
the suspension
Leaf Springs
support center nut.
Remove
5.
and
the 2 retainers, cushion, suspension support
To
install:
Using a compression tool, compress the coil spring. Do compress the spring more than necessary and do not use
6.
not
REMOVAL & INSTALLATION
coil spring.
an impact wrench. 7.
Fit
1
the lower end of the
coil
spring into the
gap
of the
spring seat of the shock absorber. 8.
Attach the spring and shock into the vehicle, tighten the
mounting nuts
to
47
1989-90 Land Cruiser
ft.
lbs.
(64 Nm).
.
Remove
and support
it
the wheels, then raise the front of the vehicle
on safety stands. Make certain the stands are
placed under the frame 2.
lower
rails.
Position a floor jack under the differential housing it
until
there
is
no tension on the
leaf springs.
and
SUSPENSION AND STEERING
8-23
Bracket
©-
Stabilizer Bar Link
Cushion
-Retainer
—©
Retainer
^— Cushion—©©
Follow Spring
Retainer
Cushion
Hs)
Shock Absorber
Lateral Control
Rod Bushing
Retainer
Cushion Stabilizer
Bar Bushing
Cushion
®
Retainer
Washer
Plate
Rod
Lateral Control
Retainer
®
1 9.
Lateral Control
Rod Bushing
@ Leading Arm Bushing
Leading Arm Bushing
^-r-4
Non-reusable part 86828g43
— Land
28 Exploded view of the coil spring and associated components
Fig.
Remove Remove
3.
4.
the shock absorber.
onto the
the U-bolt mounting nuts, pull the spring set
to
away and remove the
Remove
5.
move
the pins
U-bolts.
the hanger and shackle pin mounting nuts. Re-
and then
105
leaf.
Install
lbs.
the spring seat and nuts. Tighten the nuts
(142 Nm).
See Figures 1
.
shock compressed).
^CAUTION
Remove
35 and 36
33, 34,
the front wheel.
2.
Support the lower control arm with a suitable jack.
3.
Loosen the four
Do
bolts attaching the lower ball joint.
remove them. Remove the cotter pin and nut from the tie rod end. Throw out the old cotter pin. With special tool 09610-20012 or equivalent, disconnect the tie rod end from the not
Although nitrogen is non-toxic and non-flammable, the escaping gas may carry metal chips from the drill; always wear eye or full-face protection when drilling.
steering knuckle. 4.
Once
the gas
is
may be
released, the shock absorber
safely
Remove
the cotter pin and nut from the lower ball
Discard the cotter
discarded.
5.
With a
joint.
pin.
ball joint
remover such as
tool
09628-6201
or
1
equivalent, separate the ball joint from the lower control arm.
Upper
6.
Ball Joint
Remove
control
the ball joint
REMOVAL & INSTALLATION Tacoma and 4Runner
2. 3.
Separate the upper
ball joint
as follows:
in
Nm).
Remove
the wire
and
ball joint
remover and a deep socket, remove
With the aid of the
ball joint installer
Nm) on
the
Tacoma,
new
cotter
rod end tightening the nut to 66
lbs.
ft.
Tighten the lower lbs.
ft.
Remove
(90
cotter pin. ball joint set bolts,
59
ft.
lbs.
(80
Nm)
(113 Nm).
the jack slowly, making sure everything
is
se-
place.
in
the wheel, lower the vehicle and tighten the lug
Install
nuts. install
the ball
joint.
Using a snapring expander,
Apply multi-purpose grease, then
new
a
install
new
install
13.
snapring.
a
new
14.
Check the ABS speed sensor signal. Have the alignment checked at a reputable
repair facility.
boot. Fix
wire.
T100
Install
the steering knuckle with the axle hub.
8.
Install
the front wheel, lower the vehicle
and
tighten the
1
.
2.
lug nuts.
Have the alignment checked
at
a reputable repair
facility.
Remove
the front wheel.
Disconnect the lower
Remove 3.
T100
ball joint
from the steering knuckle.
the cotter pin and nut.
With the aid of a
ball joint
separator, disconnect the joint
from the steering knuckle.
1.
Remove
2.
Disconnect the upper
Remove
To
the front wheel.
4.
ball joint
from the steering knuckle.
the upper ball joint 4 mounting nuts. Separate
(33 Nm).
Attach the
Attach the
nut to 105
install:
Attach the
install:
ball joint
mounting nuts, tighten
to
25
6. ft.
ball joint to
the knuckle with the special
ball joint to
the steering knuckle, tighten the
in-
staller tool. 5.
the ball joint from the upper control arm.
4.
tie
new
a
and a socket
7.
To
(152
install:
with a
3.
Attach the Install
cure and
wrench,
9.
lbs.
joint.
12.
it
ft.
the 4Runner. Install a
the hole.
4Runner, 83 11.
the upper ball
6.
Nm) on
boot. 10.
5.
(142
lbs.
ft.
the steering knuckle with the axle hub.
Using a snapring expander, remove the snapring.
4.
the ball joint with the mounting nut and bolts.
Install
Tighten the nut to 112
pin
b.
To
the upper
ball joint. After
the front wheel.
a.
With a
lifting
install:
8.
9.
c.
When
remove the
removed, support the upper control arm and
7.
105
or
Remove Remove
is
steering knuckle,
knuckle securely.
To
1.
the four mounting bolts.
arm and
ft.
Install
lbs.
(142 Nm). Use a
new
cotter pin.
the front wheel, lower the vehicle and tighten the
lbs.
lug nuts. 7.
Have
the alignment checked at a reputable repair
facility.
SUSPENSION AND STEERING
Fig. Fig.
34 Loosen, but do not yet remove these four bolts
8-27
35 With special tool 09610-20012 or equivalent,
disconnect the
tie
rod end from the steering knuckle
8-28
SUSPENSION AND STEERING Disconnect the bar from the axle housing.
4.
stabilizer bar.
Remove
the 2 bolts and
Remove
the
remove the bracket
from the bar.
^Examine
the rubber bushings very carefully for any
Clean the inner and outer surfaces bushings before reinstallation. Failed or dirty bushings can create a chorus of odd noises under the vehicle, splits or deformation.
of the
particularly during cornering.
To
install:
Reassemble the cushions and cover onto the painted mark on the bar. 5.
6.
Tighten the bar-to-bracket bolts to 13
Mount the 7.
Install
Bounce the 8.
end several times
to stabilize the
Tighten the bolts at the axle tube to 19
Nm) on 1991-93 models 76 models.
Land Cruiser I See Figures 37, 38 and 39 1.
Raise the truck and support
2.
Remove Remove
3.
the
link
it
on safety stands.
the wheels. the nut, then disconnect the stabilizer bar with
from the bracket.
lbs.
(18 Nm).
the wheels and lower the vehicle to the ground. front
Tighten the nuts at the top of the small
REMOVAL & INSTALLATION
ft.
bar, tightening the fittings just snug.
ft.
lbs.
(103
link to
ft.
suspension.
lbs.
13
ft.
(25 Nm). lbs.
Nm) on 1994-96
(18
SUSPENSION AND STEERING Have
9.
the alignment checked at a reputable repair
8-29
facility.
Tacoma, T100 and 4Runner >
See Figures 1
Remove
.
40, 41,
42 and 43
the front wheels.
Disconnect the stabilizer bar
2. a.
Remove
links
as follows:
the nuts and disconnect the stabilizer bar links
from the lower control arm. b.
Hold the
tainers, 3.
link with
cushions and
Remove
a wrench, then remove the nut,
re-
link,
the bolts and stabilizer bar with cushions and
brackets.
To 4.
install:
Place the stabilizer bar into position, then
install
bar cushions and brackets to the frame. Temporarily bolts. 5. link
to
Tighten to 19-22
ft.
lbs.
Hold the stabilizer bar
ft.
lbs.
the
(25-29 Nm).
link
with a wrench, then install the
onto the lower control arm with a
14-19
both the
install
new
nut.
Tighten the nut
(19-25 Nm).
©
© ©
* ©
Stabilizer Bar
Link
Non-reusable part 86828g38
Fig.
40 Exploded view of the sway bar and associated components
SUSPENSION AND STEERING
8-30
Remove
4.
Do
the upper shock absorber mounting nut.
not
disconnect the lower end of the shock.
Disconnect the intermediate shaft from the steering gear
5.
housing.
Remove
the 2 nuts and bolt and
lift
out the upper
arm.
To
install:
131
ft.
arm and
the upper
Install
6.
Connect the intermediate
7.
tighten the mounting bolts to
(178 Nm).
lbs.
shaft to the steering gear
housing.
a
Install
8.
new upper shock absorber
Tighten
nut.
it
to
18
(25 Nm).
lbs.
ft.
Attach the upper
9.
tighten the nut to 105
ball joint to lbs.
ft.
the steering knuckle, then
(142 Nm).
a
Install
new
cotter
pin.
10.
Install
11.
Install
12.
Have
repair
the wheels and lower the vehicle.
1.
Remove
2.
Disconnect the
3.
Disconnect the upper
b.
c.
d.
To
Using a
ball joint
Support the steering knuckle securely.
Remove
sure the arm
Attach the upper
wrench, then remove the link
ft.
lbs.
8.
Install
9.
Check
hexagon wrench, con-
nect the stabilizer bar on both sides to the links with
new
nuts,
at
a reputable repair
facility.
Upper Control Arm
(105 Nm).
ABS speed
Install
a
arm. Tighten the
new
cotter pin.
sensor wire harness clamp,
inch lbs. (8 Nm).
the shock and coil spring assembly. the alignment.
Disconnect the
4.
Disconnect the upper
c.
Pick-Up and 4Runner
To
Raise the truck and support
it
nut. ft.
the torsion bar. the cotter pin
and nut and press the upper
out of the steering knuckle.
bail
sensor wire harness clamp.
ball joint
as follows:
Remove
the cotter pins and loosen the nut.
Using a
ball joint separator,
disconnect the upper
ball
Support the steering knuckle securely.
Remove
the nut. nut, bolt,
wash-
install:
Attach the upper control arm with the washer, bolt and
6.
on safety stands. Remove
ABS speed
and lowering the arm.
ers
the wheels.
the shock and coil spring assembly.
Detach the control arm, by removing the
5.
MODELS
the front wheel.
from the control arm.
joint
d.
joint
ball joint to the control lbs.
ft.
3.
b.
3.
80
Remove Remove
a.
REMOVAL & INSTALLATION
Remove Remove
87
stabilized, then tighten the nut to
is
2.
1.
Have the alignment checked
2.
wash-
Tacoma
the front wheels.
Install
8.
1.
nut, bolt,
(69-95 Nm).
7.
1989-95
to
Attach the
tighten to 71
tighten to 55-70
the nut.
(115 Nm).
lbs.
7.
with the links using a
separator, disconnect the upper ball
Attach the upper control arm with the washer, bolt and
6.
On models
as follows:
the cotter pins and loosen the nut.
mounting nut
6.
ball joint
Remove
Make
nut.
cushions and
spring assembly.
sensor wire harness clamp.
install:
5.
link with a
coil
ABS speed
and lowering the arm.
ers
43 Hold the
the shock and
Detach the control arm, by removing the
4.
(at arrow), retainers,
a reputable
from the control arm.
joint
nut
at
MODELS
a.
Fig.
and adjusted
the alignment checked
facility.
1996
ft.
the torsion bar.
Make
lbs.
7.
sure the arm
is
stabilized, then tighten the nut to
87
(115 Nm). Attach the upper
mounting nut
to
80
ft.
ball joint to the control lbs.
(105 Nm).
Install
a
arm. Tighten the
new
cotter pin.
SUSPENSION AND STEERING ABS speed
Attach the
8.
10. tighten to 71 inch lbs. (8
the shock and coil spring assembly.
Install
9.
sensor wire harness clamp,
Nm).
Check the alignment.
T100 Raise the truck and support
1.
on safety stands. Remove
it
the wheels.
ABS speed
2.
Disconnect the
3.
Remove the torsion bar. Remove upper ball joint
4.
sensor wire harness clamp.
out of the steering knuckle as
a.
Support the lower control arm with a suitable jack.
b.
Remove
the bolts, then
remove the upper
arm
control
lbs.
arm and
the upper
Install
ft.
tighten the mounting bolts to
(178 Nm).
Connect the upper
tighten the nut to 7.
25
ft.
the steering knuckle, then
ball joint to
(33 Nm).
lbs.
the torsion bar.
Install
the wheel(s) and lower the vehicle. Have the alignment checked and adjusted
9.
repair
at
a reputable
facility.
Pick-Up and 4Runner 1989-95
Raise the front of the truck and support
the cotter pin and nut from the lower ball
Place matchmarks on the front and rear adjusting cams.
9.
Remove
10.
Remove
the spring
it
with safety
Attach the spring bumpers, tighten to 17
ball joint
Attach the lower
the nut to 105
ft.
arm and adjusting cams
the lower
Connect the
Nm) and
Connect the
install
a
the arm. Tighten the nut to 105
new
stabilizer bar,
cotter pin.
then tighten the nuts to 19
9.
Install
the shock absorber.
Install
the wheels and lower the truck.
ft.
Bounce the
truck
several times to set the suspension.
ft.
lbs.
Install
the stabilizer bar
Install
the steering gear assembly.
17.
Install
the front wheel, lower the vehicle. Tighten the lug
link.
18.
Have
the alignment checked at a reputable repair
facility.
2.
Remove Remove
3.
Disconnect the stabilizer bar
4.
Disconnect the shock absorber from lower control arm.
5.
Support the upper control and steering knuckle securely.
6.
Remove
7.
With a
the front wheel. the steering gear assembly. link.
the cotter pin and nut from the lower ball
ball joint
remover, disconnect the
ball joint
joint.
from
8.
Place matchmarks on the front and rear adjusting cams.
9.
Remove
the 2 bolts, nuts, adjusting
Remove
the spring its
bumpers
cams and
lower
with a special tool
equivalent.
install:
11.
Attach the spring bumpers, tighten to 17
12.
Attach the lower control arm, placing
it
ft.
in
matchmarks. Tighten the arm
lbs.
(23 Nm).
the appropriate
to
96
ft.
lbs.
Attach the lower
the nut to 112
ft.
lbs.
ball joint with
the correct tool, tighten
(152 Nm).
14.
Attach the shock absorber to the lower control arm.
15.
Install
the stabilizer bar
16.
Install
the steering gear assembly.
17.
Install
the front wheel, lower the vehicle. Tighten the lug
link.
nuts.
Have
the alignment checked at a reputable repair
facility.
T100 at
a reputable repair
facility.
1
.
Raise the front
of the truck
and support
2.
Remove the wheels. Remove the shock absorber from
3.
Disconnect the stabilizer bar
4.
Disconnect the lower
it
with safety
stands.
MODELS
Remove
the correct tool, tighten
tighten
(196 Nm).
Have the alignment checked
See Figures
ball joint with
(142 Nm).
lbs.
16.
18.
matchmarks on the adjusting cams and
Align the
the nuts to 145
1996
lbs.
ft.
Attach the shock absorber to the lower control arm.
13.
ball joint to
10.
12.
96
(130 Nm).
to the frame.
(25 Nm).
.
to
15.
position with the
install:
Temporarily tighten the nuts.
1 1
(23 Nm).
lbs.
the appropriate
14.
To
from the control arm.
matchmarks on the front and rear adjusting cams, remove them and lift out the control- arm.
lbs.
ft.
in
it
matchmarks. Tighten the arm
position with the
10.
Paint
(142
with a special tool
Attach the lower control arm, placing
Disconnect the lower
8.
bumpers
equivalent.
12.
4.
lbs.
lower
install:
09922-10010 or
7.
its
11.
Disconnect the stabilizer bar at the lower arm.
Install
cams and
the 2 bolts, nuts, adjusting
3.
6.
joint.
from
8.
2.
To
ball joint
thew lower control arm.
control arm.
5.
remover, disconnect the
ball joint
Remove the wheels. Remove the shock absorber.
1.
>
With a
thew lower control arm.
MODELS
stands.
ft.
Remove
7.
1.
REMOVAL & INSTALLATION
.
Support the upper control and steering knuckle securely.
6.
Tacoma
Lower Control Arm
1
5.
link.
nuts.
Install
8.
Disconnect the shock absorber from lower control arm.
13.
install:
6.
4.
the steering gear assembly.
(130 Nm).
from thew frame.
131
Disconnect the stabilizer bar
To
the nuts, then disconnect the upper control steering knuckle.
Remove
c.
5.
Remove
3.
control arm.
follows:
To
2.
09922-10010 or
arm from the
8-31
44,
45 and 46
the front wheel.
move
the lower control arm.
at the
ball joint
lower arm.
from the control arm. Re-
the cotter pin, then discard. Loosen the nut.
8-32
SUSPENSION AND STEERING
*
For use with
SST 86828g20
Fig.
44 Exploded view of the lower control arm and associated components
— 1996 4Runner
SUSPENSION AND STEERING
8-33
Leading Arm
REMOVAL & INSTALLATION Land Cruiser I See Figures 47, 48 and 49 1
Raise and safely support the vehicle. Loosen the lug
.
nuts.
Remove Remove
2. 3.
the front wheel. the leading
arm
the 2 bolts
and nut from the arm on the axle
bolt, plate
washer and nut on
the frame side.
Remove
4.
Lower the arm.
side.
To
install:
Attach the leading arm on the axle housing side, tighten
5.
the bolts to 127
ft.
lbs.
(171 Nm).
Attach the leading arm on the frame side, tighten the
6.
130
bolts to
lbs.
ft.
(177 Nm).
the wheel and hand-tighten the lug nuts.
7.
Install
8.
Lower the vehicle then wrench
9.
Have
tighten the lug nuts.
the alignment checked at a reputable repair
Lateral Control
facility.
Rod
REMOVAL & INSTALLATION I
See Figure 50 Raise and safely support the vehicle. Loosen the lug
1.
nuts. 2.
Remove
3.
Disconnect the
Remove
a.
46
Fig.
Remove
09922-10010 or
the spring its
bumpers with
special tool
matchmarks on the front and remove them and lift out the control arm.
To
rear adjusting
cams,
Install
7. ft.
lbs.
the lower
Connect the (142
arm and adjusting cams
Connect the
9.
Install
to the frame.
install
a
the arm. Tighten the nut to 105
new
stabilizer bar
cotter pin.
and
ft.
lbs.
.
the wheels and lower the truck.
Bounce the
12.
matchmarks on the adjusting cams and 145 ft. lbs. (196 Nm).
Align the
the nuts to
Have
and rod from the frame
side.
Attach the nut, bolt and rod to the frame side, and
127
ft.
lbs.
(171 Nm).
Attach the bolt that connects the rod to the axle housing,
tighten to
127
ft.
lbs.
(171 Nm).
the wheel.
6.
Install
7.
Lower the
8.
Have
vehicle, tighten the lug nuts.
the alignment checked at a reputable repair
facility.
Steering Knuckle and Spindle
(137 Nm). truck
REMOVAL & INSTALLATION
several times to set the suspension. 1 1
the nut, bolt
tighten the nuts.
the shock absorber to the lower control arm,
tighten to 101 Install
ball joint to
Nm) and
8.
10.
4.
5.
Temporarily tighten the nuts.
as follows:
install:
tighten to
install:
6.
Remove
b.
Paint
lateral control rod
the bolt that attaches the rod to the axle
housing.
equivalent
To 5.
the front wheel.
the alignment checked at a reputable repair
tighten
facility.
Pick-Up and 4Runner 1989-95 1
.
MODELS
Raise the
stands.
Remove
front of the truck
the wheels.
and support
it
on safety
8-34
Fig.
48
SUSPENSION AND STEERING.
Remove
the bolts on the frame side of the
vehicle for the leading
arm
Fig.
49 The axle housing-to-leading arm side has two
bolts to
remove
SUSPENSION AND STEERING
To
-•-CAUTION
1 1
Brake pads and shoes may contain asbestos, which has
been determined to be a cancer causing agent. Never air. Avoid inhaling any dust from brake surfaces. When cleaning brakes, use commercially available brake cleaning fluids.
clean the brake surfaces with compressed
.
install:
Coat the splines
down on
Remove
4.
Disconnect the knuckle arm at the steering knuckle.
5.
Disconnect the shock absorber
6.
Disconnect the stabilizer bar at the lower control arm.
7.
Remove
the dust cover (splash shield) and
at the
oil
seal.
Use a 9.
Remove
12.
Attach the lower
the 4 bolts to 43 13.
the snapring and spacer from the end of the
ball joint
Remove
it
joint.
from the knuckle.
the 4 bolts and disconnect the lower ball joint
from the knuckle.
slide the knuckle
over the
ball joint to
Install
lbs.
ft.
the knuckle, then tighten
(58 Nm).
lbs.
ball joint to
(142 Nm).
the knuckle, then tighten
Install
a
new
cotter pin.
the spacer and snapring to the end of the axle
Connect the
stabilizer
bar and the shock absorber to the
lower arm. 16.
Connect the knuckle arm
tighten the bolt to 17.
separator to disconnect
ft.
Attach the upper
the nut to 105
15.
lower control arm.
the cotter pin and nut from the upper ball
arm and
shaft.
knuckle spindle. 8.
press
of the axle shaft with grease,
the lower control
axle shaft and into position.
14. 3.
8-35
bolt to
Install
13
ft.
135
ft.
lbs.
to the steering knuckle,
the dust cover with a lbs.
then
(183 Nm).
new
oil
seal
and
tighten the
(18 Nm).
18.
Install
the brake disc and brake caliper.
19.
Install
the wheels.
20.
Bleed the brakes.
Lower the vehicle
to the ground.
SUSPENSION AND STEERING
8-36
9.
the alignment checked at a reputable repair
Have
21.
bolts to
4Runner
MODELS
1996
59
ft.
1
Remove the front wheel. Remove the shock absorber. Remove the grease cap On models with ABS, remove
.
2. 3. 4.
lbs.
Attach the caliper and
11.
Attach the
the
ABS speed
sensor
Remove
5.
Remove
7.
Disconnect the lower
Install
14.
Attach the wheel, lower the vehicle.
15.
Tighten the lug nuts, the bleed the brake system.
16.
Have
the caliper and rotor.
Using a special
09950-40010 or equivalent, discon-
tool
Remove Remove
3.
Measure the
Remove
1 1
a new cotter
Install
59
12.
lbs.
ft.
Install
Maximum 0.039
(98
d.
If
(0.10-0.50mm).
in.
(1.0mm).
in.
the thrust clearance
more than the maximum,
is
re-
place the steering knuckle outside and inside bushings.
(28 Nm).
sensor and wire harness clamp
4.
Detach the
5.
Separate the
6.
Remove
if
inch lbs. (8 Nm).
to 71
Standard clearance: 0.0039-0.0197
c.
the four mounting
rotor.
ABS speed
lb.
N).
(80 Nm).
lbs.
ft.
removed, tighten
the grease cap.
15.
Install
the shock absorber.
16.
Attach the wheel, lower the vehicle.
shock from the lower control arm.
front
from the lower control arm.
stabilizer bar
the steering knuckle as follows:
Using a pair
a.
Install
14.
a bolt in the drive shaft. Using a feeler gauge, measure the drive shaft thrust clearance between the steering knuckle outside bushing and
ft.
the brake line bracket to the steering knuckle,
Attach the
3.
steering knuckle bushing thrust clearance
Install
pin.
ball joint, tighten
Attach the caliper and
.
the caliper and front axle hub.
spacer, by pulling the bolt and applying a load of 22
tighten to 21 1
the nut and knuckle.
Attach the lower
bolts to
the front wheels.
b.
Attach the steering knuckle and tighten the nut to 80
10.
.
a.
install:
(108 Nm).
lbs.
facility.
as follows:
nect the steering knuckle.
9.
the alignment checked at a reputable repair
2.
ball joint.
Remove the steering knuckle with hub as follows: a. Remove the cotter pin and loosen the nut.
c.
the shock absorber.
13.
1
To
if
T100
6.
b.
sensor and wire harness clamp
inch lbs. (8 Nm).
to 71
the brake line bracket from the steering
knuckle.
8.
rotor.
ABS speed
Attach the driveshaft.
12.
and wire harness clamp from the steering knuckle.
(80 Nm).
10.
removed, tighten
the four mounting
ball joint, tighten
Attach the lower
facility.
of
snapring
pliers,
remove the
ring
and
spacer. b.
Support the lower control arm with a jack.
c.
Remove
the cotter pin and nut from the upper ball
Using a
ball joint separator,
Tighten the lug nuts, the bleed the brake system.
17.
joint.
Have
18.
the alignment checked at a reputable repair
facility.
d.
Tacoma
Remove
e.
I See Figure 51
Remove Remove
1.
2.
the front wheel.
flat
bladed
tool to
b.
Remove
the cotter pin and lock cap.
c.
Have an
assistant apply the brakes, then
remove the
With free wheeling hubs, remove the free wheel hub.
e.
Using a snapring expander, removed the snapring.
Remove the spacer. On models with ABS, remove
the
ABS speed
sensor
6.
Disconnect the lower
7.
Remove the steering knuckle with hub as follows: Remove the cotter pin and loosen the nut. Using a special
To 8. lbs.
Remove
joint,
then discon-
control arm, then
damage
remove the
the seal.
the knuckle as follows:
Apply synthetic 1
oil
and
lithium
soap base chassis
or equivalent to the driveshaft.
Push down on the lower
control arm, then install the
tool
c.
new
Install
a
e.
Install
a spacer
Using a pair
ft.
ball joint to lbs.
the steering knuckle,
(142 Nm).
cotter pin.
of
to the driveshaft.
snapring
pliers, install
the ring. clear-
Using a feeler gage, measure the driveshaft thrust
clearance between the knuckle and the outside bushing and spacer, by pulling the bolt and applying a load of 22
pin.
lbs.
(98
N). h.
Attach the steering knuckle and tighten the nut to 80
a new cotter
105
d.
g.
09950-40010 or equivalent, discon-
the nut and knuckle.
Install
Connect the lower
’Mf you replace the knuckle bushing, recheck the ance of the driveshaft thrust.
ball joint.
install:
(108 Nm).
b.
f.
nect the steering knuckle. c.
Install
tighten the nut to
and wire harness clamp from the steering knuckle. 5. Remove the caliper and rotor.
b.
from the
steering knuckle.
d.
a.
install:
7.
careful not to
grease NLGI No.
locknut.
f.
Be
To
a.
remove the grease cap.
4.
joint
joint.
Push down the lower
f.
knuckle.
the shock absorber.
Without a freewheeling hub, use a
a.
the bolts from the lower ball
nect the knuckle from the
Disconnect the driveshaft as follows:
3.
detach the
knuckle.
ft.
Standard clearance should be 0.0039-0.0197
in.
(0.10-0.50mm). i.
If
spacer.
the clearance
is
not within specifications, replace the
SUSPENSION AND STEERING
8-37
SUSPENSION AND STEERING
8-36
9.
Have the alignment checked
21.
at
a reputable repair
Attach the lower
facility.
bolts to
4Runner
MODELS
1996
59
ft.
10.
Attach the caliper and
11.
Attach the
ABS speed
removed, tighten 1
Remove the front wheel. Remove the shock absorber. Remove the grease cap On models with ABS, remove
.
2. 3.
Remove
5.
Remove
7.
Disconnect the lower
Install
14.
Attach the wheel, lower the vehicle.
15.
Tighten the lug nuts, the bleed the brake system.
16.
Have
the caliper
and
rotor.
ball joint.
Remove the steering knuckle with hub as follows: a. Remove the cotter pin and loosen the nut.
lbs.
Using a special
09950-40010 or equivalent, discon-
tool
Remove
the nut and knuckle.
as follows:
(108 Nm).
Install
a
Attach the lower
Using a feeler gauge, measure the drive shaft thrust
59
lbs.
ft.
new
12.
Install
cotter pin.
the four mounting
Standard clearance: 0.0039-0.0197
Maximum 0.039
(80 Nm).
lbs.
Attach the
13.
rotor.
removed, tighten
Detach the
5.
Separate the
to 71
sensor and wire harness clamp
6.
Remove
if
inch lbs. (8 Nm).
Install
more than the maximum,
is
front
re-
shock from the lower control arm. from the lower control arm.
stabilizer bar
the steering knuckle as follows:
Using a pair of snapring
a.
14.
the thrust clearance
If
(0.10-0.50mm).
in.
(1.0mm).
in.
4.
(28 Nm).
ABS speed
(98
place the steering knuckle outside and inside bushings.
the brake line bracket to the steering knuckle, ft.
lb.
ft.
d.
tighten to 21
in
N).
ball joint, tighten
Attach the caliper and
.
the drive shaft.
Install
b.
c.
1 1
a bolt
a.
spacer, by pulling the bolt and applying a load of 22
Attach the steering knuckle and tighten the nut to 80
bolts to
the front wheels.
clearance between the steering knuckle outside bushing and
install:
10.
facility.
the caliper and front axle hub. Measure the steering knuckle bushing thrust clearance
3.
nect the steering knuckle.
9.
the alignment checked at a reputable repair
Remove Remove
1.
c.
the shock absorber.
13.
2.
To
if
T100
6.
b.
sensor and wire harness clamp
inch lbs. (8 Nm).
to 71
the brake line bracket from the steering
knuckle.
8.
rotor.
Attach the driveshaft.
12.
the ABS speed sensor 4. and wire harness clamp from the steering knuckle.
the four mounting
ball joint, tighten
(80 Nm).
lbs.
pliers,
remove the
ring
and
the grease cap.
spacer. the shock absorber.
15.
Install
16.
Attach the wheel, lower the vehicle.
b.
Support the lower control arm with a jack.
c.
Remove
the cotter pin and nut from the upper ball
Using a
ball joint
Tighten the lug nuts, the bleed the brake system.
17.
joint.
Have the alignment checked
18.
at
a reputable repair
facility.
d.
Tacoma
e.
I See Figure 51 1
Remove Remove
.
2.
the front wheel.
f.
flat
bladed
tool to
remove the grease cap.
Remove
the cotter pin and lock cap.
c.
Have an
assistant apply the brakes, then
remove the
With free wheeling hubs, remove the free wheel hub.
e.
Using a snapring expander, removed the snapring.
Remove the spacer. On models with ABS, remove
the
ABS speed
sensor
and wire harness clamp from the steering knuckle. 5. Remove the caliper and rotor. Disconnect the lower
8. lbs.
Remove
1
oil
and
lithium
soap base chassis
or equivalent to the driveshaft.
Push down on the lower
control arm, then install the
a new cotter
new
105
ft.
ball joint to lbs.
the steering knuckle,
(142 Nm).
d.
Install
a
e.
Install
a spacer to the driveshaft.
cotter pin.
Using a pair of snapring
pliers, install
the ring. clear-
Using a feeler gage, measure the driveshaft thrust
clearance between the knuckle and the outside bushing and
pin.
lbs.
(98
N). h.
Attach the steering knuckle and tighten the nut to 80 Install
Connect the lower
spacer, by pulling the bolt and applying a load of 22
the nut and knuckle.
install:
(108 Nm).
c.
g.
nect the steering knuckle.
To
the knuckle as follows:
Apply synthetic
^If you replace the knuckle bushing, recheck the ance of the driveshaft thrust.
ball joint.
Using a special tool 09950-40010 or equivalent, discon-
c.
b.
f.
Remove the steering knuckle with hub as follows: Remove the cotter pin and loosen the nut.
b.
Install
tighten the nut to
f.
a.
then discon-
steering knuckle.
d.
7.
install:
7.
grease NLGI No.
locknut.
6.
joint,
joint.
Push down the lower control arm, then remove the Be careful not to damage the seal.
To
a.
b.
4.
the bolts from the iower ball
knuckle.
the shock absorber.
Without a freewheeling hub, use a
a.
Remove
nect the knuckle from the
Disconnect the driveshaft as follows:
3.
separator, detach the joint from the
knuckle.
ft.
Standard clearance should be 0.0039-0.0197
in.
(0.1 0-0. 50mm). i.
If
spacer.
the clearance
is
not within specifications, replace the
SUSPENSION AND STEERING
8-37
SUSPENSION AND STEERING
8-38
Connect the
8.
lower control arm,
stabilizer bar to the
tighten the nut to 19
lbs.
ft.
(25 Nm).
Attach the front shock to the lower control arm, tighten
9.
the nut to 101 10.
lbs.
ft.
new
13
seal, tighten to
ft.
lbs.
full
with moly-disulfide
grease.
Place a
new gasket on
dle. Install the gasket,
Install
the front axle hub and caliper.
21.
Install
the wheel, lower the vehicle.
22.
Have
12.
Install
13.
Tighten the lug nuts. Check the front end alignment.
14.
Check the ABS speed sensor
signal.
the knuckle and
**CAUTION
ft.
(47 Nm).
lbs.
installation
Section
in
procedures
When
ing any dust from brake surfaces.
cleaning brakes,
use commercially available brake cleaning
fluids.
If
the tires are worn unevenly,
the highway or
the handling
if
if
the vehicle
ing,
wheel alignment should be checked.
lem
is
suspected,
first
check
tire inflation
not stable on
is
seems uneven
in
spirited driv-
If an alignment proband look for other
possible causes such as worn suspension and steering
3.
Remove Remove
4.
Tap the knuckle spindle gently and remove
nents, accident
the knuckle spindle mounting bolts.
the dust seal and dust cover (splash shield).
from the
it
Turn the axle so that one
faces upward;
to
or
unmatched
compo-
may be
Repairs
tires.
necessary before the wheels can be properly aligned. Wheel
a properly equipped shop.
at
part of the outer shaft
CASTER
out the axle shaft.
pull
Use a separator
6.
flat
damage
alignment requires sophisticated equipment and can only be
performed
steering knuckle. 5.
for
7.
Front End Alignment
Brake pads and shoes may contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air. Avoid inhal-
2.
facility.
Hub and Bearing
these models are given
the front axle hub.
the spin-
the alignment checked at a reputable repair
Hub and bearing removal and
Remove
install
dust cover and dust seal on the spindle.
the axle hub.
Front Axle
Land Cruiser 1
Pack the knuckle about 3/4
Tighten the spindle mounting bolts to 34
(18 Nm). 11.
Install
20.
(137 Nm).
the dust cover and
Install
the axle shaft.
18.
19.
disconnect the
tie
end from the
rod
knuckle arm.
Remove Remove
7. 8.
the
oil
Lightly tap the slits of
the knuckle
and
seal
Wheel alignment
retainer.
arm bearing and bearing cap nuts. the washers and remove them. Push out
the knuckle
arm and shims from the
steering knuckle. Don’t
lose the shims.
Mark the
bearing.
re-
position for
install:
10.
Install
a
Install
new oil a new
seal oil
if
it
was removed from
seal set
12.
Place the bearings
in
in their ,
on the knuckle and axle
Remove
Tap the bearing cap
arm and the cone washers
in their
the wheels self-centering,
in-
Excessive positive caster makes
stability.
will
cause a
side.
is
adjustable on vehicles other than the Land Cruiser
by turning the adjusting cams
arms. Land
to reposition the
required
is
if
the caster
measurement
is
out of
specification.
tighten the nuts to 71 to the
same value. 15. Use a spring
exact
into the inner race.
ft.
lbs.
Looking at the wheels from the front of the vehicle, camber
washers
(96 Nm).
knuckle arm and tighten the nuts to
castle nut to 67
the
ft.
oil
adjustment
the
is
at the top, this is
of negative
tilt
of the wheel.
negative camber.
When In
a
the wheel turn,
a
is tilted
slight
in
amount
camber helps maximize contact of the outside tire Too much negative camber makes the vehicle
with the road.
tension gauge to
preload. Correct preload
Connect the
to
Install
the
Install
make
the bearing
Install
the race supports. Install the cone
the third
17.
described as positive caster. Having
is
CAMBER
Support the lower bearing inner race.
original location.
16.
one
pull to
nents
arm over the shims, making sure the shims are exact original location. Tap the knuckle arm into the the
cap over the shims, making sure the shims are 14.
strut at the
Cruisers do not allow adjustment; replacement of bent compo-
inner race. 13.
back, this
tilted
is
Caster
position
Support the upper bearing inner race on the knuckle Install
attached to the
the wheels hard to steer, while an uneven caster
the axle
dust seal, rubber seal
(felt
housing. Place the knuckle onto the housing.
arm.
is
creasing directional
steel ring, in that order).
11.
top and the arm at the bottom. The wheel pivots around the line between these points to steer the vehicle. When the upper steering knuckle
a positive caster tends to
To
in
wheel angle. The
gle describes the steering axis rather than a
point
reassembly.
and
defined by three different adjustments
control
9. Remove the steering knuckle and moved adjusting shims and bearings by
housing.
is
three planes. Looking at the vehicle from the side, caster an-
tie
is
6.6-13.2
measure the bearing lbs.
(19-59 N).
(91
Nm).
Install
a new cotter
seal set to the knuckle.
in
Camber
rod to the knuckle arm. Tighten the
lbs.
unstable
pin.
a straight is
line.
adjustable on
all
vehicles except the Land
cams. Land Cruisers measurement is out of specidamaged components must be replaced.
Cruiser, through the turning of adjusting
are not
camber
fication,
bent or
adjustable;
if
the
SUSPENSION AND STEERING and provides a smoother
directional stability
TOE-IN
On most
way.
ment alignment
is
Toe
the distance between the front of the wheels rela-
distance between the back of the wheels.
wheels are closer
have a negative
A
amount
small
the
of negative toe
either zero or slightly positive.
enhances
adjustable on
is
measured
generally
is
they are said to be toed-in or to
at the front,
toe.
If
on the high-
ride
wheel drive vehicles, standard toe adjust-
front
When power
applied
is
to the front wheels, they tend to toe-in naturally.
Looking down at the wheels from above the vehicle, toe
tive to the
is
8-39
models covered by
all
inches or degrees.
in
loosening the locknut on each the correct reading
until
must remain equal
tie
length during
in
adjusted by
is
rod end and turning the rod
The
achieved.
is
manual, and
this
It
all
left
and
rods
right
adjustments.
2WD REAR SUSPENSION 20. Tighten the U-bolt nuts to:
Leaf Springs
•
V2 -ton Pick-Up
— 108
•
1-ton Pick-Up
and Cab & Chassis model
(123 Nm) • T 1 00 97 ft. • Tacoma 90
REMOVAL & INSTALLATION
—
—
> See Figure 52
21.
1
.
2.
Loosen the rear wheel
lug nuts.
22.
Raise the rear of the vehicle. Support the frame and
3.
end
Remove Remove of the
lbs.
ft.
and clamp.
the
Install
was removed.
Tighten the hanger pin and shackle nuts.
Install
the the
install
cotter pins.
the lug nuts and the wheel.
23.
and hand
Install
the stabilizer
Install
the wheels, remove the stands, and lower the
link
tighten
its
retaining
the cotter pin, nut, and washer from the lower nuts.
shock absorber.
24.
5.
Detach the shock absorber from the spring seat.
6.
Remove
•^Remove
it
— 90
shock absorber bushings and washers. Tighten, and
rear axle housing with stands.
4.
if
Nm)
(120
lbs.
the parking brake cable
Install
equalizer,
(147
lbs.
Nm) Nm)
(132
lbs. ft.
ft.
vehicle to the ground.
the parking brake cable clamp. 25.
the parking brake equalizer,
if
Bounce the
and then
necessary.
truck several times to set the suspension
tighten the
shock absorber
Tighten the hanger
bolt.
pin nut or bolt to: 7.
Unfasten the U-bolt nuts and remove the spring seat
assemblies. 8.
Adjust the height of the rear axle housing so that the
weight of the rear axle 9.
is
removed from the
rear springs.
Unfasten the spring shackle retaining nuts. Withdraw the
spring shackle inner plate. Carefully pry out the spring shackle
10.
lic
Remove
Remove
brake
•
1-ton Pick-Up
2 -ton
Pick-Up
— 116
ft.
lbs.
(157
Nm)
and Cab & Chassis model
— 67
lbs.
ft.
26.
— 115
•
Tacoma
•
T100-19
ft.
ft.
lbs.
(120
lbs.
(26
Nm)
Tighten the shackle pin to 67
Nm) ft.
lbs. (91
Nm)
for
all
vehicles.
spring hanger 11.
’/
Nm)
(91
with a bar.
•
the spring bracket pin from the front end of the
and remove the rubber bushing.
Use care
the spring.
line or the
not to
damage
Coil Springs
the hydrau-
and Shock Absorbers
parking brake cable.
To
install:
12.
Install
13.
Align the eye of the spring with the spring hanger
the rubber bushing
REMOVAL & INSTALLATION in
the eye of the spring.
bracket and drive the pin through the bracket holes and rubber
4Runner
bushings. I
See Figure 53
^Use
soapy water or glass cleaner as a lubricant, if necessary, to aid in pin installation. Never use oil or grease.
1
.
Elevate and safely support the vehicle on the frame
rails.
Place a floor jack under the rear axle housing and set the jack 14.
Finger-tighten the spring hanger nuts and/or bolts.
15.
Install
site
end
16.
the rubber bushing
in
to hold the axle in place.
the spring eye at the oppo-
of the spring.
3.
Raise the free end
of the spring. Install the spring
Install
4.
the shackle inner plate and finger-tighten the re-
taining nuts. 18.
Center the
head
in
the hole which
is
provided
in
spring seat on the axle housing. 19.
Fit
the U-bolts over the axle housing. Install the lower
spring seat.
shock
move bolt
Remove Remove
the wheel(s). the parking brake cable bracket from the rear
axle housing.
shackle through the bushing and the bracket. 17.
2.
the
Remove is
to
the lower shock absorber
mount
bolt.
If
the
be replaced, disconnect the upper mount and
the shock.
If
the shock
is
re-
not to be removed, the upper
mount may be left connected during spring removal. If only the is to be replaced (removal of the spring not required,
shock
skip to Step 13 for reinstallation. Refer to Inspection and/or
Disposal of Shock Absorbers this Section.
in
the Front Suspension part of
8-40
SUSPENSION AND STEERING
2WD
2WD STD 0.5 ton, 2WD Extra cab Spacer Spring
Spacer Spring
Bumper
Bumper
fl
Retainer
Spring Clip Rivet
—
Spring Clip Rivet
Spring Clip Rivet
Non-reusable part 86828g55
Fig.
52 Exploded view of the rear leaf spring and related components
— 2WD Tacoma
shown
SUSPENSION AND STEERING
N
m
(kgf
cm,
ft-lbf)
:
8-41
Specified torque
Non-reusable part 86828g58
Fig.
53 Exploded view of the
coil
springs and other rear suspension components
— 1996 4Runner shown
SUSPENSION AND STEERING
8-42
Disconnect the stabilizer bar brackets from the rear axle
5.
housing. 6.
Disconnect the
7.
Remove
right
arm
Bounce the
Use a
19.
to the
body
frame.
Very carefully begin
8.
Install
18.
lower the jack holding the axle
caution not to snap the brake
Use extreme
housing.
to
rear of the vehicle several times to stabilize
the suspension.
shock absorber lower mount.
the bolt(s) holding the lateral control
the wheel(s) and lower the vehicle to the ground.
17.
and support the axle
the lateral control rod nut to 64-101
Lower the vehicle
20.
lines
housing (not the
floor jack to raise the rear axle
of the vehicle)
to the
ft.
with stands. Tighten
lbs.
(86-137 Nm).
ground.
and/or parking brake cable.
While lowering the axle, remove the
9.
remove the upper
loses tension and spring
is
To
install:
10.
Install
end
Rear Wheel Alignment
it
Once the follow) may be
stop (spring
un-
desired.
if
the
lbs.
ft.
of the spring;
Once
enough
the spring
to hold
it
but
is
in
insulators.
correctly installed against the
a hidden cause of rear
place, jack the axle housing
comes
the spring
NOT
do
14.
14-18
path. Both of these
in place.
the point reasonably
Severe injury can occur
if
loose.
lateral control rod to
the frame, inserting the Install
the nut but
wear
tire
or a
cause
of
poor handling. exhibit un-
will
into
stem from the rear wheels attempting
to
behavior
particularly
is
of the vehicle
'For
hazardous on
may
back
slick surfaces; the
attempt to go
directions unrelated
in
braking or turning maneuvers.
camber and toe specifications, please Wheel Alignment chart in this section.
refer
caster,
to the
at this time.
mount
The
to
(20-25 Nm). Tighten the lower mount bolt to 47
(64 Nm).
Attach the parking brake cable bracket to the rear axle
6.
parts.
steer the vehicle instead of rolling straight. This ’’rear steer
wheels
Attach the stabilizer bar brackets.
15. 1
it
component
is
The usual symptoms include a different turning response and right corners and difficulty in maintaining a straight
the shock absorber. Tighten the upper
lbs.
ft.
lbs.
ft.
tighten
Install
installation of
possi-
all
alignment
left
from the front or shock absorber side.
bolt
of the rear axles
book eliminates
the rear wheels are misaligned, the vehicle
to the front during
Connect the
13.
in this
predictable handling characteristics.
no more.
Do not compress the spring beyond it
as important as
is
a check of the rear alignment can reveal
In spite of this fact,
If
wheels
The nature
of adjusting the rear alignment; correct
bility
Check the
^CAUTION necessary to hold
1
of the rear
achieved only by the correct
and upper
must be
it
removed, tighten-
(15 Nm).
spring
coil
if
stopper on the lower mount. 12.
The proper alignment
the alignment of the front wheels.
the spring follow to the frame
Install
spring as
used on the vehicles covered
ing the bolt to 11 11.
bump
removed, the
bolted from the frame
coil
insulators.
housing.
be checked any time a
rear wheel alignment should
problem
is
suspected or
after
any serious impact involving the
rear wheels. Even a low-speed encounter with a curb on a snowy day can bend an axle. If the rear alignment check reveals a component problem, the timely inspection has saved you at least the cost of new tires and possibly a more serious
accident by eliminating poor handling.
4WD REAR SUSPENSION 8.
Leaf Springs
Unfasten the U-bolt and nuts, then remove the spring
seat assemblies. 9.
Adjust the height of the rear axle housing so that the
weight of the rear axle
REMOVAL & INSTALLATION
10.
is
removed from the
rear springs.
Unfasten the spring shackle retaining nuts. Withdraw the
spring shackle inner plate. Carefully pry out the spring shackle
>
See Figures
54, 55, 56, 57, 58, 59,
60 and 61
with a bar. 1 1
1
Loosen the rear wheel
.
Raise the rear
2.
.
Remove
lug nuts.
of the vehicle.
Support the frame and 12.
the spring bracket pin from the front end of the
and remove the rubber bushing.
spring hanger
Remove
the spring.
Use care
not to
damage
the hydrau-
rear axle housing with stands.
Remove Remove
3.
4.
end 5.
of the
lic
the lug nuts and the wheel. the cotter pin, nut, and washer from the lower
shock absorber.
On the Land Cruiser, perform a. Remove the cotter pins and
the following:
brake
To
line
or the parking brake cable.
install:
the rubber bushing
13.
Install
14.
Align the
eye
in
the eye of the spring.
of the spring with the spring
hanger
bracket and drive the pin through the bracket holes and rubber
nuts from the lower end of
bushings. the stabilizer b.
link.
Detach the
link
from the axle housing.
6.
Detach the shock absorber from the spring seat.
7.
Remove
soapy water or glass cleaner as a
lubricant, oil
if
nec-
or grease.
the parking brake cable clamp (except Land
Cruiser).
'Remove
'Use
essary, to aid in pin installation. Never use
the parking brake equalizer,
if
necessary.
15.
Finger-tighten the spring hanger nuts and/or bolts.
16.
Install
site
end
the rubber bushing
of the spring.
in
the spring eye at the oppo-
SUSPENSION AND STEERING
8-43
86828g59
Fig.
54 Exploded view of the rear
leaf
spring and components
— 4WD Tacoma
shown
8-44
SUSPENSION AND STEERING
86828p50 86828p53
Fig.
55 Support the rear axle of the vehicle with a set Fig.
of jackstands
58
Remove
the U-bolt from the rear
86828p54
86828 p5
Fig.
56 Unbolt the rear axle mounting bracket attached
to the spring
Fig.
59 Proceed to the front of the spring, and remove
the pin
86828p52
Fig.
57 Lower the seat assembly
86828p55
Fig.
60 Unbolt the rear mount then
.
.
.
SUSPENSION AND STEERING
8-45
and Shock Absorbers
Coii Springs
REMOVAL & INSTALLATION 4Runner 1
Elevate and safely support the vehicle on the frame
.
rails.
Place a floor jack under the rear axle housing and set the jack to hold the axle in place.
Remove Remove
2. 3.
the wheel(s). the parking brake cable bracket from the rear
axle housing.
Remove
4.
shock
to
is
move
the lower shock absorber
the shock.
mount may be shock
to
is
mount
bolt.
If
the
be replaced, disconnect the upper mount and the shock
If
is
connected during spring removal.
left
re-
not to be removed, the upper
be replaced (removal
If
only the
of the spring not required,
skip to Step 13 for reinstallation. Refer to Inspection and/or 17.
Raise the free end
Disposal of Shock Absorbers
of the spring. Install the spring
shackle through the bushing and the bracket. 18.
the Front Suspension part of
Disconnect the stabilizer bar brackets from the rear axle
5.
the shackle inner plate and finger-tighten the re-
Install
in
this Section.
housing. taining nuts. 19.
Center the
head
bolt
the hole which
in
is
provided
spring seat on the axle housing. 20.
the U-bolts over the axle housing. Install the lower
Fit
bumper on
spring seat. Install the spring
later
4WD
• • • • 22.
Pick-Up
lbs.
lbs.
lbs.
ft.
1
Nm)
spring
was removed.
the stabilizer
Install
To
install: Install
the
11.
link
and hand-tighten
its
retaining
and then
shock absorber
bolt.
Tighten the hanger
pin nut or bolt to:
(91
— 90
Land Cruiser
•
V2 -ton Pick-Up
-116
•
1-ton Pick-Up
and Cab & Chassis model
ft.
lbs. ft.
Nm) (157 Nm)
(122
• T1
00
— 115
lbs.
— 67
ft.
-19
ft.
lbs.
lbs.
(26
(120
Nm)
67
lbs.
13.
lbs.
do (91
Nm)
for all
removed, tighten-
Check the
correctly installed against the
it
is
in
place, jack the axle housing
but no more.
the spring
lbs.
ft.
15. 1
Connect the
NOT
14-18
vehicles.
comes
it
beyond the point reasonably
in place.
Severe injury can occur
6.
tighten
Install ft.
lbs.
it
if
loose.
lateral control rod to the
from the front or shock absorber side.
14. ft.
if
(15 Nm).
must be
the spring
to hold
Do not compress
Nm)
27. Tighten the shackle pin to
lbs.
;:*CAUTION
bolt ft.
Once
the spring
Nm)
Tacoma
it
necessary to hold
•
•
un-
stopper on the lower mount.
truck several times to set the suspension
tighten the
it
desired.
the coil spring and upper insulators.
Install
enough
remove the stands, and lower the
ft.
of the spring;
vehicle to the ground.
Bounce the
spring as
Once the follow) may be
the spring follow to the frame
the
install
12.
the wheels,
if
coil
insulators.
removed, the bump stop (spring
ing the bolt to 11
nuts.
26.
is
10.
end
Install
lower the jack holding the axle
remove the upper
bolted from the frame
cotter pins.
25.
to
caution not to snap the brake lines
While iowering the axle, remove the
9.
Tighten the hanger pin and shackle nuts.
Install
Use extreme
loses tension and
shock absorber bushings and washers. Tighten, and 24.
to the
and/or parking brake cable.
the parking brake cable and clamp. Install the it
arm
lbs.
ft.
if
shock absorber lower mount.
right
the bolt(s) holding the lateral control
Very carefully begin
8.
lbs.
ft.
Install
equalizer, 23.
ft.
ft.
Remove
housing.
— 90 (123 Nm) — 108 (147 Nm) Land Cruiser — 105 (142 T 00 — 97 (132 Nm) Tacoma — 90 (120 Nm) Cab
Xtra
Disconnect the
7.
frame.
models.
21. Tighten the U-bolt nuts to: •
6.
the
in
frame, inserting the Install
the nut but
at this time.
the shock absorber. Tighten the upper
mount
to
(20-25 Nm). Tighten the lower mount bolt to 47
(64 Nm).
Attach the stabilizer bar brackets. Attach the parking brake cable bracket to the rear axle
housing. the wheel(s) and lower the vehicle to the ground.
17.
Install
18.
Bounce the
the suspension.
rear of the vehicle several times to stabilize
SUSPENSION AND STEERING
8-46 Use a
19.
body
floor jack to raise the rear axle
housing (not the
the lateral control
Lower the vehicle
20.
to the ground.
Bar
Stabilizer
and support the axle with stands. Tighten rod nut to 64-101 ft. lbs. (86-137 Nm).
of the vehicle)
REMOVAL & INSTALLATION
Land Cruiser > See Figure 62 1
1
Elevate and safely support the vehicle on the frame
.
Place a floor jack under the rear axle housing
rails.
Remove Remove
3.
the lower shock absorber
mount may be
mount
bolt.
If
shock
be replaced (removal
to
is
connected during spring removal.
left
tainers,
the
If
Disposal of Shock Absorbers
3.
in
install:
4.
Install
5.
the Front Suspension part of
the bolt(s) holding the lateral control
arm
to the
Very carefully begin
lower the jack holding the axle
to
Use extreme caution
remove the upper
loses tension and is
bolted from the frame
To
end
insulators.
spring as
Once the may be
of the spring;
it
Nm) on
ft.
lbs.
(13
Nm) on
link with
76
ft.
7.
Install
a wrench, then
ft.
Nm) on
(103
lbs.
lbs.
(19-25
install
Nm) on
a
links.
new
Hold
nut.
the 4Runner,
the Land Cruiser.
the nuts to the stabilizer bar, tighten to 51
Nm) on
the
the Land Cruiser.
Attach the retainers and cushions to the bar
the 4Runner, or 19
un-
ft.
lbs.
(25
Nm) on
ft.
lbs.
the Land
the front wheels.
8.
Install
9.
Have the alignment checked
Lateral Control ft.
bolts to 9
(18
at
a reputable repair
facility.
desired.
if
lbs.
if
Rod
removed, tighten-
(15-28 Nm).
the coil spring and upper insulators.
Install
lbs.
Cruiser.
it
stop (spring follow)
the spring follow to the frame
ing the bolt to 11-21 9.
coil
install: Install
8.
bump
removed, the
or
(69
While lowering the axle, remove the
spring
ft.
the stabilizer bar
not to snap the brake lines
and/or parking brake cable. 7.
the bar to the rear axle housing, with bushings
Install
Tighten the nut to 14-19
rear axle housing.
10.
the bushings to the stabilizer bar so the cutout of
4Runner, or 13 6.
Remove
6.
the bolts and stabilizer bar with cushions and
and brackets. Tighten the
Disconnect the stabilizer bar brackets from the rear axle
re-
link.
the bushing faces the under side of the vehicle.
housing.
housing.
Remove
a wrench, then remove the nut,
link with
cushions and
To
of the spring not required,
this Section.
5.
as follows:
brackets.
only the
skip to Step 13 for reinstallation. Refer to Inspection and/or
4.
stabilizer bar links
the nuts and disconnect the stabilizer bar links
Hold the
b.
the wheel(s).
to
is
Remove
from the stabilizer bar.
be replaced, disconnect the upper mount and remove the shock. If the shock is not to be removed, the upper
shock
Disconnect the a.
and set the jack
to hold the axle in place. 2.
Jack, up and support the vehicle.
.
2.
must be
Check the
REMOVAL
& INSTALLATION
correctly installed against the
stopper on the lower mount.
Once enough
the spring
to hold
it
is
in
Land Cruiser
place, jack the axle housing
but no more.
**CAUTION
1.
Raise and support the rear
2.
Remove Remove
3.
Do
not compress the spring beyond the point reasonably
necessary to hold the spring
comes
it
in place.
Severe injury can occur
if
Connect the
12.
37
ft.
lbs.
Install
lateral control rod to
lbs.
NOT
tighten
it
the axle housing,
shock absorber
in-
side. Install
4.
at this time.
the shock absorber. Tighten the upper
(50 Nm). Tighten the lower
mount
bolt to
mount
to
47-51
ft.
13.
Install
the stabilizer bar to the axle housing.
14.
Install
the wheel(s) and lower the vehicle to the ground.
15.
Bounce the
floor jack to raise the rear axle housing,
support the axle with stands. Tighten the to
130 17.
nut and plate washer, then disconnect
Remove
the bolt and lateral control rod from the axle
install:
Attach the bolt that connects the rod to the axle housing,
tighten to 181
lbs.
ft.
(245 Nm).
Attach the bolt with washer and tighten the nut to the
rod to 130
ft.
lbs.
(177 Nm).
the wheel.
7.
Install
8.
Lower the
9.
Have
vehicle, then tighten the lug nuts.
the alignment checked at a reputable repair
facility.
4Runner
rear of the vehicle several times to stabilize
the suspension.
Use a
5.
6.
(64-69 Nm).
16.
bolt,
housing.
loose.
serting the bolt from the front or
the nut but do
the
the lateral control rod.
To 11.
of the vehicle.
the rear wheel.
ft. lbs. (177 Nm). Lower the vehicle to the ground.
then
lateral control rod nut
1.
Raise and support the rear of the vehicle.
2.
Disconnect the
3.
Remove
the
right side
bolt,
shock absorber.
then disconnect the harness for the
Load Sensing Proportioning and Bypass Valve (LSPBV). 4.
Remove
the bolt, nut and plate washer, then disconnect
the lateral control rod from the frame. 5.
Remove
housing side.
the bolt and lateral control rod from the axle
SUSPENSION AND STEERING
Fig.
62 Exploded view of the
coil
springs and other rear suspension components
— Land
Cruiser
shown
8-47
SUSPENSION AND STEERING
8-48 To 6.
Attach the bolt that connects the rod to the axle housing,
64
tighten to 7.
8.
install:
(86 Nm).
lbs.
ft.
Attach the bolt with washers, then tighten the rod to the
frame side
64
to
ft.
lbs.
9.
10.
(86 Nm).
Attach the
bolt,
then connect the harness for the Load
Sensing Proportioning and Bypass Valve (LSPBV). Tighten the bolt to 9 ft. lbs. (13 Nm).
1 1
.
Attach the right side shock absorber.
Lower the vehicle. Have the alignment checked
at
a reputable repair
facility.
STEERING Toyota offers two types
There
is
of
power steering on
their trucks.
standard and Progressive Power Steering (PPS). Both
types have a recirculating
system and rotary type hydraulic
ball
control valve.
On
PPS, the vehicle speed is detected by a speed fluid pressure acting on the piston is varied acWhen the truck is stopped or when moving at a low
the
sensor and cordingly.
speed,
fluid
pressure
for steering. At high
the
amount
of assist
is
increased to lighten the force required
speeds, the pressure
reduced to lessen
is
and provide appropriate steering wheel
response.
Steering Wheel
REMOVAL & INSTALLATION 86828p25
Fig.
Without Air Bag I
See Figures
63 Using a suitable prytool, loosen the mounting
for the center
63, 64, 65, 66,
pad
67 and 68
^WARNING Do not attempt to remove or install the steering wheel by hammering on it. Damage to the energy absorbing steering column could result. Always use a steering wheel puller to extract the wheel from the shaft.
1.
Position the wheels
2.
Remove
in
the straight
ahead
the steering wheel center pad.
position.
Check the back
wheel spokes for recessed screws holding the pad and remove them if present. If no screws are found, the pad should snap out with firm finger pressure. of the steering
aid
3.
Remove
4.
Scribe matchmarks on the hub and the steering shaft to
in
5.
proper
the steering wheel retaining nut.
installation.
Use the
puller to extract the
wheel from the
shaft.
plug any wiring connectors running to the wheel once
it
Unis
loose.
To 6.
install:
Align the
matchmarks on the wheel hub and
tach any wiring connectors to the wheel and wiring 7.
is
positioned correctly.
Install
(34-47 Nm).
the center nut
Install
and
make
shaft. At-
certain the
the wheel onto the shaft.
tighten
it
to
25-35
ft.
lbs.
8.
Install
the center pad, making sure
it
is
correctly
secured. 9.
Test drive the vehicle, checking for correct steering
wheel alignment and horn function.
SUSPENSION AND STEERING
8-49
86828p30 86828p27
68
Fig. Fig.
65
... to release
it
from the steering wheel
the wheel off the column, and separate any
Lift
wires that
may be
attached
With Air Bag > See Figures 69, 70 and 71
^CAUTION Work must not begin
90 seconds
until at least
ignition switch is turned to the
negative battery cable
is
LOCK
position
after the
and the
disconnected from the battery.
The SRS is equipped with a back-up power source so that if the work is started within the 90 seconds of disconnecting the negative terminal, the
1.
Disarm the
SRS
2.
On models
without
a.
SRS may
be deployed.
system. tilt
steering,
proceed as follows:
Place the front wheels facing straight ahead.
b. Remove the 2 steering wheel lower covers. Using a Torx® driver, loosen the Torx® screws until the groove 86828p28
Fig.
66 Place a socket on the center nut and loosen
along the screw circumference catches on the screw case. c.
Pull out the
detach the
86828p29
Fig. Fig.
67 Use the puller to extract the wheel from the
shaft
air
wheel pad from the steering wheel, then
bag connector.
69 Using a Torx® driver, loosen the Torx® screws
the groove along the screw circumference catches on the screw case until
SUSPENSION AND STEERING
8-50
ignition Switch
REMOVAL & INSTALLATION I See Figures 72 and 73
Both the electrical portion of the
may be
key/lock portion
or bracket holding them.
switch assembly
were
The bracket holding
broken
the bracket must be
removed would be
be removed, the headless drilled
and removed
with a
In
if
whose heads
About the only time
off at installation.
must be replaced.
or tube
and the
the ignition
held to the column by bolts
is
intentionally
ignition switch
replaced without removing the housing
the steering column
the event that the bracket must
must be center-punched,
bolts
screw extracting
tool.
•'CAUTION Work must be Remove the steering wheel set nut. A special wheel may be needed. Place matchmarks on the steering wheel and mainshaft assembly. Remove the wheel. 3.
negative battery cable
puller
Align the
6.
Attach the harness.
7.
Attach the
air
8.
(9
ft.
lbs.
(34 Nm).
1
install
circumference groove
the wheel pad of the
driver, tighten the
Install
3.
screws
to
78 inch
lbs.
SRS
ignition
system.
OFF and remove
Remove
the key from the
the steering wheel pad and
4. Remove the upper and lower Remove the combination switch.
the steering wheel covers.
Check the
Disarm the Turn the
remove the
steering wheel center point.
5.
Unplug the
6.
If
ignition wiring
steering
column covers.
harness connector.
only the electrical switch needs replacement,
the retaining screw at the back of the lock housing
move
Combination Switch Removal and ered
Section
installation of the
the switch.
must be changed, combination switch
lose the spring is
cov7.
in
steering
wheel.
Nm). 9.
deployed.
ignition.
Torx®
caught on the screw case.
Using a Torx®
.
2.
bag harness, then
after confirming that the is
SRS may be
matchmarks on the wheel and the mainshaft.
Tighten the wheel set nut to 25
screw
disconnected from the battery.
necting the negative terminal, the
To install: 10. 5.
is
seconds from the time the LOCK position and the
The SRS is equipped with a back-up power source so that if the work is started within the 90 seconds of discon-
Unplug the harness.
4.
started after 90
ignition switch is turned to the
If
it
may be
and lock
unbolted from the housing; don’t
pin.
the key lock assembly
the switch
and
re-
the automatic transmission interlock relay
If
is
to
6. in
remove
and
turn the
key
to the
be changed, place the key
ACC
position. Insert a
SUSPENSION AND STEERING thin rod in the hole at the
bottom
housing and press the
of the
stop tab inward. While holding the tab
in,
pull
the cylinder out
8.
Install
the key
is
in
new
the the
lock cylinder
ACC
if
necessary, making certain
and be sure the stop tab engages the installed, turn the switch OFF and remove the back
Align the electrical switch with the
hole.
heavy and
key. of the
key
is
correctly routed
and held by
its
Make
certain the
clamps and
clips.
Install
the combination switch.
12.
Install
the steering wheel. Install the upper and lower
steering 13.
umn from the To install:
and
correct function
all
positions, checking for
column inside the
The column
is
not supported.
if
disconnecting the
into the vehicle,
Remove
the steering col-
vehicle.
Under the
onto the
worm
vehicle, align the
Make
gear.
Pick-Ups and 4Runner,
lack of binding.
26
Steering
assembly
heavily on you
Place the column assembly
12.
13.
ignition switch in
col-
the nut(s)
into the vehicle
and
the
fit
mainshaft through the floor hole.
column covers.
Operate the
come down
will
Pull the
11.
cylin-
11.
Remove
assistant support the steering
mainshaft from the steering gearbox.
Attach the wiring harness connector.
harness
two bolts holding the steering
panel subframe.
vehicle before removing the other mounting bolt.
der. Install the retaining screw. 10.
Have an
10.
Once
of the
to the instrument
holding the column.
position before installation. Insert the
cylinder
9.
Remove one
9.
umn
install:
bolts holding the rubber
steering hole cover to the floorboard.
of the housing.
To
remove the
Inside the vehicle,
8.
8-51
lbs.
ft.
14.
Column
the column into position
lift
retaining bolts, tightening 1.
REMOVAL & INSTALLATION
the pinch bolt and tighten
install
it
to
(35 Nm).
the cab,
In
matchmarks and fit the shaft marks align exactly. For
certain the
them
to
19
ft.
and
install
the
(25 Nm).
lbs.
15.
Reposition the floor hole cover and
16.
Install
17.
Attach the wiring harnesses for the ignition and combina-
install
the bolts.
the combination switch.
tion switches.
Pick-Up and 4Runner
Install
the upper and lower steering column covers.
Install
the heater duct;
20.
Install
the steering wheel
21
Connect the negative battery cable.
18. 2.
1989-95 >
19.
MODELS
See Figures 74 and 75 1.
Disconnect the negative battery cable.
2.
Remove
the steering wheel.
Matchmark the wheel and
Remove
the lower
heater duct (No.
1)
left
side dash trim panel.
Remove
5.
Unplug the wiring connectors
6.
7.
left
dash
trim
I
and center pad.
MODELS
See Figure 76
the
from below the dash.
4.
and the
Remove
.
1996
mainshaft. 3.
the lower
install
panel.
Disconnect the negative battery cable.
the upper and lower steering column covers. for the
•'CAUTION
combination switch
ignition switch.
Remove
Work must be
the combination switch.
Below the
vehicle, at the steering gearbox,
make
matchmarks on the steering mainshaft and the worm shaft entering the gearbox. Loosen or remove the pinchbolt holding the mainshaft to the
worm
started after 90
ignition switch is turned to the
negative
(-)
battery cable is disconnected.
Remove
shaft.
seconds from the time the LOCK position and the
the steering wheel pad.
a.
Place the front wheels straight ahead.
b.
Remove
c.
Using a Torx®
Loosen them
the two steering wheel lower No. 2 covers.
until
driver,
loosen the
Torx® screws.
the groove along the screw circumference
catches on the screw case. d.
Pull out the
disconnect the
air
wheel pad from the steering wheel and
bag connector.
•'CAUTION The air bag system (SRS) must be disarmed before removing the steering wheel. Failure to do so may cause accidental deployment, property jury.
Always store the
air
damage
or personal in-
bag with the pad facing upward.
4.
Matchmark the steering wheel to the mainshaft. Using a remove the steering wheel. Remove the upper and lower column covers.
5.
Remove
3.
steering wheel puller,
the instrument lower finish panel. Disconnect
the hood lock control cable 6.
Remove
and
fuel
lid
control cable.
the No. 2 heater register duct.
8-52
Fig.
SUSPENSION AND STEERING
74 Exploded view of the steering column
— 1989-95
Pick-Up and 4Runner
Remove
7.
Remove Remove Remove
8. 9.
10.
the combination switch with the spiral cable,
Unplug the two connectors and the
a.
bag
wiring.
the brake pedal return spring. the intermediate shaft No.
2.
Place matchmarks on the universal
a.
air
the spiral cable.
intermediate shaft No. 2.
Remove
the
A
joint
No. 2 and the
bolt.
Place matchmarks on the intermediate shaft No. 2 and
b.
the control valve shaft.
Remove
the
B
bolt.
Slide the intermediate shaft No. 2
c.
and remove the
shaft.
Remove
11.
the column hole cover and the column hose
cover No. 2 set
Remove
12. joint
No.
bolt.
the steering column assembly with the universal
2.
Disconnect the universal
13. a.
and the universal b.
joint
No.
2.
Place matchmarks on the steering column assembly
Remove
the
joint bolt.
No.
2.
Remove
the column hose cover No.
2.
the column hole cover and
SUSPENSION AND STEERING
W/ CRUISE CONTROL
-Steering
8-53
Wheel Pad
/ Steering Wheel Lower 34 (350, 25)
|
Steering Wheel
Steering Wheel Lower No.2 Cover
Column Upper Cover 9.0 (90, 78 in.'lbf)
Brake Pedal Return Spring Steering
26 (260, 18)
Column Assembly
-Column Hole Cover No.2
Lower LH
Finish Panel
Universal Joint
Hood Lock Release
Column Hole Cover
Lever Fuel Lid
Release Lever Intermediate Shaft No.2
1
35 (360, 26)
|
|N-m (kgf-cm,
No.2 Heater ft
•
Ibf)
:
to
Register Duct
Specified torque 86828g82
Fig.
76 Exploded view of the steering column
— 1996 4Runner
SUSPENSION AND STEERING
8-54 To
14. Connect the universal joint No. 2. a. Insert the column hole cover and the column hole
cover No.
2.
Install
No.
Install
ft
lbs.
lbs.
17.
Install
ft.
ft.
lbs. (8
matchmarks on the
loosen the
Torx® screws.
joint
No. 2 and
bag connector.
The air bag system (SRS) must be disarmed before removing the steering wheel. Failure to do so may cause accidental deployment, property
and
control valve shaft
air
^CAUTION
Nm).
matchmarks on the universal
driver,
the groove along the screw circumference
wheel pad from the steering wheel and
Pull out the
d.
the intermediate shaft No. 2.
Align the
until
disconnect the
the intermediate shaft No. 2. b.
Using a Torx®
the column hole cover and the column hole cover
Align the
a.
the steering wheel lower No. 2 and No. 3
catches on the screw case.
(35 Nm).
(26 Nm).
Tighten the five bolts to 5.9
2.
Remove
c.
the column assembly with the universal joint No.
Tighten the nuts to 18 16.
b.
Loosen them
Tighten the bolt to 26
c.
Place the front wheels straight ahead.
matchmarks on the column assembly and the
universal joint No. 2.
15.
the steering wheel pad.
a.
cover.
2.
Align the
b.
Remove
2.
install:
Always store the
jury.
air
damage
or personal
in-
bag with the pad facing upward.
the intermediate shaft No. 2.
Tighten the
c.
18.
Install
19.
Install
Attach the 20. 21.
Install
hood
lock
26
ft.
lbs.
(35 Nm).
lid
spiral cable.
b.
Turn the cable counterclockwise by hand
wheels are facing
until
7.
ahead.
straight
8.
be-
it
Unplug the two connectors and the
to turn the cable.
either
left
Install
The cable
rotate
about three turns
10.
1 1
the steering wheel.
ft.
lbs.
matchmarks on the wheel and mainshaft
Attach the air bag connector.
25.
Install
4WD: Place matchmarks on worm gear valve shaft. b. 2WD: Place matchmarks on
is
(9
c.
12.
caught on the screw
Using a Torx®
the intermediate shaft and
Remove the bolts A, B and C. Remove the intermediate shaft assembly and
with the shaft
case. 26.
the intermediate shaft and
the control valve shaft.
the wheel pad after confirming that the circumfer-
Torx® screws
slid-
yoke sub-assembly.
the
(34 Nm).
of the
bag connector.
Disconnect the intermediate shaft assembly and the
.
a.
24.
ence groove
air
the spiral cable.
ing with the shaft
Attach the connector and tighten the wheel set nut to
b.
the
and the parking lock cable and remove the parking lock cable.
assembly.
25
Remove
equipped with A/T, place matchmarks on the cap nut
If
to
or right of the center.
Align the
a.
will
Remove
9.
Rotate the cable clockwise about three turns to align
c.
the red mark.
the instrument lower finish panel.
Remove the front door scuff plate and the cowl side Remove the light control rheostat and locknut. Remove the No. 2 heater register duct. Remove the combination switch with the spiral cable.
trim.
that the front
the upper and lower column covers.
hood release lever from the panel.
control cables.
Check
23.
5.
6.
fuel
a.
comes harder
Remove Remove
4.
the upper and lower column covers. the instrument lower finish panel. Connect the
and the
Matchmark the steering wheel to the mainshaft. Using a remove the steering wheel.
3.
steering wheel puller,
bag connector.
Center the
22.
bolts to
the combination switch the with the spiral cable.
air
Install
A and B
the brake pedal return spring.
driver, tighten the
screws
to 6.6
ft.
13.
lbs.
a.
Nm).
the sliding
yoke sub-assembly.
Remove the steering column assembly. A/T: Remove the locking wire, the bolt and
the control
shaft lever.
'Hf the wheel pad has been dropped or there are other defects, replace the wheel pad with a new one. Make sure that the wires do not interfere or are pinched between other parts 27.
when
installing.
Enable the
29.
Road
air
the steering column assembly with the control
Remove
d.
check
that the steering
wheel
Remove
M/T:
e.
the control shaft lever assembly from the
column assembly. the two steering column assembly set
is
bolts
straight.
T100 >
Remove
c.
steering
bag system.
test the vehicle to
the two control shaft assembly mounting bolts
shaft assembly.
Connect the negative battery cable.
28.
Remove
b.
from the steering column assembly.
and
nuts.
To
install:
14.
Install
a.
See Figures 77 and 78
the
tilt
steering column assembly.
A/T: Install the control shaft
assembly
to the steering
column assembly. 1.
Disconnect the negative battery cable.
b.
Tighten the two steering column assembly set bolts
and nuts
:'*CAUTION Work must be
c.
started after 90
ignition switch is turned to the
negative
(-)
battery cable
is
seconds from the time the LOCK position and the
disconnected.
ft.
lbs.
d.
to
Install
19
ft.
lbs.
(25 Nm).
the control shaft lever and tighten the bolt to 26
(35 Nm).
M/T: Tighten the two sheering column assembly set
bolts to
19
ft.
lbs.
(25 Nm).
SUSPENSION AND STEERING
For
N-m
AT
(kgf-cm,
Control Lever
ft
•
Ibf )
: |
Steering
8-55
Wheel Pad
Specified torque
Non-reusable part 86828g83
Fig.
77 Exploded view of the steering column
— T1 00 with automatic transmission
8-56
SUSPENSION AND STEERING For
MT Steering
Wheel Pad
34 (350, 25)
Upper Column Cover Steering
Steering
Wheel
Column
35 (360, 26)
Column Hole Cover Dust Seal
\
7.8 (80, 69 1
in.-lbf) \
35 (360, 26)
Sliding Shaft
Intermediate Shaft
35 (360, 26)
Heater Register Dust Instrument Lower Finish Panel
[N-m (kgf-cm,
ft-lbf)
:
Specified torque 86828g84
Fig.
78 Exploded view of the steering column
— T100 with
manual transmission
SUSPENSION AND STEERING
8-57
2.
Connect the intermediate shaft assembly and the
15.
Disarm the Supplemental Restraint System (SRS).
sliding
with shaft yoke sub-assembly.
Connect
a.
C
to
26
b.
On 4WD
A
to
26
worm gear
ft.
valve body assembly.
accidental deployment, property
lbs.
ft.
removed, connect and adjust the parking lock cable.
17.
If
removed,
the mounting bolts to 22 18.
removed,
If
19.
Install
Attach the
install
shift lever
lbs.
ft.
assembly and
the parking lock cable.
Install Install
the front door scuff plate and the cowl side trim.
22.
Install
and the
control rheostat
Install
24.
Center the
wheels are facing
the red mark.
until
be-
it
either
25.
left
Install
8.
about three turns to 10.
the steering wheel.
Attach the
27.
Install
ence groove
air
ft.
lbs.
No.
(35 Nm).
Torx® screws
is
Using a Torx®
caught on the screw
driver, tighten the
screws
to
7
ft.
lbs.
Remove
the wheel pad has been dropped or there are other
pad with a new one. Make sure that the wires do not interfere and are not pinched between other parts when installing. defects, replace the wheel
Connect the negative battery cable.
Road
test the vehicle to
check
-that the steering
clip
and disconnect the cable as-
shift lever
assembly.
Place matchmarks on the intermediate No. 2 shaft and
Remove
To
install:
15.
Install
19
ft.
the column hole cover. the column hole cover No.
2.
lbs.
and remove the intermediate
shaft.
the steering column assembly.
the steering column assembly. Tighten the bolts to
(26 Nm).
2WD: install the intermediate No. 2 shaft and A and B to 27 ft. lbs. (36 Nm). the 2WD: Install the column hole cover and tighten
For the
16.
tighten bolts
wheel
For
17. is
ft.
lbs. (8
Nm).
4WD: install the intermediate No. 2 tighten bolts A and B to 26 ft. lbs. (35 Nm). 19. For the 4WD: Install the column hole cover For the
18.
Tacoma See Figures 79 and 80
tighten the bolts to 6
Disconnect the negative battery cable.
For the
20. trol
2WD
ft.
lbs. (8
column
shaft
and
No. 2 and
Nm).
shift,
connect the transmission con-
cable assembly.
^CAUTION
Connect the cable assembly
a.
to the
column
shift lever
assembly. started after 90
ignition switch is turned to the (-)
and
13.
straight.
negative
disconnect the trans-
12.
the bolts to 6
Work must be
2WD,
2WD: Remove 4WD: Remove
14.
I
the pin
the control valve shaft
30.
shift
(9
Nm).
29.
bag connector.
the two bolts and disconnect junction block
sembly from the column 11.
case. 28.
air
the spiral cable.
1.
b.
bag connector.
the wheel pad after confirming that the circumferof the
the combination switch with the spiral cable.
Remove
a.
1.
the
the No. 2 heater register duct.
equipped with column
If
Remove
the instrument lower finish panel.
mission control cable assembly.
matchmarks on the wheel and mainshaft
Tighten the wheel set nut to 26
b.
Remove
9.
assembly.
26.
wheel pad from the steering wheel and
air
Unplug the two connectors and the
a.
or right of the center.
Align the
a.
Torx® screws.
lever from the panel.
Remove Remove
7.
rotate
will
Remove
6.
hood release
to turn the cable.
The cable
loosen the
bag connector. Matchmark the steering wheel to the mainshaft. Using a steering wheel puller, remove the steering wheel. 5. Remove the upper and lower column covers.
Rotate the cable clockwise about three turns to align
c.
Pull out the
disconnect the
ahead.
straight
Turn the cable counterclockwise by hand
b.
comes harder
driver,
the groove along the screw circumference
until
4.
spiral cable.
that the front
Using a Torx®
d.
locknut.
the upper and lower column covers.
23.
the steering wheel lower No. 2 and No. 3
catches on the screw case.
the instrument lower finish panel. Install the hood
Check
Remove
2.
release lever to the panel with the two screws.
a.
b.
cover. c.
21.
light
the steering wheel pad.
Place the front wheels straight ahead.
Loosen them
20.
the
or personal in-
a.
bag connector.
the duct heater to the register No.
Install
Remove
3.
tighten
(29 Nm).
the combination switch the with the spiral cable.
air
damage
bag with the pad facing upward.
air
(35 Nm).
If
the
Always store the
jury.
16.
install
The air bag system (SRS) must be disarmed before removing the steering wheel. Failure to do so may cause
inter-
(35 Nm).
lbs.
Tighten bolt B to .26
c.
matchmarks on the
vehicles: Align the
^CAUTION
bolt
(35 Nm).
mediate shaft and the Tighten bolt
column assembly, tighten
to the steering
lbs.
ft.
battery cable
is
seconds from the time the LOCK position and the
Install
b.
No.
1
disconnected. 21
.
the pin and clip and connect the junction block
with the two bolts.
Install
Attach the
the combination switch the with the spiral cable.
air
bag connector.
22.
Install
the duct heater to the register No. 2.
23.
Install
the instrument lower finish panel. Install the hood
release lever to the panel with the two screws. 24.
Install
the upper and lower column covers.
8-58
SUSPENSION AND STEERING
Floor Shift
:
w/o CRUISE CONTROL Steering Wheel
Steering Wheel Pad
Lower No. 2 Cover Torx Screw Steering
Wheel
Torx Screw Steering Wheel Lower No. 2 Cover
Steering Wheel Lower No. 2 Cover
Combination Switch (w/ Spiral Cable)
Steering Column Assembly
Column Upper Cover
Column Hole Cover
Column Lower Cover
Intermediate No. 2 Shaft
4WD
:
,«#£$>
'
Column Hole Cover No.
Hood Lock No. 2 Heater to Register Duct
Release Lever
^
Universal Joint No.
Intermediate
No. 2 Shaft
Junction Block No.1 86828g86
Fig.
79 Exploded view of the steering column
— Tacoma
with floor shifter
SUSPENSION AND STEERING
Column
Shift
w/o CRUISE CONTROL Steering Wheel Lower No. 2 Cover
Fig.
80 Exploded view of the steering column
**
— Tacoma
Steering Wheel Pad
with
column
shifter
8-59
SUSPENSION AND STEERING
8-60
Center the
25.
wheels are facing
a.
Check
b.
Turn the cable counterclockwise by hand
that the front
comes harder
until
be-
it
17.
either
1
to
Align the
26
matchmarks on the wheel and mainshaft
27. Attach the air bag connector. 28.
the wheel pad after confirming that the circumfer-
Install
ence groove
of the
Torx® screws
is
caught on the screw
screws
driver, tighten the
to
7
lbs.
ft.
defects, replace the wheel
do not
that the wires
when
other parts
Remove
Unplug the wiring connectors
combination switch
Remove
Below the
the combination switch.
make
vehicle, at the steering gearbox,
shaft
worm gear and
to the shaft.
Inside the vehicle,
8.
remove the
bolts holding the rubber
Remove one
umn
Road
Have an
SRS
heavy and
system.
test the vehicle to
wheel
that the steering
is
umn from
81
3. 4.
Disconnect the wiring harnesses for the combination and
the center pad
Remove
left air
duct under the dash.
the bolts holding the steering hole cover to the
upper intermediate steering shaft
The pinch
mark the lower pinch
vehicle.
bolt is at the
shaft
and the
is
a
lower intermediate
engine side of the joint.
Loosen
or
joint;
in
match-
install:
10.
Install
flexible joint
Remove
the column assembly into the vehicle,
it
to
26
the column into position and
to 18
ft.
lbs.
Fit
13.
Install
fitting
the
ft.
lbs.
install
them
to
19
ft.
lbs.
Install
17.
Connect the wiring harnesses
install
the
(25 Nm).
install
the bolts.
the combination switch. for the ignition
and combi-
18.
Install
the upper and lower steering column covers.
19.
Install
the heater duct;
20.
Install
the steering wheel and center pad.
21
Connect the negative battery cable.
install
the lower
left
dash
trim
.
>
MODELS
See Figure 82 Disconnect the negative battery cable.
.
(35 Nm).
i'CAUTION Work must be negative
(•)
battery cable
Remove
2. install
started after 90
ignition switch is turned to the is
seconds from the time the LOCK position and the
disconnected.
the nuts; tighten
(25 Nm).
the hole cover into place and
12.
the column into position and
Reposition the floor hole cover and
the column from the cab.
onto the lower shaft and aligning the matchmarks.
the pinch bolt and tighten Lift
lift
into the vehicle, releasing the flexible
from the lower shaft.
To
Install
the cab,
the
the two nuts holding the column to the dash-
column
certain the
16.
1
Pull the
Make
panel.
remove the column
matchmarks and fit the shaft marks align exactly. them to 25 ft. lbs. (34 Nm).
vehicle, align the
gear.
the 2 bolts and tighten In
1995-96 assistant support the steering
Remove
the
fit
nation switches.
flexible joint holding the
to the
worm
15.
board subframe. 9.
Under the
bolt.
Have an
8.
the steering col-
the vehicle.
retaining bolts, tightening
the combination switch.
Just behind the hole cover
shaft.
disconnecting the
Remove
Place the column assembly into the vehicle and
14.
and lower steering column covers.
the upper
the lower
and the steering wheel.
floorboard. Slide the cover up the shaft. 7.
into the vehicle,
is
not supported.
if
install:
Install
Remove Remove
Remove Remove
assembly
heavily on you
To
onto the
Disconnect the negative battery cable.
5.
come down
12.
13.
6.
inside the
The column
mainshaft through the floor hole.
MODELS
ignition switches.
col-
the nut(s)
column
assistant support the steering
mainshaft from the steering gearbox.
Land Cruiser
.
will
Pull the
11.
check
straight.
2.
Remove
holding the column. 10.
Enable the
See Figure
panel subframe.
vehicle before removing the other mounting bolt.
32.
1989-90
two bolts holding the steering
of the
to the instrument
installing.
31.
them
for the
ignition switch.
7.
9.
pad with a new one. Make sure pinched between
Connect the negative battery cable.
11.
the
the upper and lower steering column covers.
6.
interfere or are
30.
joint
Remove
trim panel.
steering hole cover to the floorboard.
the wheel pad has been dropped or there are other
1
dash
matchmarks on the steering mainshaft and the worm
(9
Nm).
>
side
5.
to the
Using a Torx®
left
from below the dash.
1)
entering the gearbox. Disconnect the bolts holding the coupling
case. 29.
the lower
4.
and the
(35 Nm).
lbs.
the steering wheel.
heater duct (No.
Attach the connector and tighten the wheel set nut to
ft.
Remove Remove
3.
assembly. b.
Disconnect the negative battery cable.
.
2.
the steering wheel.
Install a.
about three turns
rotate
will
or right of the center.
left
MODELS
1991-94
to turn the cable.
The cable
the red mark.
26.
ahead.
straight
Rotate the cable clockwise about three turns to align
c.
Install the steering wheel and center pad. Connect the negative battery cable.
16.
spiral cable.
the bolts.
the combination switch. Connect the harnesses for
the ignition and combination switches. 14.
Install
the under dash air duct.
15.
Install
the upper and lower steering column covers.
the steering wheel pad.
a.
Place the front wheels straight ahead.
b.
Remove
the steering wheel lower No. 2 and No. 3
cover. c. Using a Torx® driver, loosen the Torx® screws. Loosen them until the groove along the screw circumference
catches on the screw case.
SUSPENSION AND STEERING
8-61
Wheel
Steering
Upper Column Cover
Steering
No 2
Column Assembly
Intermediate Shalt
Lower Joint Protector
Air
Duct 86828g88
Fig. 81
d.
Exploded view of the steering column
10.
wheel pad from the steering wheel and
Pull out the
disconnect the
— 1989-90
air
bag connector.
1 1
Place matchmarks on the sliding yoke sub-assembly and
.
worm gear valve body shaft. Loosen bolt A and remove bolt B. Remove the yoke sub-assembly. 12. Remove the tilt steering column assembly. To install:
the
i-CAUTION
The air bag system (SRS) must be disarmed before removing the steering wheel. Failure to do so may cause accidental deployment, property
Land Cruiser
damage
13.
Always store the
air
bag with the pad facing upward.
the instrument lower finish panel. Disconnect
the hood lock control cable and fuel 5. 6.
7.
Remove Remove Remove
9.
Remove Remove Remove
control cable.
the upper and lower column covers. the combination switch with the spiral cable.
Unplug the two connectors and the 8.
lid
the No. 2 heater register duct.
air
bag connector.
the spiral cable.
lbs.
Install
matchmarks and connect the sliding yoke subA and B to 25 ft. lbs. (34 Nm).
the
link joint protector.
Tighten the bolts to 9
ft.
Tighten the four column hole cover set bolts to 9
16.
ft.
lbs.
(12 Nm). 17.
Install
the combination switch the with the spiral cable.
Attach the air bag connector. 18.
Install
the upper and lower column covers.
19.
Install
the instrument lower finish panel. Connect the
hood
lock
and the
Center the
20. a.
link joint protector.
steering column assembly. Tighten the
(25 Nm).
(12 Nm).
the four column hole cover set bolts. the
tilt
lbs.
Align the
15.
Matchmark the steering wheel to the mainshaft. Using a steering wheel puller, remove the steering wheel.
Remove
ft.
assembly. Tighten bolts
3.
4.
18
or personal in14.
jury.
the
Install
bolts to
Check
fuel
lid
control cables.
spiral cable.
that the front
wheels are facing
straight
ahead.
8-62
SUSPENSION AND STEERING
Steering Wheel
Fig.
82 Exploded view of the steering column
— 1995-96
Land Cruiser
SUSPENSION AND STEERING Turn the cable counterclockwise by hand
b.
comes harder
it
be-
3.
To
Rotate the cable clockwise about three turns to align
c.
The cable
the red mark. either
21.
until
to turn the cable.
about three turns
4.
25
Attach the connector and tighten the wheel set nut to
ft.
23.
Install
the wheel pad after confirming that the circumfer-
ence groove
of the
Torx® screws
is
caught on the screw
case. 24.
rod ends.
The tie rod The remaining
tie rod.
ends should always be equal.
ft.
mounting nuts to 67
tighten the
(25 Nm).
lbs.
rod to the knuckle
tie
arm and
relay rod
(90 Nm).
lbs.
ft.
RELAY ROD
bag connector.
air
tie
rod ends so they cross at about 90°.
tie
Connect the
and
(34 Nm).
lbs.
Attach the
rod ends onto the
tie
Tighten the clamp nuts to 19
matchmarks on the wheel and mainshaft
6.
22.
Screw the
Turn the
5.
assembly. b.
remove the
rod and
tie
length of threads on both
the steering wheel.
Align the
the
install:
length should be approximately (314.5mm).
to
or right of the center.
left
Install
a.
rotate
will
Remove
8-63
1.
Disconnect the
2.
Using a
ends from the
rod
tie
relay rod.
rod end puller, disconnect the Pitman
tie
arm
from the relay rod. Using a Torx®
driver, tighten the
screws
to
7
ft.
lbs. (9
3.
Using a
Nm).
the relay rod.
wheel pad has been dropped or there are other defects, replace the wheel pad with a new one. Make sure
damage.
4.
i-Hf the
that the wires
do not
when
other parts
interfere or are
pinched between
To
Remove
the rod and inspect
for
it
arm
relay rod to the idler
installing.
and 25.
Connect the negative battery cable.
26.
Enable the
27.
Road
air
check
test the vehicle to
Connect the
the nut to 67 that the steering
wheel
is
7.
Connect the
to the relay rod
(59 Nm).
lbs.
(90 Nm). rod ends to the relay rod, then tighten
tie
(90 Nm).
lbs.
ft.
ft.
relay rod to the Pitman arm, then tighten
lbs.
ft.
the nuts to 67
straight.
43
tighten the nut
6.
bag system.
cracks or other
install:
Connect the
5.
arm from
rod end puller, disconnect the idler
tie
KNUCKLE ARM Steering Linkage
REMOVAL & INSTALLATION
1.
Remove
2.
Separate the
3.
Pick-Up
4.
5.
of the following steering linkage
components, disconnect the battery cable, raise the front of the truck and support it with safety stands.
PITMAN 1.
Remove
the strut bar.
Loosen the Pitman arm
3.
Using a
tie
rod
end
tie
nut.
puller or similar tool, disconnect the
Pitman arm from the sector Using a
shaft.
5.
ft.
TIE
ft.
to the relay rod
lbs.
and
(123 Nm).
damper
to the
frame bracket and tighten the
(13 Nm).
lbs.
Connect the other end
IDLER .
(90 Nm). the strut bar.
Using a
To tie
rod end puller, disconnect the
tie
rod from
43
ft.
lbs.
to the
(59 Nm).
tie
the knuckle arm.
rod end puller, disconnect the
ARM
Separate the relay rod from the
Remove
idler
the 3 mounting bolts and
arm.
remove the
idler
arm
tie
rod from
install:
Position the bracket
the bolts to 48-58 4.
Using a
damper
of the steering
bracket with the arm attached.
the relay rod. 2.
ft.
rod.
washers and cushions.
all
the
Install
nut to 9
tighten the nut to
ROD .
rod to the knuckle arm, then tighten the
tie
(90 Nm).
the front axle hub.
Install
damper with To install:
3. 1
lbs.
knuckle and tighten the
marks on the Pitman arm and sector shaft and
Connect the arm Install
Connect the ft.
to the steering
(108 Nm).
Disconnect the damper at the frame, then remove the
2. 7.
lbs.
relay rod, then tighten the nut to
Align the
lbs.
ft.
Separate the steering damper at the relay
1
67
cracks or other damage.
1.
4.
install:
connect them. Tighten the nut to 90 6.
for
2.
3.
rod end puller or similar tool, disconnect the
Pitman arm from the relay rod.
To
arm
the
Install
nut to 67 6.
arm
Inspect the
STEERING DAMPER
ARM
2.
4.
remove
install:
nut to 80
I See Figure 83
^Before working on any
rod at the knuckle arm, then
tie
the arm.
To
2WD
the front axle hub.
Connect the
nut to 43
ft.
lbs.
ft.
lbs.
idler
and arm on the frame and
arm
(59 Nm).
tighten
(65-78 Nm). to the relay rod, then tighten the
8-64
SUSPENSION AND STEERING
'Before working on any
of the following steering linkage
components, raise the front of the truck and support
it
the relay rod. 2.
with safety stands.
3.
PITMAN ARM 1
.
2.
To
Remove Using a
the Pitman tie
arm
Using a
tie
4.
and washer.
shaft.
5. ft.
marks on the Pitman arm and sector shaft and to 130 ft. lbs. (177 Nm). Attach the arm to the relay rod, then tighten the nut to
Align the
(90 Nm).
rod from
4.
Remove
the
tie
rod and
remove the
tie
rod ends.
Screw the
tie
rod ends onto the
tie rod. in.
The
tie
rod
(314.5mm). The
re-
equal.
Turn the
rod
tie
ends so they cross at about 90°. ft. lbs. (25 Nm).
Tighten the clamp nuts to 19
install:
lbs.
tie
install:
length should be approximately 12.38
5.
rod.
connect them. Tighten the nut
67
rod end puller, disconnect the
tie
maining length of threads on both ends should always be
rod end puller or similar tool, disconnect the
Pitman arm from the relay
To
set nut
rod end puller or similar tool, disconnect the
Pitman arm from the sector 3.
Using a
the knuckle arm.
Install
a
new
6.
Attach the
tighten the
tie
rod to the knuckle
mounting nuts
to
67
ft.
lbs.
arm and
relay rod, then
(90 Nm).
RELAY ROD
cotter pin. 1.
Separate the
2.
Using a
tie
tie
rod
from the relay rod.
rod ends from the relay rod.
end
puller,
disconnect the
PITMAN arm
SUSPENSION AND STEERING Tie
8-65
Rod End Sub-Assembly
Clamp Tie
Rod
Tj
0 Rod Sub-Assembly
Knuckle Arm
Rod Assembly
Tie
Knuckle Arm
Bushing
Oil
Seal Cotter Pin
Bushing Idler
Arm
S
C
I
90 (920, 67)
1
>
\
-Pitman |
Arm
59 (600, 43)1
Cotter Pin 1
177 (1,800,130)~
Cotter Pin
Nm (kgf-cm,
1
Ibf)
ft
:
Specified torque
|
Non-reusable part
Precoated part 86828g71
Fig.
3.
84 Exploded view of the Using a
end
rod
tie
puller,
4WD
Pick-Up and 4Runner steering linkage components
disconnect the
arm from
idler
the relay rod. 4.
Remove
the rod and inspect
it
for
cracks or other
damage. 5.
6.
the cotter pin and set nut and then disconnect
damper from
the relay rod.
Install
nut to 120
Connect the relay rod ft.
to the idler
lbs.
(59 Nm).
arm
to the relay rod,
Install
a
new
cotter
7.
Connect the relay rod
8.
lbs.
Connect the
the nuts to 9.
ft.
67
ft.
to the
(90 Nm).
(90 Nm).
lbs.
43
a
new
cotter pin.
rod ends to the relay rod, then tighten
tie
Install
Connect the steering damper
tighten the nut to
Pitman arm, then tighten
Install
ft.
lbs.
new
cotter pins.
to the relay rod,
(50 Nm).
Install
a
new
then cotter pin.
KNUCKLE ARM .
67
1
.
2.
tie
rod at the knuckle
arm and remove the
arm. 2.
arm
for
tie
rod to the knuckle arm, then tighten the
(90 Nm).
Disconnect the damper
cracks or other damage.
with
To
install:
3.
Install
nut to 9 4.
new
1
ft.
the
remove the
damper
to the
frame bracket and tighten the
(13 Nm).
lbs.
and
at the relay rod.
at the frame, then
washers and cushions.
all
Connect the other end
relay rod
of the steering
tighten the nut to
43
ft.
lbs.
damper
(59 Nm).
to the Install
a
cotter pin.
.
2.
Inspect the
lbs.
ft.
knuckle and tighten the
to the steering
(162 Nm).
Separate the steering damper
IDLER
Separate the
arm
lbs.
Connect the
nut to
damper
pin.
the nut to 67
the
ft.
STEERING DAMPER
install:
then tighten the nut 43
1
install:
3.
4.
Remove
the steering
To
To
ARM BRACKET
Separate the relay rod from the
Remove
idler
the 3 mounting bolts and
bracket with the
arm attached.
arm.
remove the
idler
arm
SUSPENSION AND STEERING
8-66 To
Position the bracket
the bolts to
70
lbs.
ft.
Connect the
4.
43
nut to
ft.
Attach the
6.
install:
3.
lbs.
and arm on the frame and tighten
tighten the
idler
arm
(59 Nm).
Connect the
7.
(95 Nm). to the relay rod
a
Install
new
and tighten the
rod to the knuckle
tie
mounting nuts tie
Connect the
8.
tie
pin.
Remove Remove
3.
Using a puller such as
the engine under cover. the Pitman
Pitman arm from he cross
arm
set nut
tool
and spring washer.
09628-62011, disconnect the
Remove
5.
With the aid of another
SST 09611-22012
or equivalent,
67
shaft.
7.
Install
tighten
Connect the Pitman arm
9.
Install
the nut and
11.
Check the
Remove
new
Install
IDLER
to the relay rod.
cotter pin. Tighten the the nut to 1
Using a
Using a
end alignment.
Remove
3.
tie
rod end puller, disconnect the
tie
rod from
tie
rod end puller, disconnect the
tie
rod from
and
4.
tie
rod and
remove the
tie
new
cotter pin, tighten to
43
ft.
lbs.
09610-20012 or equivalent, disconnect the
relay rod.
the three bolts, washers and nuts.
install:
Attach the
idler
nuts, tighten to
Connect the
6.
Install
arm assembly
105
idler
ft.
arm
lbs.
with the bolts,
washers
(142 Nm).
to the relay rod.
the nut and tighten to 43
ft.
lbs.
(59 Nm).
Install
a
cotter pin.
1989-90 Land Cruiser
Screw the
tie
rod ends onto the
tie rod. in.
The
tie
rod
(329.2mm). The
maining length of threads on both ends should always be
>
See Figure 88
re1.
move
equal.
Turn the
lbs.
rod ends.
install:
length should be approximately 12.96
5.
tool
5.
new
the
ft.
the cotter pin and nut for the idler arm.
arm from the
To
the knuckle arm.
Remove
damper assembly.
ARM
Using the
idler
the relay rod.
3.
cotter
the bolt and nut.
the nut and a
Remove
.
2.
front
the cotter pin and nut on the
Tighten the steering dampener bolt and nut to 19
4.
To
new
(59 Nm).
ROD
2.
a
I See Figure 87
the engine under cover.
Install
1.
Install
install:
4.
(90 Nm).
10.
TIE
(90 Nm).
Remove
(177 Nm).
8.
lbs.
lbs.
Using a damper remover, and separate the damper from
5.
marks on the Pitman arm and the cross the spring washer and Pitman arm set nut,
Align the
ft.
ft.
(25 Nm).
install:
lbs.
new
a
1.
3.
6.
ft.
Install
2.
To
the cotter pin and nut.
4.
130
(90 Nm).
lbs.
the relay rod.
shaft.
disconnect the Pitman arm from the relay rod.
to
ft.
STEERING DAMPER
ARM
2.
To
relay rod, then
(90 Nm).
rod end to the relay rod. Install the nut,
I See Figures 85 and 86
.
arm and
cotter pin.
cotter pin.
then tighten the nut to 67
1
lbs.
ft.
rod assembly to the relay rod. Install the
then tighten the nut to 67
nut,
T100
PITMAN
67
to
tie
rod ends so they cross at about 90°.
Tighten the clamp nuts to 16
ft.
lbs.
(22 Nm).
2.
Raise the truck and support
it
with safety stands. Re-
the wheels.
Remove
the cotter pin and nut, then disconnect the relay
rod at the Pitman arm.
SUSPENSION AND STEERING
|N-m
(kgf-cm,
ft-lbf
)
|
:
8-67
Specified torque
Non-reusable part 86828g74
Fig.
86 Exploded view of the
4WD
T100 steering linkage components 3.
Remove
the cotter pin and nut, then disconnect the
tie
rod at the knuckle arm. 4.
Remove
damper 5.
at the
Remove
the mounting nut, then disconnect the steering
frame bracket.
damper
the nut, then disconnect the steering
at
the relay rod. 6.
Remove
rod at the
To 7.
move
the cotter pin and nut, then disconnect the relay
tie rod.
install:
To replace the ends.
the
approximately 47.5 8
.
tie
Install in.
To replace the
rod ends, loosen the clamp and re-
the ends, then turn
them
relay rod ends, loosen the
and remove the ends. Remove the Coat the parts with grease, 87 Tool 09610-20012 or equivalent can be used to separate the idler arm from the knuckle and the tie rod
from the knuckle
install
completely. Loosen the plug 1-1 cotter pin.
3
them and turns and
end clamps the
and spring
seat.
tighten the plug install
a
new
Turn the rod ends onto the rod so they are 37.8
(96cm) apart. Tighten the clamp bolts
to
so they are
Remove
cotter pin.
plug, 2 ball stud seats, link joint knob, spring
Fig.
in
(121cm) apart. Tighten the clamps.
9.
Connect the
67
ft.
lbs.
(90
relay rod to the
Nm) and
install
tie
to
33
ft.
lbs.
in.
(44 Nm).
rod, then tighten the nut
a new cotter
pin.
8-68
SUSPENSION AND STEERING
Bracket
Cotter Pin Link Joint
[Tie
Rod Side]
[Pitman Link Joint
Arm
Knob
Side]
Knob Cotter Pin
Set Ring
Set Ring Plug
Ball
Q
Dust Seal
Relay Rod End
ffo,
Grease Nipple
Ball
Stud Seat Spring
Spring Seat Plug
Grease Nipple Spring Seat
Relay
kg-cm
(ft-lb,
N m)
:
Stud Seat Spring
Set Ring Set Ring
Rod End
Specified torque
Non-reusable part 86828g75
Fig.
88 Exploded view of the steering linkage
— 1989-90
Land Cruiser
SUSPENSION AND STEERING Connect the steering damper
10.
54
tighten the nut to 1 1
Connect the damper
.
the nut to 54
Attach the
12.
67
nut to
14.
Install
install
a new cotter
Nm) and
(90
the rod loosely
Install
in
position at the Pitman
arm and
new
a
install
Tighten the Pitman arm nut and the knuckle rod to 67
(90 Nm).
Install
cotter pin.
a
new
43
ft.
each
cotter pin in
Connect the steering damper tighten the nut to
pin.
relay rod to the Pitman arm, then tighten
lbs.
ft.
9.
lbs.
Nm) and
(90
Connect the
13.
the nut to 67
10.
frame bracket, then tighten
to the
rod to the knuckle arm, then tighten the
tie
lbs.
ft.
8.
knuckle arm.
(74 Nm).
lbs.
ft.
to the relay rod, then
(74 Nm).
lbs.
ft.
8-69
lbs.
then
to the relay rod,
(50 Nm).
Install
ft.
fitting.
a
new
cotter pin.
KNUCKLE ARM
the wheels and lower the truck.
1
.
Disconnect the
tie
rod at the knuckle
arm and remove
the arm.
1991-96 Land Cruiser 2.
See Figure 89
>
install:
3.
Install
(^Before working on any of the following steering linkage
components, raise the front of the truck and support
nut to 71 4.
ARM
Remove
.
rod
tie
end
set nut
Using a
1
2.
rod end puller or similar tool, disconnect the
tie
4.
shaft
rod to the knuckle
Separate the steering damper
To install, align the marks on the Pitman arm and sector and connect them. Tighten the nut to 130 ft. lbs. (177
Install
all
Connect the arm lbs.
tighten the
54
ft.
4.
(90 Nm).
to the relay rod,
Install
a
new
at the relay rod.
lbs.
the
washers and cushions.
damper
to the bracket
and
tighten the nut to
(74 Nm).
Connect the other end
relay rod. Tighten the nut to
ft.
arm and
Disconnect the damper at the bracket, then remove the
damper with To install: 3.
5.
of the steering
54
ft.
lbs.
damper
to the
(74 Nm).
then tighten the nut to
Manual Steering Gear
cotter pin.
ROD
TIE 1
tie
(90 Nm).
lbs.
ft.
install:
Nm).
67
.
puller or similar tool, disconnect the
Pitman arm from the relay rod.
To
knuckle and tighten the
to the steering
(96 Nm).
and washer.
Pitman arm from the sector shaft. 3.
cracks or other damage.
STEERING DAMPER arm
the Pitman
Using a
2.
arm
lbs.
Connect the
nut to 67
1
the
ft.
for
it
with safety stands.
PITMAN
arm
Inspect the
To
Using a
.
end
rod
tie
puller,
disconnect the
rod from
tie
ADJUSTMENTS
the knuckle arms.
Remove
2.
To
the
tie
rod and
remove the
Screw the
3.
length should
tie
rod ends onto the
be approximately 47.51
rod ends.
Adjustments
Turn the
4.
Connect the
5.
to
tie rod.
tie
67
The
tie
ft.
in
the
same
direc-
of overhaul.
REMOVAL & INSTALLATION
(37 Nm).
lbs.
rod to the knuckle arms, then tighten the
ft.
lbs.
2WD
(90 Nm).
See Figure 90
>
Using a
2.
tie
rod
end
puller,
disconnect the Pitman arm
3.
Disconnect the steering damper from the relay rod.
4.
Separate the relay rod from the knuckle arm. Always use
joint
separator
Remove
the rod and inspect
it
for
cracks or other
them and set the length to approximately 42.34 in. (108cm). The amount of threads projecting from each side of the rod must be equal. 7.
to
be replaced,
install
Set the rod ends so that the end for Pitman arm (with
the flange for the steering
damper) faces up and the knuckle
end points down. Tighten the clamp bolts Nm).
Separate the relay rod from the Pitman arm.
3.
Remove
4.
ends are
to
27
ft.
lbs.
(37
it
2.
To relay rod
Remove the steering coupling set bolt where connects worm shaft. Make matchmarks on the shaft and flexible
and
the 3 mounting bolts
lift
out the steering
gear housing.
install:
The
.
coupling.
tool.
damage. 6.
1
to the
from the relay rod.
To
MODELS
Separate the relay rod from the Pitman arm.
.
5.
Pick-Up
1989-95
RELAY ROD
a
manual steering gear are not necessary
rod
(121cm). The remain-
in.
rod ends so they point
tie
Tighten the clamp nuts to 27
mounting nuts
1
to the
during normal service. Adjustments are performed only as part
on both ends should always be equal.
ing length of threads
tion.
tie
install:
up
87
in
install:
Position the gear housing so that the
worm
shaft
is
lined
the steering coupling and tighten the mounting bolts to
(118 Nm).
ft.
lbs.
5.
Tighten the Pitman arm mounting nut to 90
ft.
lbs.
(123
Nm). 6.
Connect the Pitman arm
the nut to 67
ft.
lbs.
to the relay rod,
then tighten
(90 Nm).
7.
Tighten the coupling set bolt to 26
8.
Fill
the gear housing with gear
oil.
ft.
lbs.
(35 Nm).
8-70
SUSPENSION AND STEERING
Engine Under Cover
Non-reusable part 86828g76
Fig.
89 Exploded view of the steering linkage
— 1991-96
Land Cruiser
SUSPENSION AND STEERING
I
See Figure 91 1
.
2.
Remove
1
the joint protector set
Matchmark the
remove the
.
Remove Remove
4.
Disconnect the
5.
Disconnect the intermediate No. 2
6.
Remove
bolt.
universal joint to the
U-joint bolts.
worm
shaft
and
worm
Disconnect the U-joint from the
shaft. 3.
Remove
the Pitman
arm
set nut
and then disconnect the
arm from the gear housing. 4.
Remove
lift
7.
out the gear housing.
To
the steering wheel pad. the steering wheel. right
and
left
hand
tie
rod ends.
shaft.
the manual steering gear assembly set bolts,
nuts and washers, then lower the assembly from the vehicle.
To
the 3 housing-to-frame mounting bolts and
Place the wheels facing straight ahead.
3.
2.
8-71
cle.
install:
Attach the manual steering gear assembly into the vehi-
Tighten the set bolts, nuts and washers to 148
ft.
lbs.
install:
(201 Nm). 5.
Position the housing, then tighten the bolts to 105
ft.
lbs.
8.
Attach the intermediate No. 2 shaft.
9.
Connect the
(142 Nm). 6.
Connect the
U-joint to the
worm
shaft so that the
marks 10.
are
in
7.
alignment, then tighten the bolts to 26 Install
the joint protector
and
its
ft.
lbs.
bracket set
(35 Nm).
left
to
130
ft.
side
the front of the vehicle jacked up. 1 1
lbs.
and
bolt.
Connect the Pitman arm, then tighten the nut (177 Nm).
8.
right
.
tie
rod ends.
Position the front wheels facing straight ahead.
Center the
spiral cable.
Do
it
with
SUSPENSION AND STEERING
8-72
12.
Install
the steering wheel. Align the
matchmarks on the
wheel and steering column mainshaft. Temporarily tighten the wheel set
then connect the harness.
nut,
13.
Check the
14.
Tighten the steering wheel set nut to 26
15.
Check the
6.
steering wheel center point.
front
end alignment.
5.
7. ft.
lbs.
(35
Nm)
arm.
the Progressive
Power Steering (PPS) solenoid
Disconnect the intermediate No. 2
shaft.
Remove the bolt and spring washer from the Pitman Using SST 09610-55012 or equivalent, disconnect the
Pitman arm from the gear housing. 8.
Power Steering Gear
Remove
connector.
Using
SST 09631-22020
or equivalent, disconnect the
pressure feed tube and the return tube from the gear housing. 9.
Remove
the union bolt, gaskets, and the return tube
from the gear housing.
REMOVAL
& INSTALLATION
To
install:
10.
Connect the pressure feed tube and tighten
lbs.
Pick-Up and 4Runner 1989-95 .
11.
2WD MODELS
Drain the power steering
fluid.
2.
Disconnect the negative battery cable.
3.
Remove Remove
4.
Connect the
return tube
and
Tighten the union bolt with a
of the return
13.
tube to 34
cross shaft, and
the
nut to 130
cleaner assembly.
ft.
Align the alignment
the reservoir tank. air
to
26
ft.
tighten
it
to
30
ft.
lbs. (41
Nm). 12.
1
it
(36 Nm).
ft.
install
lbs.
lbs.
new gasket on each
side
(47 Nm).
marks on the Pitman arm and the
the spring
(177 Nm).
washer and
nut.
Tighten the
SUSPENSION AND STEERING
8-73
9.
15.
Install
the Progressive
Power Steering (PPS) solenoid
(36 Nm).
lbs.
Connect the
connector. the
17.
Install
the reservoir tank.
18.
Connect the negative battery cable.
19.
Refill
1989-95
air
and
return tube
tighten
it
to
30
10.
Align the alignment
cross shaft.
and bleed the power steering system.
ft.
lbs. 1 1
4WD MODELS
.
Install
washer and
nut; tighten
Connect the intermediate No. 2 shaft
Drain the power steering
12.
Install
the air cleaner assembly.
Disconnect the negative battery cable.
13.
Install
the reservoir tank.
3.
14.
4.
Remove Remove
Connect the negative battery cable. Refill and bleed the power steering system.
5.
Disconnect the intermediate No. 2 shaft from the steer-
the reservoir tank.
15.
cleaner assembly.
1996
4WD MODELS
ing gear. 6.
Remove
the set nut from the Pitman arm. Using
SST
1
.
Place the front wheels facing straight ahead.
09628-62011, or equivalent, disconnect the Pitman arm from
2.
Disconnect the negative battery cable.
the gear housing.
3.
Remove
7.
Using
SST 09631-22020,
or equivalent, disconnect the
pressure feed tube and the return tube from the gear housing.
to
to the steering
gear. fluid.
it
(177 Nm).
1.
air
lbs. (41
marks on the Pitman arm and the
the spring
2.
the
ft.
Nm).
cleaner assembly.
Install
16.
the steering wheel pad.
130
SUSPENSION AND STEERING
8-74 4.
Remove
Disconnect the intermediate No. 2 shaft from the steer-
5.
the steering wheel.
**CAUTION
-
ing rack.
#
SST 09631-22020
Using
6.
or equivalent,
remove the pres-
sure feed and the return tubes.
Work must be
started after 90
ignition switch is turned to the
negative
(-)
battery cable
seconds from the time the LOCK position and the
install:
8.
Install
disconnected.
is
148 5.
Raise and safely support the vehicle.
7.
Remove Remove
8.
Disconnect the
6.
9.
1 1
.
12.
lbs.
power steering
the
Install
a
new
the stabilizer bar.
tighten to
right
and
left tie
rod ends from the steer-
10.
rack.
rack, then tighten the bolts to
(201 Nm).
then tighten to 33
36
O-ring and
the return tube, then
Install
(49 Nm).
lbs.
ft.
the pressure feed tube,
install
(45 Nm).
lbs.
ft.
Connect the intermediate No. 2
shaft to the steering
rack.
Disconnect the intermediate No. 2 shaft from the steer-
ing rack. 10.
ft.
power steering
the
the engine under cover.
ing knuckle. 9.
Remove
7.
To
1 1
.
Connect the
right
and
left tie
rod ends to the steering
knuckle. Tighten the castle nuts to specification and
Disconnect the pressure feed tube and return tube.
Remove Remove
the
power steering rack assembly.
To
install: Install
the bracket and grommet.
14.
Install
the
13.
Lower the vehicle. Connect the negative battery cable.
14.
Check the
15.
Bleed the power steering system.
16.
Check
12.
the bracket and grommet.
13.
power steering rack assembly then
install
new
cotter pins.
tighten the
bolts to:
the front wheel alignment. Tighten the
locknuts to 67
Rack assembly bolt: 123 ft. lbs. (167 Nm) Rack assembly nut and bolt: 141 ft. lbs. (191 Nm) • Nut and bolt to the bracket: 123 ft. lbs. (167 Nm) Connect the pressure feed tube and the return tube.
steering wheel center point.
ft.
(90
lbs.
tie
rod end
Nm)
•
•
15.
Tighten to 29 16.
ft.
lbs.
4WD MODELS See Figure 94
>
(40 Nm).
Connect the intermediate No. 2 shaft
to the steering
rack. 17.
Connect tne
right
and
left tie
Place the front wheels facing straight ahead.
Disconnect the negative battery cable.
'•''•'CAUTION
rod ends to the steering
knuckle.
1.
2.
Work must be
18.
Attach the stabilizer bar.
19.
Position the front wheels facing straight ahead.
started after 90
ignition switch is turned to the
Do
this
negative
(-)
battery cable
seconds from the time the LOCK position and the
disconnected.
is
with the front of the vehicle jacked up. 20.
Center the
21.
Install
spiral cable.
the steering wheel, align the
matchmarks on the
wheel and column mainshaft. 22.
Bleed the power steering system.
23.
Check the
24.
Tighten the steering wheel set nut to 25
25.
Install
the steering wheel pad.
26.
Install
the engine under covers.
27.
Lower the
3.
Raise and safely support the vehicle.
4.
Remove
5.
Disconnect the
6. ft.
lbs.
(34 Nm).
Check the
end alignment.
front
left tie
rod ends from the steer-
Tacoma
Disconnect the intermediate No. 2 shaft from the steer-
7.
Disconnect the pressure feed tube and return tube.
8.
Remove Remove
9.
Connect the negative battery cable.
and
ing rack.
vehicle.
29.
right
ing knuckle.
steering wheel center point.
28.
the engine under cover.
the
power steering rack assembly.
the bracket and grommet.
To
install:
10.
Install
the bracket and grommet.
11.
Install
the
power steering rack assembly then
tighten the
bolts to:
2WD MODELS
•
1.
Place the front wheels facing straight ahead.
2.
Disconnect the negative battery cable.
(-)
started after 90
seconds from the time the LOCK position and the
battery cable is disconnected.
3.
Raise and safely support the vehicle.
4.
Disconnect the
knuckle.
123
lbs.
ft.
(167
Nm)
right
12.
ft.
lbs.
(40 Nm).
Connect the intermediate No. 2
shaft to the steering
rack.
ignition switch is turned to the
negative
bolt:
Rack assembly nut and bolt: 141 ft. lbs. (191 Nm) • Nut and bolt to the bracket: 123 ft. lbs. (167 Nm) Connect the pressure feed tube and the return tube.
Tighten to 29 13.
^CAUTION Work must be
Rack assembly
•
See Figure 93
>
and
left tie
rod ends from the
14.
Connect the
right
and
left tie
rod ends to the steering
knuckle.
the engine under covers.
15.
Install
16.
Lower the
vehicle.
17.
Check the
steering wheel center point.
18.
Bleed the power steering system.
1
9.
20.
Connect the negative battery cable.
Check the
front
end alignment.
SUSPENSION AND STEERING
8-75
Intermediate No. 2 Shaft
Cotter Pin
Non-reusable part 86828g95
Fig.
93 Exploded view of the power steering gear
— Tacoma
T100
2WD
4.
10.
per
2WD MODELS
1 1
>
See Figure 95 1
.
2.
Secure the steering wheel so
driver’s seat belt 3.
can be used
to
that
it
does not
turn.
The
secure the steering wheel.
Place matchmarks on the intermediate shaft and control
valve shaft.
Remove
the lower
and upper
joint bolts
from the
install
a
shaft. Install the lower
Tighten the bolts to 26
Connect the
.
and
Position the front wheels facing straight ahead.
Connect the intermediate
joint bolts.
new
tie
ft.
rod ends, tighten to 67
and up-
(35 Nm). ft.
lbs.
(90
Nm)
cotter pin.
12.
Connect the negative battery cable.
13.
Fill and bleed the Check and adjust
14.
lbs.
steering system. toe-in.
4WD MODELS I See Figure 96
intermediate shaft. Disconnect the shaft. 4.
Remove
Disconnect the 5.
the cotter pin and nut from the tie
tie
rod ends.
rod ends using a separator tool.
Disconnect the pressure and return pipes using
flare nut
1.
Place the front wheels facing straight ahead.
2.
Drain the power steering
3.
Disconnect the negative battery cable.
fluid.
wrenches. 6. 7.
To to
Remove Remove
•'^CAUTION
the bracket bolts and grommets. the steering rack assembly from the vehicle.
install:
8.
Install
65
ft.
9.
Install
lbs.
Tighten the
the gear housing then tighten the mounting bolts
negative
(88 Nm). the pressure fittings to
Work must be
15
and ft.
return tubes using
lbs.
(20 Nm).
new
started after 90
ignition switch is turned to the (-)
battery cable
is
seconds from the time the LOCK position and the
disconnected.
O-rings.
Raise and safely support the vehicle.
8-76
SUSPENSION AND STEERING Intermediate No.2 Shaft
Engine Under Cover
Non-reusabte part 86828g96
Fig.
5.
Using
94 Exploded view of the power steering gear
— Tacoma
Remove the Pitman arm set nut and the spring washer. SST 09628-62011, or equivalent, disconnect the Pitman
arm from the gear assembly.
4WD washer and the Pitman arm set
nut,
then tighten to 130
6.
Disconnect the pressure feed tube and return tube.
14.
7.
Make matchmarks and disconnect
15.
Lower the vehicle. Check the steering wheel center point. Fill and bleed the power steering system.
16.
Connect the negative battery cable.
13.
the intermediate shaft
from the steering gear. 8.
Remove
the
power steering gear mounting
bolts
and
Install
the
the bolts to 105 10.
Align the
Land Cruiser
power steering gear assembly, then ft.
lbs.
lbs.
re-
move the gear assembly. To install: 9.
ft.
(177 Nm).
tighten
1.
Drain the power steering
2.
Disconnect the negative battery cable.
fluid.
(142 Nm).
matchmarks and connect the intermediate
shaft
i-i'CAUTION
to the steering gear.
Work must be *Hf installing a new gear assembly, be sure the gear box and the steering wheel are centered. 11.
Connect the pressure feed tube and the
Tighten the 12.
line fittings to
Align the alignment
26
ft.
lbs.
(36 Nm).
marks on the cross
Pitman arm and connect the Pitman arm.
started after 90
ignition switch is turned to the
negative
(-)
battery cable
is
seconds from the time the LOCK position and the
disconnected.
return tube. •
shaft
Install
and the
the spring
3.
Raise and safely support the vehicle.
4.
Remove Remove
5.
the frame seal. the
link joint protector.
SUSPENSION AND STEERING
arm from the gear assembly.
SST 09631-22020,
Using
7.
or Equivalent, disconnect the
pressure feed and the return tubes.
Separate the
8.
sliding
yoke sub-assembly from the steer-
8-77
17.
Lower the
18.
Connect the negative battery cable.
19.
Test drive the vehicle. Check the steering wheel center
vehicle.
point.
ing gear. 9.
Remove
the mounting bolts and the
power steering gear
assembly.
To
install:
10.
Install
the
the bolts to 105 1 1
.
power steering gear assembly, then ft.
Connect the
lbs.
REMOVAL & INSTALLATION
tighten
(142 Nm).
sliding
yoke sub-assembly
to the steering
gear. 12.
1
Connect the pressure feed and the
the tube fittings to 26 13.
ft.
lbs.
washer and the Pitman arm
return tubes. Tighten
(36 Nm).
Connect the Pitman arm and
Install
Refill
marks
the spring
set nut. Tighten the nut to
(177 Nm).
14.
.
and bleed the power steering system.
130
it
will
be necessary to remove the
Disconnect the high tension lines
disconnect the 3.
ft.
On some models
air
cleaner. 2.
align the alignment
on the cross shaft and the Pitman arm.
lbs.
Power Steering Pump
air lines at
at the distributor,
then
the air valve.
With a suitable device, suck
some
fluid
out of the reser-
voir tank. 4.
Disconnect the return hose at the power steering pump.
SUSPENSION AND STEERING
8-78
16.
5.
Separate the pressure
have a union 6.
Loosen the
idler pulley 7. 8.
line at
bolt with gaskets.
Some models
drive belt pulley retaining nut.
and adjusting
Remove Remove
the pump.
Discard the old gaskets.
bolt
and remove the
9. fluid,
10.
27-29 11.
32
ft.
12.
On
the
Install lbs.
42
the
it
to the
pump
power steering
pump assembly.
in its
bracket, then tighten the nuts to
(36-39 Nm). the drive pulley and
(43
ft.
ft.
lbs.
BLEEDING
**WARNING
Nm) and check
belt.
Tighten the pulley bolt to
lbs.
(45 Nm), and the union bolt with
new gaskets
(56 Nm).
13.
Connect the
14.
Connect the
15.
If
removed,
of an electronic brake found only at dealers.
Without 1.
return hose. air
Vehicles equipped with Rear Wheel Anti-Lock (RWAL) brakes use a different bleeding procedure than those not so equipped. Bleeding the RWAL system requires the use
the
air
RWAL
an expensive unit usually
cleaner.
System
Check the
correct level
hoses and the high tension leads.
install
tester,
the drive belt tension.
Attach the pressure line to the pump; tighten the flare
nut to 33 to
install
lbs.
ft.
bleed the system and check
power steering pump. Some models have
the O-ring type, coat the O-ring with
Install
fluid,
the drive pulley and Woodruff key.
install:
then
the reservoir with
Loosen the
drive belt.
an O-ring, discard the old O-ring.
To
Fill
for leaks.
fluid level in
(HOT
or
the reservoir.
It
should be at the
COLD) depending on engine
temperature.
engine and run
below 1000 rpm.
2.
Start the
3.
Turn the steering wheel from lock-to-lock 3 or 4 times.
it
SUSPENSION AND STEERING Shut the engine OFF. Connect a clear
4.
plastic
tube to the
bleeder port on the steering gearbox. Place the other end of the tube
end
is
5.
in
a container of power steering
immersed
in
the
fluid.
Make
sure the
fluid level.
system.
the problem persists, repair the
air
Start the engine again.
Turn the wheel lock-to-lock 3-4
Loosen the bleeder
plug.
Observe the
tubing;
when no
bubbles are seen, close the bleeder plug.
With
The
come
off the
bleed port. The
under high pressure and may be
re-bleeding the
try
power steering
RWAL
System system uses power steering
never mix,
air in
the
in
pressure to
fluid
the brake system. While the
power steering system can render
the any of the lines or
the engine running; the
should not be foamy or cloudy. Shut the engine
MUST
will
the
is
eliminate most of the
be taken to a dealer
bled using the Toyota fluid
OFF and
in
power steering
bled as well. Preliminary bleeding of both the power steering
cle fluid level with
components
system are loosened or removed, the brake system must be
and brake systems
very hot.
Inspect the
RWAL
maintain control pressures
If
not allow the tubing to fluid is
level rises too
the rear anti-lock brakes ineffective.
^CAUTION power steering
If
system.
fluids
7.
Do
If
fluid.
times and return the steering wheel to the centered position. 6.
much,
check the
8-79
ABS
to
air,
Checker. Be warned that
done, the rear wheel anti-lock brake function
impaired.
but the vehi-
have the systems properly until this
may be
8-80
SUSPENSION AND STEERING WHEEL ALIGNMENT Camber
Caster
Year
Model
1989
2WD 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 4WD Pick-up Pick-up
Model Type
0 0 © © 0 0 © © © © © © © © ©
© © © © Q © © 0 © © © 0 © © ©
4-Runner
Land Cruiser 1990
2WD 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 4WD Pick-up Pick-up
1991
® © © © © ® ® © © © © © © © © © © ©
© © © © © © © © © © © © © © © © © ©
Range
Setting
(deg.)
(deg.)
Steering Preferred
Preferred
Range (deg.)
0.06N-0.94P
Axis Toe-in
Setting (deg.)
Inclination (deg.)
(in.)
0.44P
0.05N-0.08N
10.00
0.19P-1.19P
0.69P
0.25P-1.25P
0.75P
0.50P
0.03N-0.09N
10.00
0.50P-1.50P
IP
0.06N-0.94P
0.44P
0.02N-0.13N
10.03
0.63P-1.63P
1.13P
0.13N-0.88P
0.38P
0.1
3N-0.19N
10.13
0.25P-1.25P
0.75P
0.50P
0.03N-0.09N
10.00
0.50P-1.50P
IP
0.44P
0.06N-0.13N
10.03
3N-0.19N
10.13
0-1
0-1
0.06N-0.94P
0.69P-1.69P
1.19P
0.13N-0.88P
0.38P
0.1
0.69P-1.69P
1.19P
0.13N-0.88P
0.38P
0.13N-0.19N
10.13
0.88P-1.88P
1.38P
0.31N-0.69P
0.19P
0.22N-0.28N
10.31
0.63P-1.63P
1.13P
0.06N-0.94P
0.44P
0.06N-0.13N
10.00
0.06P-1.06P
0.56P
0.06P-1.06P
0.56P
0.19N-0.25N
9.91
0.44N-0.56P
0.06P
0.06P-1.06P
0.56P
0.1
0.81 P-1 .81
1.31
P
0.13N-0.88P
0.38P
0.09N-0.16N
10.09
P
0.16N-0.22N
10.19
7N-0.23N
9.94
0.94P-1.94P
1.44P
0.19N-0.81P
0.31
0.38N-0.63P
0.13P
0.06P-1.06P
0.56P
2P-3P
2.50P
0.25P-1.25P
0.75P
0-0.06N
11.81
1.63P-2.63P
2.13P
0.13P-1.13P
0.63P
0.08N-0.16N
11.94
0.06P-1.56P
0.81
P
0.25P-1.75P
IP
0.05N-0.14N
9.50
0.06N-0.94P
0.44P
0-1
0.50P
0.03N-0.09N
10.00
0.13P-1.13P
0.63P
0-1
0.50P
0.03N-0.09N
10.00
0.19P-1.19P
0.69P
0-1
0.50P
0.02N-0.08N
10.00
0.44P-1 .44P
0.94P
0.06N-0.94P
0.44 P
0.06N-0.13N
10.00
0.75P-1.75P
1.25P
0.13N-0.88P
0.38P
0.09N-0.16N
10.09
0.19P-1.19P
0.69P
0-1
0.50P
0.03N-0.09N
10.00
0.19P-1.19P
0.69P
0-1
0.50P
0.02N-0.08N
10.00
0.44P-1.44P
0.94P
0.06N-0.94P
0.44P
0.06N-0.13P
10.00
0.63P-1.63P
1.13P
0.88N-0.88P
0.38P
0.25N-0.38N
10.13
0.75P-1.75P
1.25P
0.88N-0.88P
0.38P
0.09N-0.16N
10.09
0.88P-1.88P
1.38P
0.31N-0.69P
0.19P
0.19N-0.25N
10.25
0.38P-1.38P
0.88P
0.06N-0.94P
0.44P
0.06N-0.13P
10.00
0.06P-1.06P
0.56P
0-1
0.50P
0.16N-0.22N
10.00
0.44N-0.56P
0.06P
0-1P
0.50P
0.16N-0.22N
10.00
0.75P-1.75P
1.25P
0-1
0.50P
0.1
9N-0.25N
10.00
0.69P-1.69P
1.19P
0.06N-0.94P
0.44 P
0.09N-0.16N
10.06
0.69P-1.69P
1.19P
0.06N-0.94P
0.44P
0.06N-0.13N
10.06
0.50P
0.19N-0.25N
10.00
0.50N-0.50P
0
0-1
0.1
6N-0.22N
9.94
2P-3P
2.50P
0.25P-1.25P
0.75P
0-0.06N
11.81
4-Runner
2P-3P
2.50P
0.25P-1.25P
0.75P
0.03N-0.09N
11.81
Land Cruiser
0.06P-1.56P
2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up
© © © © 0 © ©
© © © 0 © © ©
P
0.25P-1.75P
IP
0.05N-0.14N
9.50
0.75P
0.25N-1.25P
0.50P
0.03N-0.16N
10.00
0.06N-1.44P
0.69P
0.31N-1.19P
0.44P
0.03N-0.16N
10.00
0.22P-1.72P
0.97P
0.31N-1.19P
0.44P
0-0. 19N
10.03
0.50P-2.00P
1.25P
0.38N-1.13P
0.38P
0.03N-0.22N
10.09
0.19N-1.31P
0.56P
0.25N-1.25P
0.50P
0.1
N
10.00
0.19N-1.31P
0.56P
0.25N-1.25P
0.50P
0.09N-0.28N
10.00
50P
1.75P
0.25N-1.25P
0.50P
0.09N-0.28N
10.00
0-1.50P
1. OOP-2.
0.81
3N-0.31
86828c01
SUSPENSION AND STEERING
8-81
WHEEL ALIGNMENT Camber
Caster
Range Year
Model
1991
2WD Pick-up 2WD Pick-up 2WD Pick-up 4WD Pick-up
Model Type
© © ©
0 0 0
4-Runner
© © © © © © © © © © © ©
Land Cruiser Land Cruiser 1992
2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 4WD Pick-up
© 0 0)
© © © © © © ©
4Runner
© © © © © © © © © ©
Land Cruiser
Land Cruiser 1993
2WD 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 2WD Pick-up 4WD Pick-up Pick-up
4-Runner
Land Cruiser
2WD T100 2WD T100 4WD Pick-up 2WD Pick-up 2WD Pick-up 4WD T100
1994
© ©
(deg.)
(deg.)
Range
Axis
(deg.)
Toe-in
Setting (deg.)
Inclination (deg.)
(in.)
0.44P-1.31P
1.19P
0.38N-1.13P
0.38P
0.03N-0.22N
10.09
0.44P-1
1.19P
0.31N-1.19P
0.44P
0.03N-0.22N
10.06
1.75P
0.25N-1.25P
0.50P
0.1
2P-3P
2.50P
0.25P-1.25P
0.75P
0-0.06N
11.81
2P-3P
2.50P
0.25P-1.25P
0.75P
0.03N-0.09N
11.81
0.69P-2.69P
1.69P
0.25P-1.75P
IP
.31
1. OOP-2.
50P
3N-0.31
0-0.
N
10.00
19N
13.00
9N
13.00
3P
0.25P-1.75P
IP
0.75P
0.25N-1.25P
0.50P
0.03N-0.16N
10.00
0.06N-1.44P
0.69P
0.31N-1.19P
0.44P
0.03N-0.16N
10.00
0.22P-172P
0.97P
0.31N-1.19P
0.44P
0-0. 19N
10.03
0.50P-2.00P
1.25P
0.38N-1.13P
0.38P
0.03N-0.22N
10.03
0.19N-1 .31
0.56P
0.25N-1.25P
0.50P
0.1
N
10.00
0.19N-1.31P
0.56P
0.25N-1.25P
0.50P
0.09N-0.28N
10.00
2P-4P 0-1
.50P
0-0.1
3N-0.31
1.00P-2.50P
1.75P
0.25N-1.25P
0.50P
0.09N-0.28N
10.00
0.44P-1.94P
1.19P
0.38N-1.13P
0.38P
0.03N-0.22N
10.09
0.44P-1.94P
1.19P
0.31N-1.19P
0.44P
0.03N-0.22N
10.06
1.00P-2.50P
1.75P
0.25P-1.25P
0.50P
0.1
N
10.00
2P-3P
2.50P
0.25P-1.25P
0.75P
0-0.06N
2P-3P
2.50P
0.25P-1.25P
0.75P
0.03N-0.09N
11.81
0.69P-2.69P
1.69P
0.25P-1.75P
IP
0-0. 19N
13.00
2P-4P
3P
0.25P-1.75P
IP
0-0. 19N
13.00
0-1. 50P
0.75P
0.25N-1.25P
0.50P
0.03N-0.13P
9.25
0-1. 50P
0.75P
0.25N-1.25P
0.50P
0.02N-0.14P
9.25
0.25P-1.75P
1.00P
0.25N-1.25P
0.50P
0.50P-2.00P
1.25P
0.25N-1.25P
0.33P
0.05N-0.20P
9.25
0.25N-1.25P
0.50P
0.25N-1.25P
0.50P
0.14N-0.30P
9.25
25P
1.75P
0.25N-1.25P
0.50P
0.14N-0.30P
9.25
0.50P-2.00P
1.25P
0.25N-1.25P
0.33P
0.05N-0.20P
9.25 9.25
1. OOP-2.
3N-0.31
0-0.1
6P
11.81
9.25
50P
1.75P
0.25N-1.25P
0.50P
0.014N-0.30P
1.75P-3.25P
2.50P
0-1.50P
0.75P
0.04N-0.012P
11.00
0.04N-0.012P
11.00
1. OOP-2.
1.75P-3.25P
2.50P
0-1. 50P
0.75P
2.00P-4.00P
3.00P
0.25P-1.75P
i.o6p
1.75P-3.25P
2.50P
0.25N-1.25P
0.50P
0.04N-0.20P
9.25
2.25P-3.75P
3.
0-1.50P
0.50P
0.27N-0.43P
8.75
OOP
0-0.1
6P
12.25
0.75P-2.25P
1.50P
0-1.50P
0.75P
0.04N-0.20P
11.00
0-1. 50P
0.75P
0.25N-1.25P
0.50P
0.03N-0.13P
9.25
0.50P-2.00P
1.25P
0.25N-1.25P
0.33P
0.05N-0.20P
9.25
1.75P-3.25P
2.50P
0-1.50P
0.75P
0.04N-0.12P
11.00
4-Runner
1.75P-3.25P
2.50P
0-1.50P
0.75P
0.04N-0.12P
11.00
Land Cruiser
2.00P-4.00P
3.00P
0.25P-1.75P
1.00P
1.75P-3.25P
2.50P
0.25N-1.25P
0.50P
0.04N-0.20P
2.25P-3.75P
3.00P
0-1.50P
0.50P
0.27N-0.43P
8.75
0.75P-2.25P
1.50P
0-1.50P
0.75P
0.04N-0.20P
11.00
2WD T100 2WD T100 4WD Pick-up 2WD Pick-up 2WD Pick-up 4WD T100
1995
.
Setting
Steering Preferred
Preferred
© ©
© © © © ©
0-0.
16P
12.25 9.75
0-1.50P
0.75P
0.25N-1.25P
0.50P
0.03N-0.13P
9.25
0.50P-2P
1.25P
0.25N-1.25P
0.33P
0.05N-0.20P
9.25
1.75P-3.25P
2.50P
0-1.50P
0.75P
0.04N-0.12P
11.00 86828c02
8-82
SUSPENSION AND STEERING WHEEL ALIGNMENT Camber
Caster
Range Year
Model
1995
4Runner
© © © ©
4Runner
© ©
1996
4Runner
© © © ©
2WD Tacoma 4WD T100 2WD T100 2WD T100 4WD 1
NOTE:
0-1. 50P
0.75P
(in.)
Inclination (deg.)
0.04N-0.12P
11.00
2P-4P
3P
0.25P-1.75P
IP
0-0.16P
12.25
1.83P
0.50N-0.50P
0
0.04N-0.04P
10.00
2.33P-3.33P
2.83P
0.50N-0.50P
0
0.08N-0.08P
10.75
1.75P-3.25P
2.50P
0.25N-1.25P
0.50P
0.04N-0.20P
9.75
2.25P-3.75P
3P
0-1.50P
0.50P
0.27N-0.43P
8.75
0.75P-2.25P
1.50P
0-1. 50P
0.75P
0.04N-0.20P
11.00
2.67P-4.17P
3.37P
0.97N-0.54P
0.22N
0.03N-0.31 P
10.97
1.88P-3.38P
2.63P
0.58N-0.92P
0.1
0-0.40P
10.58
2P4P
3P
0.25P-1.75P
IP
0.08P-0.24P
13.00
1.08P-2.67P
1.83P
0.75N-0.75P
0
0.08N-0.08P
10.00
2.08P-3.58P
2.83P
0.75N-0.75P
0
0.08N-0.08P
10.75
Land Cruiser
Tacoma
(deg.)
2.50P
Axis Toe-in
1.33P-2.13P
Land Cruiser
2WD Tacoma 4WD T100 2WD T100 2WD T100 4WD
Setting
(deg.)
(deg.)
1.75P-3.35P
Tacoma
Range
Setting
(deg.)
Model Type
Steering Preferred
Preferred
v
7P
1.75P-3.25P
2.50P
0.33N-1.17P
0.42P
0.04N-0.20P
12.08
0.83N-2.33P
1.58P
0.33N-1.17P
0.42P
0.20P-0.36P
12.08
0.75P-2.25P
1.50P
0-1. 50P
0.75P
0.04N-0.20P
12.00
Front end alignment specifications are qiven
accordmq
to
21
VZN85L-TRMR. VZN85L-TRSR
22 VZN85L-TWMR,
15
RN90L-CRMS, RN90L-CRSS
VZN85L-TWSR VZN85L-TWSREA6 25 VZN90L-CRMO, VZ90L-CRSD 26 VZN90L-CRMG. VZN90L-CRPG 27 VZN90L-CRMDEA, VZN90L-CRMDEK. VZN90L-CRSDEA. VZN90L-CRSDEK VZN90L-CRMGEA, VZN90L-CRPGEA 28 RN90L-CRSDEA. RN90L-CRMDEA. RN90L-CRSDEK RN901-CRMDEK. VZN90L-CRMDEA. VZN90L-CRMDEK. VZN90L-CRSDEA, VZN90L-CRSDEK. VZ90L-TMWREA6. VZN95L-TWSREA6. VZN95L-TWSEK6 29 RN90L-CRSDEA. RN90L-CRMDEA. RN90L-CRSDEK. RN90L-CRMDEK. VZN90L-CRMDEA VZN90L-CRMDEK. VZN90L-CRSDEA. VZN90L-CRSDEK VZN90L-CRMGEA. VZN90L-CRPGEA (unloaded) 30 RN90L-CRSDEA, RN90L-CRSDEK. RN90L-CRMDEA. RN90L-CRMDEK 31 VZN95L-TWMR, VZN95L-TWSR 32 VZN95L-TWMREA6, VZN95L-TWSREA6. VZN951-TWSREK6 33 RN90L-CRLDL
17
VZ85L-TRMD. VZ85L-TRSD
34 Manual steermq qear
18
VZ851-THMD. VZ85L-THSD
the Vehicle Identification verify that the
VIN
is
Number
Before usinq
this information,
correct for the aliqnment data
used
2
RN80L-TRLD. RN80L-TRMR
3
6
RN80L-TRMR RN80L-TRMD, RN80L-TRSD RN80L-TRSDEA. RN80L-TRSDEK RN80L-TRMDEA. RN80L-TRMDEK RN80L-TRMREA, RN80L-TRMREK
7
RN80L-TRSDEA. RN80L-TRMDEA. RN80L-TRMREA. RN80L-TRMREK
4
5
8
RN85L-TRMD, RN85L-TRSD
9
RN80L-TRKR. RN80L-TRTR
10
RN85L-TRLD, RN85L-TRMD
11
RN85L-TRMS, RN85L-TRSS
12 13
RN85L-TRMDEA. RN85L-TRMDEK, RN85L-TRSDEA. RN85L-TRSDEK RN90L-CRLD. RN90L-CRMD
14
RN90L-CRMD, RN90L-CRDS
VZN85L-THMD 20 VZN85L-THSO 19
24 VZN85L-TWMREA6.
Power
steerinq qear 2
5R
35 With 10
1
50P
tire
36 Without 10.5R
tire
37 1/2 ton
38
1
39
Tire size
ton
225/75R 15
40 Tire size 265/70R16 41
Loaded vehicle 86828c03
4-WHEEL ANTI-LOCK BRAKE SYSTEM
ACTUATOR
9-48
DECELERATION SENSOR 9-48 DIAGNOSIS AND TESTING 9-43 GENERAL INFORMATION 9-42 SPEED SENSOR 9-44 BRAKE OPERATING SYSTEMS BASIC OPERATING PRINCIPLES 9-2 BRAKE SYSTEM ADJUSTMENTS 9-3 BLEEDING THE BRAKE SYSTEM 9-10 BRAKE HOSES AND LINES 9-8 BRAKE LIGHT SWITCH 9-5 LOAD SENSING PROPORTIONING (LSP) AND BYPASS VALVE (BV) 9-7
MASTER CYLINDER 9-5 POWER BRAKE BOOSTER 9-5 FRONT DISC BRAKES BRAKE CALIPER 9-17 BRAKE DISC 9-19 BRAKE PADS 9-11 PARKING BRAKE BRAKE LEVER 9-30 BRAKE SHOES 9-31 REAR DISC BRAKES BRAKE CALIPER 9-29 BRAKE DISC 9-29 BRAKE PADS 9-27 REAR DRUM BRAKES BRAKE DRUM 9-19 BRAKE SHOES 9-21 WHEEL CYLINDERS 9-26 REAR WHEEL ANTI-LOCK BRAKE SYSTEM ACTUATOR 9-40 ACTUATOR SYSTEM BLEEDING 9-42 DECELERATION SENSOR 9-38 DIAGNOSIS AND TESTING 9-33 ELECTRONIC CONTROL UNIT (ECU) 9-40
GENERAL INFORMATION
9-33
SOLENOID RELAY 9-38 SPEED SENSOR 9-35 SPECIFICATIONS CHARTS BRAKE SPECIFICATIONS 9-48
BRAKES 4-WHEEL ANTI-LOCK BRAKE
SYSTEM BRAKE OPERATING SYSTEMS BRAKE SYSTEM FRONT DISC BRAKES PARKING BRAKE REAR DISC BRAKES REAR DRUM BRAKES REAR WHEEL ANTI-LOCK BRAKE SYSTEM SPECIFICATIONS CHARTS
9-42 9-2 9-3 9-11
9-30 9-27
9-19
9-33 9-48
BRAKES
9-2
BRAKE OPERATING SYSTEMS actuated directly by mechanical linkage from the brake pedal
Basic Operating Principles
through the power booster. The secondary piston
by Hydraulic systems are used to actuate the brakes of
trapped between the two pistons.
fluid
secondary
front of the
piston,
If
moves forward
it
until
automobiles. The system transports the power required to force
against the front of the master cylinder, and the
the frictional surfaces of the braking system together from the
between the pistons
A
pedal to the individual brake units at each wheel.
system
is
used
for
automobile by small pipes and
amount
a significant
room
of
flexible
to
parts of an
all
it
hoses without taking up
or posing routing problems.
Second, a great mechanical advantage can be given to the of the system, and the foot pressure required brakes can be reduced by making the surface
area of the master cylinder pistons smaller than that the pistons
any
of
of
the wheel cylinders or calipers.
in
The master
systems hydraulically
in
case
and rear braking
frame near each
of the vehicles wheels.
carried to the calipers
The
then
fluid is
and wheel cylinders by
flexible
In
tubes
in
directions.
disc brake systems, the cylinders are part of the calipers. in
each caliper
is
used
brake pads
to force the
against the disc.
rubber, to minimize fluid leakage.
A
of the piston
of
dirt.
The boot
fits
on disc brake calipers, and
around the brake actuating rod on wheel cylinders.
The
hydraulic system operates as follows:
entire system,
from the piston(s)
in
in
Upon
application of the brake pedal, fluid trapped
the master cylinder piston(s)
wheel cylinders. Here,
it
is
at rest, the
the master cylinder to
the wheel cylinders or calipers,
those
brake
of
is full
in front of
forced through the lines to the
forces the pistons outward,
in
the
in
Upon release
of the
brake pedal, a spring located inside the
in
it.
These The
are uncovered as the pistons reach their normal position.
some
side, light.
body also contains a
cases, a proportioning valve. The
until
the brake shoes on the rear front
never be used alone. The proportioning valve
will
chance
controls the pressure to the rear brakes to lessen the
wheel lock-up during very hard braking.
of rear
lights
screws.
new
If
lamp,
it
this
may be
tested by depressing the brake pedal
while opening
one
of the
does not cause the
make
wheel cylinder bleeder
go on, substitute a
light to
continuity checks, and, finally, replace the
switch as necessary. hydraulic system
may be checked
for leaks
pressure to the pedal gradually and steadily. floor,
compression will
If
by applying
the pedal sinks
the system has a leak. This
be confused with a springy or spongy of air within the lines.
be a gradual change
in
If
is
not to
due to the the system leaks, there feel
the position of the pedal with a
Check
for leaks
along
lines
all
and
wheel cylinders.
at
external leaks are apparent, the problem
is
If
no
inside the master
cylinder.
DISC BRAKES
return springs force the brake position, the It
any
is
excess
fluid
pads or shoes
fluid that
Braking effect into the
reservoir through the
during the time the pedal
has leaked out
released
in
compensating
of the
the released position
system
will
circuit
the
same
cylinder.
The primary
achieved
in
be
The
disc (rotor)
is
manner
similar to the
a casting with cooling
the braking surfaces making
piston
a
utilize
either side of
a
it.
way you
fins
between
the two braking surfaces. This enables air to circulate between
master cylinders employ two pistons, located one in
is
pads positioned on
would squeeze a spinning phonograph record between your fingers.
is
replaced through the compensating ports.
behind the other,
Instead of the traditional expanding brakes that press
disc (rotor) with brake
cylinders or calipers as the pistons withdraw. Then, as the
Dual
one
to
outward against a circular drum, disc brake systems
piston check valves allow fluid to flow toward the wheel
that
that circuit during
in
push the piston
activating the brake warning
in
in
has a
circuit
normal position. The pistons contain check valves and
the master cylinder has compensating ports drilled
ports.
When one
disc brakes.
master cylinder immediately returns the master cylinder pistons to the
pressure being
the pressures are
constant pressure.
of
spring seals,
When
wheels have contacted the drums, ensuring that the
very slowly to the
fluid.
drum brakes, and inward toward the disc, in the case of disc brakes. The motion of the pistons is opposed by return springs mounted outside the cylinders in drum brakes, and by case
and
will
firewall or the
hydraulic piston receives
circuit’s
of the piston.
brakes on the front wheels
The
When
A
disc brake systems, this valve
and holding
rubber dust boot seals the
outer end of the cylinder against dust and
around the outer end
made
type of seal, usually
mounted on the
is
each
circuits,
one end
metering valve and,
Warning
some
pistons employ
All
a valve body which
however, the greater pressure
brakes
cylinder
when
is
metering valve keeps pressure from traveling to the disc
drum brake systems, each wheel cylinder contains two pistons, one at either end, which push outward in opposite In
In
in
closing the switch
order to allow for suspension and steering movements.
One
located
application of the brakes
Steel lines carry the brake fluid to a point on the vehicles
the brakes
available.
is
operational. This switch
is
frame below the master cylinder.
leak,
when
farther
balance, the piston remains stationary.
a leak.
of
forward
dual circuit systems use a switch to warn the driver
applied to
double cylinder and piston assembly. Double type master cylinders are designed to separate the front
moves
only half of the brake system
pressure from both
and a
cylinder consists of a fluid reservoir
move
force the secondary piston to actuate the front brakes. In
will
either case, the brake pedal
All
will
trapped
the rear
If
contact with the secondary piston takes place, and
are applied, and less braking power
brake pedal end to actuate the
brakes develop a leak, the primary piston until direct
under pressure can be carried
First, fluid
hydraulic
two reasons.
in
bottoms
it
fluid
operate the rear brakes.
will
actuated
is
a leak develops
buildup and
more
them
less sensitive to heat
resistant to fade. Dirt
affect braking action since
and water do not
contaminants are thrown
off
by the
is
centrifugal action of the rotor or scraped off the
by the pads.
BRAKES Also, the equal clamping action of the two brake
ensure uniform, straight self-adjusting.
• • •
A A A
The
pads tends
to
There are three general types
of disc brake: Virtually
sliding caliper
uses two pistons mounted on either
(in each side of the caliper). The caliper is mounted rigidly and does not move. The sliding and floating designs are quite similar. In fact, these two types are often lumped together. In both designs,
the pad on the inside of the rotor the rotor by hydraulic force.
The
slightly,
Some
on mounting
assisted power
is
moved
caliper,
effort
is
not held
pad
bringing the outside
in
pivot at the
bolts. In
bottom or
a
into
and some
top,
any event, the end
result
is
the vehicles covered
in this
book employ the
is
A vacuum
efficient.
in
applying the brakes, reducing both the
must put
travel the operator
into
moving the brake
pedal.
into contact with
which
and
simple and
is
located on the front of the master cylinder and
is
assists the driver
The vacuum diaphragm housing is connected to the intake vacuum hose. A check valve is placed at the point where the hose enters the diaphragm housing, so that during periods of low manifold vacuum brake assist will not be manifold by a
lost.
Depressing the brake pedal closes
the
the
off
vacuum source
and allows atmospheric pressure to enter on one side of the diaphragm. This causes the master cylinder pistons to move
same. All
vacuum
always available when the engine
is
operating, the system
diaphragm
contact with the rotor. There are various methods of attaching floating calipers.
vehicles today use a
Since vacuum
effort.
fixed caliper design
moves
all
brake system to multiply the braking force and reduce pedal
floating caliper
side of the rotor
slide
POWER BRAKE BOOSTER
Disc brakes are inherently
line stops.
fixed caliper
fixed position,
9-3
sliding
and apply the brakes. When the brake pedal is released, is applied to both sides of the diaphragm and springs
caliper design.
vacuum
DRUM BRAKES
return the
diaphragm and master cylinder pistons
to the
released position.
stationary backing plate. circular
drum which
shoes are held
in
These shoes are positioned
rotates with the wheel assembly.
inside a
and drums
in
alignment. is
higher pedal effort
1
.
vacuum
Operate the engine
Test for the presence of assist
off
bear directly against the top of the brake shoes, the tops of
the brake pedal and releasing
the shoes are then forced against the inner side of the drum.
will
This action forces the bottoms of the two shoes to contact the
If
servo action).
When
(known as
pressure within the wheel cylinder
relaxed, return springs pull the
produce less and less pedal
there
Test
is
4.
is
to self-adjust
themselves during application when the vehicle reverse. This motion
causes both shoes
with the drum, rocking
an adjusting
is
moving
in
to rotate very slightly
lever,
thereby causing
no vacuum,
for
air is
vacuum by depressing
several times. Light application travel,
vacuum was
if
present.
leaking into the system
system operation as
Pump
vacuum
drum.
it
somewhere.
shoes back away from the
Most modern drum brakes are designed
brake
the engine, and wait one minute.
Turn
3.
slightly
to stop the
leak as described below:
2.
brake drum by rotating the entire assembly
will
driver will
at idle without touching the
the brakes are applied, hydraulic pressure forces
When
The
needed
is
the wheel cylinder’s actuating links outward. Since these links
plate.
contact
will
pedal for at least one minute.
backing
at the top of the
much
Test for a system
The shoes are actuated by a
mounted
the brake pedal rod
vehicle and that the pedal feels “harder” than usual.
toward the drums (when they are applied) while keeping the linings
fails,
apply the brakes without any power assistance. notice that
The
place by springs. This allows them to slide
wheel cylinder which
vacuum supply
the
If
the end of the master cylinder actuator rod and the system
Drum brakes employ two brake shoes mounted on a
is
follows:
the brake pedal (with engine
entirely
Put a
6.
Start the engine,
and operate
operating, the brake pedal should
constant pressure
the supply
steady pressure on the pedal.
5.
light,
off) until
gone.
is
it
fall
at idle.
If
the system
toward the
floor
is
if
maintained on the pedal.
rotation of the adjusting screw.
BRAKE SYSTEM DRUM BRAKES
Adjustments
>
See Figure
1
DISC BRAKES ^Toyota procedure All
disc brakes are inherently self-adjusting.
adjustment
is
either
No
periodic
trucks is
utilize self-adjusting
necessary only
brakes. The following
after the
brake shoes have
been changed.
necessary or possible. 1
not
.
Place blocks under the front wheels so that the truck
roll
2.
forward
when
it
Fully release the
is
jacked up at the rear.
emergency brake.
will
BRAKES
9-4 3.
Raise the rear
and support the
of the truck
differential
housing with jackstands.
**WARNING Brake pads and shoes may contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air. Avoid inhaling any dust from brake surfaces.
When
cleaning
Stop Light Switch
brakes, use commercially available brake cleaning fluids.
4.
of the 5.
Remove
the plug from the adjusting hole at the bottom
backing plate.
Turn the adjusting starwheel
While doing
this,
have a
to
friend step
expand the shoes
fully.
on the brake pedal
occasionally to center the shoes. 6.
pedal 7.
Tighten the shoes is
the wheel
until
not turn
will
when
the
released.
From
this position
back
the adjuster
off
until
the wheel
turns with just a slight drag. 8.
Back
off
the adjuster an additional five notches.
wheel should turn smoothly.
If
two or three notches. Should
it
does
this
fail,
not,
back
check
for
off
The
another
worn or defec-
tive parts. 9.
Adjust the other wheel
in
the
same manner.
BRAKE PEDAL Pedal Height
86829g03
> See Figure 2 1
.
of the
Measure the distance between the center (upper surface) pedal pad and the floor pad, not the carpet. out of specifications, loosen the brake
2.
If
3.
Loosen the
pedal height
is
2WD 4WD
•
Tacoma
• •
light
switch.
pushrod
until
the
within specifications:
•
•
locknut, then turn the pedal
Pick-Up Pick-Up
— 5.83 — 5.71
inches (148mm)
inches (145mm)
— 6.283-6.677 inches (159.6-169.6mm) 1989-95 4Runner — 5.71-5.91 inches (145-150mm) 1996 4Runner — 6.224-6.618 inches (158.1-168.1mm)
Fig. 2
Pedal height
is
measured from the
floor pad, not
the carpet •
T100
(Extra cab
4WD)
- 5.776-6.196
inches
(146.7-156.7mm) •
T100 (Except
extra
cab 4WD)
— 5.894-6.287
inches
(149.7-159.7mm) •
1989-90 Land Cruiser
— 6.34-6.73
inches
(161-171mm) •
1991-93 Land Cruiser
•
1994-96 Land Cruiser
(167.5-1
— 7.09 inches (180mm) — 6.59-6.99 inches
77.5mm)
4.
Tighten the pushrod locknut to 19
5.
Move
the brake
light
switch
until
ft.
lbs.
(25 Nm).
the plunger
is
just
touching the pedal stopper. Tighten the switch. 6.
Check
the brake pedal free-play.
Free-Play I See Figure 3 1.
With the engine turned
eral times until there 2.
sure 3.
is
Push the pedal down this distance;
it
off,
depress the brake pedal sev-
no vacuum until
left
in
the brake booster.
resistance
is first felt.
Mea-
should be 0.12-0.24 inches (3-6mm).
Adjust the free-play by turning the pedal pushrod.
BRAKES
9-5
Master Cylinder
REMOVAL & INSTALLATION I See Figures
5 and 6
4,
^WARNING Pedal Push
Rod Be It
careful not to spill brake fluid
will
damage the
paint.
If
on the painted surfaces.
a spill occurs, flush the area
with plenty of fresh water.
1
Bleed the
.
from the master cylinder.
air
2.
Unplug the
3.
Use a
fluid level
warning switch connector.
syringe or similar tool to remove as
much
fluid
as
possible from the reservoir. Carefully disconnect the brake lines at the master cylin-
4.
To prevent line damage, use a line wrench. Regular openend wrenches are NOT recommended. Take great care not to bend or deform the lines. Plug the lines to keep dirt from der.
entering.
Remove
5.
the nuts holding the master cylinder to the
booster. Unbolt the 3-way or 4-way union.
When
removing the
cylinder, take care to recover the clamps, gaskets, etc.
To
install:
new
Using a
6.
gasket,
install
the master cylinder onto the
brake booster. Tighten the mounting nuts to 9 threading them into place by hand.
tially
ft.
lbs.
(13 Nm).
Attach the union. Carefully connect the brake tubes,
7.
gaged, tighten the
fittings to 11
Connect the wiring harness
9.
Fill
the brake
fluid
lbs.
ft.
8.
Once
ini-
properly en-
(15 Nm).
for the
brake
fluid switch.
reservoir with fluid to the
MAX
line.
Check the leakage.
Fig. 3
Pedal free-play
is
the
amount
of
motion before
and recheck the Recheck the pedal height.
Start the engine
5.
Bleed the brake system. Check again
11.
Check and
REMOVAL
free-play.
for
any leakage.
adjust the brake pedal.
Power Brake Booster
the brakes are applied
4.
10.
I
& INSTALLATION
See Figures
7,
8 and 9
Brake Light Switch 1
.
2.
REMOVAL & INSTALLATION 1.
Disconnect the
2.
Remove
electrical
clevis
harness
at the switch.
the locknut (closest to the pedal).
Remove
the
switch from the brake pedal.
To
the master cylinder.
remove the
clip
and separate the
from the pedal.
3.
Remove
4.
Disconnect the vacuum hose from the booster.
5.
Loosen the
the pedal return spring.
four nuts, then pull out the
vacuum
booster,
bracket and gasket.
To
install:
install:
Insert the
3.
new
switch and loosely
Adjust the switch so that plunger at the held
Remove
At the brake pedal,
in
by the pedal
in its
pedal holds the switch
off;
install
at-rest position.
the locknut.
of the switch
tip
is
Remember that the come on when the
the brake lamps
moves away from the switch. Once positioned, tighten the locknut and connect the wiring. Check the switch function by pressing the pedal. Have
^Some
models employ a spacer and additional gaskets
6.
Using a new gasket,
mounting bolts
to
9
ft.
lbs.
install
the booster, then tighten the
(13 Nm).
pedal
7.
Install
the clevis pin to the clevis through the brake
4.
pedal. Secure the pin with the 8.
an assistant observe the brake lamps
for
proper operation.
at
the firewall.
Install
clip.
the pedal return spring.
9-6
BRAKES
BRAKES
9-7
9.
Adjust the length of the booster pushrod as follows: the gasket to the master cylinder.
a.
Install
b.
Set the
SST 09737-00010
then lower the pin
Turn the
c.
tool
or equivalent
until its tip slightly
on the gasket,
touches the piston.
upside down and position
it
on the
booster.
Measure the clearance between the booster pushrod
d.
and the
pin head.
It
should be
null.
Adjust the booster pushrod length
e.
lightly
until
touches the pin head. While doing
this
the pushrod
depress the
brake pedal enough so that the pushrod sticks out. the master cylinder.
10.
Install
1 1
Attach the
.
vacuum hose
to the booster.
the reservoir with brake
12.
Fill
13.
Check for leakage. Check and adjust the brake
14.
fluid,
then bleed the system.
pedal.
Fig.
9 Set the tool on the gasket, then lower the pin
touches the piston
until its tip slightly
Load Sensing Proportioning (LSP) and Bypass Valve (BV) The purpose
of this valve
is
to control the fluid
pressure
applied to the brakes to prevent rear wheel lock-up during
weight transfer at high speed stops.
REMOVAL & INSTALLATION I
See Figures 1
.
10, 11
and 12
Disconnect the shackle from the bracket.
cotter pin, then the nut
and cushion
retainer.
shackle and remove the cushions and 2.
the
collar.
Disconnect the brake lines attached to the valve. Plug
the lines to keep 3.
Remove
Disconnect the
Remove
dirt
from entering.
the mounting bolt,
if
used, and remove the
valve.
Fig. 8
Install
the tool on top of the gasket as
shown
86829p03
Fig.
10 The load sensing valve can be found secured to
the frame
rail
BRAKES
9-8
ADJUSTMENT I See Figure 13
**This
is
an
initial
adjustment which should bring the
valve close to specifications. Since
it requires the use of pressure gauges and determines the exact weight of the
load on the rear axle,
it
not practical for the
is
owner/mechanio. Have the a reputable 1
adjustments performed
at
shop as soon as possible.
down the load sensing moves slowly.
Pull
.
piston 2.
final
spring to determine that the
Set the valve body so that the piston
lightly
touches the
load sensing spring. 3.
Tighten the mounting bolts.
4.
Adjust the length of the shackle. Lengthening the dis-
tance between the centers lowers the pressure; shortening the distance raises the pressure. Fig. 11
Detach the shackle from the bracket
One
psi.
(75-96 kPa) on
other vehicles.
all
full
turn of the nut increases
on Land Cruiser or about 11-14
pressure about 20
Initial
psi
length of this link
should be: •
Pick-Up and 4Runner (1989-95)
Land Cruiser (1989-90) • Land Cruiser (1991-96) •
• • • 5.
— 3.07 — 3.54
— 3.54
inches (90mm)
inches (78mm) inches (90mm)
T100—-4.72 inches (120mm) Tacoma 2WD — 3.07 inches (78mm) Tacoma 4WD — 4.72 inches (120mm) If
the
initial
distance
is
correct, fluid metering should
be
very close to specification.
Brake Hoses and Lines
REMOVAL & INSTALLATION Metal lines and rubber brake hoses should be checked
fre-
quently for leaks and external damage. Metal lines and particularly
prone
to crushing
deformation can
and kinking under the
restrict the
proper flow of
vehicle.
fluid
Any such
and therefore
impair braking at the wheels. Rubber hoses should be checked
^This 4.
valve can not be rebuilt.
Install
19-22
ft.
the
It
must be replaced.
LSP and BV assembly
to the frame, tighten to
(25-29 Nm).
lbs.
the shackle to the load sensing spring.
5.
Install
6.
Attach the shackle to the shackle bracket, tighten to 9
lbs.
(13 Nm). Install a
new
7.
Attach the brake lines, tighten to 11
8.
Set the valve body as follows:
When
a.
valve piston
pulling the load
moves down
Position the valve
b.
ft.
lbs.
(15 Nm).
sensing spring, confirm that the
siowly.
body so
that the valve piston lightly
contacts the load sensing spring.
Tighten the valve body mounting nuts to 9
c.
Nm). 9.
ft.
cotter pin.
Bleed the brake system.
ft.
lbs.
(13
BRAKES for cracking or scraping; in
and
the hose
could
it
such damage can create a weak spot
removed or disconnected, extreme cleanliness must be observed. The slightest bit of dirt in the system can plug a fluid port and render the brakes defective. Clean all joints and connections before disassembly (use a stiff
Any time the
lines are
brush and clean brake
fluid)
soon as they are opened.
and plug the
New
blown or flushed clean before
To
tamination.
replace a
lines
lines
and ports as
When bending crack the
be repaired, then support the vehicle safely using jackstands.
Disconnect the hose from the wheel cylinder or caliper
3.
and plug the opening
to avoid
excessive
fluid loss
openings
for rear
or
and plug the
brakes or 18
(24
lbs.
ft.
Nm)
make
sure the hose
is
the hose to the wheel cylinder or caliper using
washers, then tighten the retainer
36
to
ft.
lbs.
(49 Nm).
and
the supports
carefully lower the vehicle.
Brake Line There are 2 options available when replacing a brake first,
line
using a
and probably most preferable, line of similar
machined
length which
flared ends.
Such
line.
is
to replace the entire
is
already equipped
lines are usually available
from auto parts stores and usually require only a minimum of order to properly
is
bend and
to
fit
then to the vehicle. The second
flare the entire
replacement
line (or
made
Buying a
cause
line with
of the time
special tools
machined
and
duced by hand
effort
flares
is
usually preferable be-
saved, not to mention the cost of
a
much
Remove line
the
which
is
Trace the
for
access
fittings at
The
is
hard to duplicate with most kits. is
can leak with resultant loss
flare
a great amount of
the hydraulic system.
in
line
fluid
loss or contamination.
from the
line
An improperly
of stopping
power.
If
these instructions
follow the instructions
1
kit,
to cut
it
and
If
flare the end.
of the line,
line that is
the line If
is
the
same
longer,
you
you have decided
see the procedure on brake
length
and allow an
charts
line flaring.
the
in
additional Ve
in.
in
kit,
flarin
kit.
replacement or
for the
(3.2mm)
for
each
flare.
the figure, then cut the brake line to the necessary
Do
length using an appropriate saw. 2.
Square the end
Remove
of the
not use a tubing cutter.
tube with a
file
and chamfer the
burrs from the inside and outside diameters of
the cut line using a deburring tool. 3.
Install
the required
4.
Install
SA9193BR,
and
5.
to
install
6.
die
clamp screw and
Select the required die set
Insert the
push forward the
onto the
Make
hexagon
line.
rotate the locking plate
die carrier opening.
the carrier with the
8.
fittings
or an equivalent flaring tool, into a
the handle into the operating cam.
Loosen the
expose the
will
to repair
flaring
Select a length of tubing according to the repair/replacement
install:
was removed.
SA9193BR
any way from those
differ in
Determine the length necessary
.
7.
line that
practice forming double-flares on
satisfied with the results.
following procedure applies to the
and counter bore
Try to obtain a replacement
kit;
you are
If
from one end to the other and disconnect
remove the
until
ing kits.
of the line, then plug
vehicle.
a portion
which
inexpensive flaring
your
vice
each end
the line from any retaining clips, then
have
work with
but should be similar to commercially available brake-line
to the
being replaced.
the openings to prevent excessive
as the
try to
most auto parts stores and have machine
the brakes are applied, there
scrap tubing
edges.
components necessary
Disconnect the
3.
lbs.
LINE FLARING
yourself with the flaring
be repaired, then support the vehicle safely using jackstands. 2.
ft.
which should
any removed components, then remove the sup-
pressure developed
higher quality than those pro-
flaring tools or kits.
Raise the end of the vehicle which contains the hose to
brake
fitting
(19 Nm).
lbs.
ft.
flares, the quality of
repair
they are not readily available. Also, machined
if
flares are usually of
1.
14
tighten to 18
carefully lower the vehicle.
of the available
a
repair section of line) using the appropriate tools.
5.
and
line fittings
you have never formed a double-flare, take time to familiarize
The
option
to
lines are available at
formed
in
that could
only brake line tubing approved for automotive use;
When
Remove
To
does not contact any components
never use copper tubing. Whenever possible,
tions for leaks.
bending
to attach the line
as necessary. Make sure the replace-
brake lines that are already cut to the length needed. These
Properly bleed the brake system, then check the connec-
4.
line
with brake
it
Be sure
the line into the vehicle.
Install
and
ports
Use
Install
with
line, flush
or foreign material.
dirt
for front
routed properly.
9.
or
or contamination.
fluid loss
a front brake hose,
installing
If
8.
be careful not to kink or
becomes kinked
Properly bleed the brake system and check for leaks.
BRAKE
Nm)
(19
lbs.
7.
brake
installing the
be tightened
brakes.
NEW
line,
the brake hose to the brake line and tighten to 14
Install
6.
the brake
Connect the brake
9.
10.
install:
5. ft.
excessive
to avoid
line
the
being
must be replaced.
Install
11.
Disconnect the hose from the brake
make
line
rub the line and cause a leak.
contamination. 4.
the necessary
those on the
(24 Nm), except for the rear line-to-hose
hose.
To
it
ment brake
necessary, remove the wheel for easier access to the
If
to
the brake line
If
to the retaining clips,
Raise the end of the vehicle which contains the hose to
2.
line.
Before
7.
8.
.
make
to
slowly and carefully; try to
replaced.
cleaner to remove any
Brake Hose 1
Work
line.
bends look as close as possible
remove any con-
hose:
line or
bender
suitable tubing
the
in
cracked,
and hoses should be
installation to
Use a
6.
bends
under pressure.
fail
9-9
full
of both
prepared
until
(4.75mm DIN) and
install in
side of either half facing clamp screw
halves facing punch line
turret.
through the rear of the die and
the line end
is
flush with the die face.
sure the rear of both halves of the die rest against die stops, then rotate the locking plate to the fully
BRAKES
9-10 9.
closed position and clamp the die firmly by tightening the
clamp screw. Rotate the punch turret
(4.75mm DIN)
the appropriate size
until
points towards the
open end
of the line to
be
flared.
handle against the
Pull the operating
10.
order to create the
flare,
line
resistance
in
then return the handle to the original
position. 1 1
Release the clamp screw and rotate the locking plate
.
open
the
Remove
12.
to
position.
the die set and
line,
then separate by gently
tapping both halves on the bench. Inspect the flare for proper
and shape. Measurement should be 0.272-0.286
size
in.
(6.92-7.28mm). 13.
necessary, repeat the steps for the other end of the
If
line or for
the end of the line which
Bend
14.
is
being repaired.
the replacement line or section using
SA91108NE,
or an equivalent line bending tool. 15.
repairing the original line, join the old
If
tions using
a female union and
and new sec-
tighten.
Bleeding the Brake System necessary
is
It
bleed the hydraulic system any time the
to
system has been opened or has trapped lines.
may be necessary
It
brakes
if
air
air within
bleed the system at
to
has been introduced through a low
the fluid all
four
fluid level or
by disconnecting brake pipes at the master cylinder. a
If
line is
that brake
disconnected at one wheel only, generally only
needs bleeding.
If
lines are
disconnected at any
between the master cylinder and the brake, the system
fitting
served by the disconnected pipe must be bled.
^WARNING Do not
allow brake fluid to splash or
surfaces; the paint
will
be damaged.
If
spill
onto painted
spillage occurs,
flush the area immediately with clean water.
MASTER CYLINDER >
See Figures
14,
15 and 16
the master cylinder has been removed, the lines discon-
If
nected or the reservoir allowed to run dry, the cylinder must
be bled before the
lines are bled.
To bleed the master
cylinder:
Check the
1. fill
with
level of the fluid in the reservoir.
necessary,
Disconnect the brake lines from the master cylinder.
2.
Plug the lines to keep
dirt
from entering.
Place a pan or rags under the cylinder.
3.
Have an
4.
hold
If
fluid.
assistant slowly depress the brake pedal
and
down.
it
5. Block off the outlet ports with your fingers. Be sure to wear gloves. Have the assistant release the pedal. Make a tight seal with your fingers; do not allow the cylinder to ingest
air
when
the pedal
is
released.
6.
Repeat three or four times.
7.
Connect the brake
up the
fluid reservoir.
lines to the
master cylinder and top
BRAKES LINES
AND WHEEL CIRCUITS
5.
the
wheel >
See Figure 17 Insert
1.
wheel.
If
all
a clear vinyl tube onto the bleeder plug
be
wheel and the
rear wheel, the right front
in
left
front
that order.
Bleed the load sensing proportioning and bypass valve.
6.
four wheels are to
bleeding the entire system, repeat the procedure at
If
left
9-11
at the
bled, begin with the right
rear.
Insert the other
2.
with brake
filled
fluid.
end
tube
of the
Make
a
into
sure the end
is
jar
which
half
is
submerged
the
in
fluid.
Have an
3.
times.
On
assistant slowly
pump
depressed. While the pedal
fully
the brake pedal several
the last pump, have the assistant hold the pedal
bleeder plug
until fluid starts to
depressed, open the
is
run out, then close the plug.
^If the brake pedal is pumped too fast, small air bubbles will form in the brake fluid which will be very difficult to remove. 4.
Repeat
procedure
this
no
until
air
bubbles are
visible in
the hose. Close the bleeder port.
^Constantly replenish the brake fluid in the master cylinder reservoir, so that it does not run out during bleeding.
FRONT DISC BRAKES INSPECTION
^CAUTION Brake pads may contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.
I
See Figure 18 The
front
brake pads
may be
wheel(s). Unlock the steering column lock
so that the brake caliper
is
center of the caliper.
pad
to look at the thickness of the
friction material (the part that actually
change
Keep front disc
brake pads are equipped with a metal tab
come
into contact with the rotor after the friction
will
may to
surface material has worn near indicators
make a
usable minimum. The wear
its
constant, distinct metallic sound that should
be easily heard. The sound has been described as similar either fingernails
on a blackboard or a
key to recognizing that other brake noise
being driven
is
is
is
it
the
that the
WITHOUT
wear
sound
field full of crickets.
is
and
is
The
It
may
or
may
heard during normal
in
mind
that
you are looking
should also be noted that any disc brake system, by
design, cannot be
made
to
work
silently
Each system includes various shims,
under
all
its
wear on a taper which
not be visible through the window.
check the contact surface
position. This quick
check can be
detailed inspection requires
It
is
also not possible
for cracking or scoring
helpful only
from
this
as a reference;
pad removal.
REMOVAL & INSTALLATION 2WD
Vehicles
Some
t See Figures 19, 20 and 21
conditions.
plates, cushions
and
brackets to suppress brake noise, but no system can com-
1.
brake noise, either high or low
2. 3.
all
noises.
totally eliminated.
Raise the front of the truck and safely support
it
with
jackstands.
frequency, can be controlled and perhaps lessened, but cannot
be
at the profile of the pad,
PD60 AND 66 TYPE BRAKES
driving.
pletely silence
does not
with wear.
heard when the vehicle
the brakes applied.
not be present under braking
It
presses on the disc)
to
and not some
indicators
wheel
outer, through the cut-out in the
Remember
not the whole thing. Brake pads can
which
turn the
rather than the thickness of the backing plate which
WEAR INDICATORS The
and
out from under the fender.
View the pads, inner and
Brake Pads
inspected without removal.
With the front end elevated and supported, remove the
Remove Remove
The torque
the lug nuts and the wheel. the lower installation bolt from the torque plate.
plate
is
the framework that holds the caliper.
9-12
BRAKES 4.
Pivot the caliper
assembly upwards and suspend
the suspension with a wire.
Do NOT disconnect
but take care not to stretch
it.
5.
from
it
the brake
line,
Remove
the 2 anti-squeal springs and
Remove
the 2 anti-squeal shims and the 4 pad support
lift
out the brake
pads. 6.
plates. Pull the 2 7.
Check
pad wear
indicator off the pads.
the pad thickness and replace the pads
are less than 0.039
(1mm)
in.
proximately 0.374-0.472
in.
thick.
(9.6-1
if
they
New pads measure
2.0mm)
thick
ap-
depending on
the vehicle. 10. minimum thickness measurement may disagree (This
with your state inspection laws.
To
install:
the 4 pad support plates into the torque plate.
8.
Install
9.
Install
a
Install
the large anti-squeal shim to the back of the outer
new pad wear
pad (PD 60) or
Fig.
19 Exploded view of the
PD 60 and 66
type brake components
to the
back
indicator plate to
of
each pad.
each pad (PD 66) and then
BRAKES Swing the
13. to
29
ft.
14.
down and
the lower
the wheel and lower the truck.
Install
the reservoir and
should have risen
level
fit
Tighten
bolt.
it
(39 Nm).
lbs..
fluid level in
(The
caliper
9-13
fill
to the
when
Check the brake
max
the piston
line
if
necessary.
was pushed
back.)
Apply the parking brake and put the vehicle
15.
pedal application
The pedal
Do NOT
in
Park or
on the brake pedal two or three times. The
Neutral. Step
travel
will
be due
to the pistons
first
being pushed back.
should be normal after two or three pumps.
has a normal
drive the vehicle until the pedal
feel.
If
necessary, bleed the brakes to remove pedal sponginess.
'Braking should be moderate for the first 5 miles (8 km) or so until the new pads seat correctly. The new pads will bed best if put through several moderate heating and cooling cycles. Avoid hard braking until the brakes have
experienced several long, slow stops with time to cool between. Taking the time to properly bed the brakes yield quieter operation, position both
springs
•When
pads
into the
torque plate.
Install
Do
new brake pads, make sure your hands
not allow any grease or
oil
contact face of the pads or the brakes
to
may
1 1
Remove a
See Figures
22,
23 and 24
touch the
1.
Remove
2.
Raise the front of the truck and safely support
the hub cap and loosen the lug nuts. with
it
jackstands.
amount of fluid from the reservoir, using tool. Use a C-clamp or hammer handle
4.
Remove Remove
5.
Swivel the caliper up and
3.
small
a syringe or similar
and press the
I
not stop the
truck properly. 12.
stopping and con-
FS17 AND 18 TYPE BRAKES
installing
are clean.
efficient
life.
the anti-squeal
place.
in
more
extended brake
tribute to
in
will
caliper piston
back
into the
the lug nuts and the wheel. the caliper slide pin on the sub-pin (lower) side.
housing. Tie the caliper to a suspension
way.
•-WARNING
Do
6.
Never press the piston into the caliper when the pads are out on both sides of the truck. The opposite piston
pop completely out
of the caliper. This
may
may
spoil your
afternoon.
away from
member so
not disconnect the brake
the torque plate. it
is
out of the
line.
the 2 brake pads out of the torque plate.
Lift
Remove
the anti-squeal shim. 7.
Remove
the 4 pad support plates. Pull the 2 pad
wear
indicator plates off the pads. 8.
Check the pad thickness and replace the pads they in. (1mm) thick. New pads measure approxif
are less than 0.03
For
PD 60
types, press the round anti-squeal shim over
the caliper piston; position the caliper over the torque plate so the dust boot
is
not pinched.
imately 0.374
in.
(9.6mm)
thick.
•This minimum thickness measurement may disagree with your state inspection laws.
To
install:
9.
Install
the 4 pad support plates into the torque plate.
10.
Install
a
new pad wear
indicator plate to the bottom of
each pad. 11.
the anti-squeal shim to the back of the outer pad
Install
and then
position both
pads
into the
torque plate.
•-WARNING When
new brake pads, make sure your hands Do not allow any grease or oil to touch the
installing
are clean.
contact face of the pads or the brakes
will
not stop the
truck properly.
12.
Use a syringe or similar tool to remove some fluid from Use a C-clamp or hammer handle and press the
the reservoir.
caliper piston 13.
back
into the
housing.
Untie the caliper and swivel
torque plate so that the dust boot slide pin
and
tighten
it
to
65
ft.
it
is
lbs.
back
into position
over the
not pinched. Install the
(88 Nm).
9-14
BRAKES
BRAKES 14.
Check the
15.
Install
line
if
fluid level in
the reservoir and
necessary. (The level should have risen
was pushed
piston 17.
condition of the cylinder side bushing boot.
the wheel and lower the truck.
Check the brake
16.
max
9-15
in
Park or
on the brake pedal two or three times. The
pedal application
the
back.)
Apply the parking brake and put the vehicle
Neutral. Step
to the
fill
when
be due
will
first
being pushed back.
to the pistons
The pedal travel should be normal after two or three pumps. Do NOT drive the vehicle until the pedal has a normal feel. If necessary, bleed the brakes to remove pedal sponginess.
^Braking should be moderate for the first 5 miles (8 km) new pads seat correctly. The new pads will bed best if put through several moderate heating and
or so until the
cooling cycles. Avoid hard braking until the brakes have
experienced several long, slow stops with time to cool between. Taking the time to properly bed the brakes
more
yield quieter operation,
extended brake
tribute to
4WD
efficient
in
will
86829p08
stopping and con26 The pins can be removed with a
Fig.
life.
drift
Vehicles
I See Figures 25, 26, 27, 28, 29 and 30 1.
Raise the front of the truck, support
and remove the
front
2.
Pull out the wire clip at the
3.
Remove
the pins.
shaped on older
it
on jackstands,
wheel.
Remove
trucks), the
ends
of the
pad
pins.
the anti-rattle spring (W-
brake pads and the four
anti-
squeal shims. 4.
Check the pad thickness and replace the pads they in. (1mm) thick. New pads measure approxif
are less than 0.03 imately 0.374
in.
(9.6mm)
thick.
'This minimum thickness measurement may disagree with your state inspection laws. 5.
Check the
pins for straightness
and wear, and replace
if
necessary.
To 6.
install:
86829pl0
Use a syringe
or similar tool to
remove a small amount
27
Fig. of fluid
from the master cylinder reservoir.
Remove
the anti-rattle clips from the pads
86829pll 86829p07
Fig. Fig.
25
Remove
the wire clips securing the pins
28 The pads can be removed with a pair of needle-
nose
pliers
9-16
BRAKES Use a C-clamp
7.
or
hammer
handle and press the caliper
pistons back into the housing.
'Never press
the pistons into the caliper
when
the pads
are out on both sides of the truck. Install
8.
the 4 anti-squeal shims so that the black shims
are between the silver shims and the brake pad.
or
Install
on the inner surfaces Install
11.
Slide the 2
12.
line
piston 86829pl2
Fig.
29
Remove
the shims from the back of the pad
14.
pad
if
the wheel and lower the truck. Bleed the brakes
fluid level in
Apply the parking brake and put the vehicle
Neutral. Step
front brake
components
— 1991
fill
when
to the
the
back.) in
Park or
on the brake pedal two or three times. The will
be due
travel should
to the pistons
be normal
Brake Tube
4WD
the reservoir and
necessary. (The level should have risen
was pushed
The pedal
30 Exploded view of the
and
clip.
test the vehicle.
pedal application
Fig.
careful not to get grease
pads.
retaining pins through the caliper
the retaining
Check the brake
13.
max
install
Install
and road
of the
the anti-rattle spring.
10.
pads and
Be very
the brake pads.
9. oil
Land Cruiser shown
after
first
being pushed back.
two or three pumps.
BRAKES Do NOT
has a normal
drive the vehicle until the pedal
feel.
9-17
If
necessary, bleed the brakes to remove pedal sponginess.
'Braking should be moderate for the first 5 miles (8 km) or so until the new pads seat correctly. The new pads will bed best if put through several moderate heating and cooling cycles. Avoid hard braking until the brakes have
experienced several long, slow stops with time to cool
in
between. Taking the time to properly bed the brakes will yield quieter operation, more efficient stopping and contribute to
extended brake
life.
Brake Caliper
REMOVAL & INSTALLATION 86829pl5
2WD
Fig- 31
Vehicles
With a
line
wrench, loosen the brake
line
from
the caliper 1
.
Elevate and safely support the vehicle.
2.
Remove
3.
Disconnect the brake
4.
Remove Remove Remove
5. 6.
To
the wheel. line
from the caliper.
the bolts holding the caliper to the torque plate. the caliper from the torque plate. the pads and shims.
install:
7.
Install
8.
Fit
the pads and shims.
the caliper into position. Install the two retaining or
slide bolts, then tighten to:
• FS-17 or 18 brakes •
PD 60
•
T100 V2 ton -27 ft. T100 1 ton -29 ft.
• 9.
Install
66 brakes
or
the brake
line,
— 65 — 29
(39
(39
lbs.
ft.
(36
lbs. lbs.
(88
lbs.
ft.
Nm) Nm)
Nm) Nm)
tightening the
11-22
fitting to
ft.
(15-30 Nm).
lbs.
the wheel.
10.
Install
11.
Lower the vehicle
to the
ground. Bleed the brakes and
road test the vehicle.
4WD I
Fig.
Vehicles
See Figures 1.
31,
Remove
the upper and lower mounting bolts
front
of the truck,
support
it
on jackstands,
wheel.
Plug the vent hole on the master cylinder cap to prevent
fluid leak.
Loosen the brake
not to deform the 3.
32
32 and 33
Raise the front
and remove the 2.
86829pl4
Remove
line
from the caliper, being careful
fittings.
and remove the
the 2 caliper mounting bolts,
caliper. 4.
Pull out the
two wire
5.
Pull out the
pads and
6.
To 7.
Remove
clips at the
ends
pad
pins.
the brake pads, and the anti-squeal shims.
install:
Position the caliper
and
install
the mounting bolts.
Tighten the caliper mounting bolts to 90 certain to position the 8.
of the
anti-rattle spring.
shims
Connect the brake
lbs.
ft.
(123 Nm). Be
correctly.
line to
the caliper.
except 1991-96 Land Cruisers, tighten the
On
all
models
line fitting to 11
lbs.
(15 Nm). For 1991-96 Land Cruisers, tighten
lbs.
(30 Nm).
it
to
22
ft.
86829pl3
ft.
Fig. 9.
Install
the brake pads.
33 Slide the caliper assembly
off of the rotor
BRAKES
9-18 10. Install
and road
the wheel and lower the truck. Bleed the brakes
test the vehicle.
OVERHAUL 2WD 1
Vehicles Raise the front of the truck and support with safety
.
Remove the wheels. Remove the caliper. Remove the slide bushings,
stands. 2. 3.
(PD60 4.
and 2
collars
Carefully pry the dust boot set ring out of the caliper.
Remove 5.
pin dust boots
only).
the dust boot.
Insert
a piece cloth or rag between the caliper claw and
the piston. 6.
Apply compressed
the piston out of
its
air to
bore.
Be
the brake line union to force
careful; the piston
may come
86829pl8
out
Using a seal pick, remove the dust boot rings forcefully.
•-CAUTION Keep fingers away from the removal. Injury
7.
Remove
front of the piston during
may occur when
the piston
comes
the piston seal from the caliper cylinder bore.
Check the piston and cylinder bore for wear and/or Replace components as necessary. To assemble: 8. Coat all components with clean brake fluid or soap base 9.
10.
Install
11.
Fit in
5.
corrosion.
lithium
glycol grease.
the piston seal and then the piston into the caliper
cylinder bore. Seat the piston
press
out.
in
6.
the bore with your fingers.
the boot into the groove
in
the cylinder bore and
the set ring.
On FS17
plate. Install the
types, install the
sub
pin slide
main
bushing
pin boots to the torque into the
caliper. Install the
bushing
into the
86829p20
torque plate.
On PD60 types, install the collar and dust boots into caliper. Make sure they are firmly secured to the groove in 12.
boots so that
it
is
the the
7. Fig.
35 Place a piece of
then apply compressed
wood between air to
the pistons,
force them out
firmly set 1
in
»
the boot groove.
Apply compressed
13.
Install
the caliper and brake pads.
14.
Install
the wheels and lower the truck. Bleed the brakes
and road
4WD
the piston out of
careful; the piston will
come
out
-•-'•-CAUTION
Vehicles
Keep fingers away from the
front of the piston during
may occur when
the piston
comes
out.
Raise the front of the truck and support with safety
2.
Remove the wheels. Remove the caliper.
3.
Carefully pry the dust boot set rings out of the caliper.
stands.
Remove 4.
Be
forcefully.
removal. Injury .
bore.
the brake line union to force
test the vehicle.
I See Figures 34, 35 and 36 1
its
air to
Remove
the piston seals from the caliper cylinder bores.
Check each piston and cylinder bore Replace components as necessary.
for
wear and/or
corrosion.
the dust boots.
Insert
a piece of
wood about V2
in.
thick
between the
•-*WARNING
caliper pistons.
Do
not loosen the four bolts holding the two halves of
the caliper together.
To assemble: Coat soap based
all
components
glycol grease.
with clean brake fluid or lithium
BRAKES To
9-19
install:
Coat the hub
7. install
oil
seal
with multi-purpose grease
lip
and
the disc/hub assembly.
8.
Adjust the wheel bearing.
9.
Using a
measure the
dial indicator,
against the specifications
disc run-out.
Check and
it
the Brake Specifications chart
in
the figures noted earlier.
^If the wheel bearing nut run-out will be affected. 10.
improperly tightened, disc
is
the remainder of the
Install
components as
outlined
in
the appropriate sections. 11.
Bleed the brake system.
12.
Road
Double check the wheel bearing
test the truck.
preload.
86829p21
INSPECTION
36 Once the pistons are removed, use the seal
Fig.
pick to withdraw the piston seals
Examine the 8.
Install
the piston seals then the pistons into the caliper
cylinder bores. Seat the pistons 9.
press
in
the bores with your fingers.
in
the boots into the grooves
Fit
in
the cylinder bores and
replaced.
cations given
10.
Install
the caliper and brake pads.
thickness
1 1
Install
the wheels and lower the truck. Bleed the brakes
is
.
and road
not
REMOVAL & INSTALLATION
•
ABS speed
sensor from the knuckle
•
if
2.
Remove
3.
Check the
4.
it
must be
If
below
specifi-
Use a micrometer to measure the thickness. allowable wear from new thickness to minimum it.
only approx. 0.078
is
runout
is
in.
(2mm), resurfacing the discs
specification, replace the disc. Maxi-
as follows:
— 0.0035 (0.09mm) — 0.0047 (0.12mm) Pick-Up FS 17 or 18 brakes — 0.0035 (0.09mm) 1989-95 Pick-Up and 4Runner — 0.0035 Pick-Up Pick-Up
PD 60 PD 66
brakes
in.
brakes
in.
in.
in.
disc run-out at this point.
use during
installation.
Make a
Tacoma and 1996 4Runner
• T100,
the brake pads and the caliper.
Refer to the inspection
Land Cruiser
•
note of the
*-Be sure
procedure.
Remove
the grease cap from the hub.
and the castellated
ter pin
worn, warped or scored,
(0.09mm)
equipped.
results for
is
recommended.
2WD 2WD 2WD 4WD
• •
Disconnect the
it
the Brake Specifications chart.
exceeds the maximum
mum
.
If
the thickness of the rotor against the specifi-
The disc run-out should be measured before the rotor is removed and again, after the rotor is installed. Use a dial indicator mounted on a stand to determine run-out. If run-out
test the vehicle.
Brake Disc
1
in
cations, replace
Because the
the set rings.
disc.
Check
Remove
is not,
Remove
6.
Perform the rotor inspection procedure.
— 0.0028
in.
(0.07mm)
(0.015mm)
in.
wheel bearing nut is properly tightened. an inaccurate run-out reading may be obtained.
that the
If
it
If
different run-out readings are obtained with the
the cot-
nut.
5.
— 0.0059
the wheel hub with the brake rotor attached.
disc,
between removal and
installation, this is
same
probably the
cause.
REAR DRUM BRAKES Brake Drum
-•--•'CAUTION Brake shoes may contain asbestos, which has been deterto be a cancer causing agent. Never clean the
mined
brake surfaces with compressed
Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.
REMOVAL & INSTALLATION
air!
> See Figures 37, 38 and 39 1.
Remove
the hub cap
(if
used) and loosen the lug nuts.
Release the parking brake. 2.
Block the front wheels, raise the rear of the truck, and
support 3.
it
with jackstands.
Remove
the rear wheels.
BRAKES
9-20 4. all
Unfasten the brake drum retaining screws,
if
used. Not
models have them. 5. 6.
driver
Tap the drum lightly with a mallet in order to free insert a screwIf the drum cannot be removed easily, into the hole in the backing plate and hold the automatic it.
adjusting lever
bladed
away from
tool, relieve
justing bolt clockwise. puller, but first
the adjusting
bolt.
Using another
flat-
the brake shoe tension by turning the adIf
the
make sure
drum
still
will
not
come
that the parking brake
off,
use a
is fully
released. 7.
To
install:
•^WARNING Do not depress the brake pedal once the brake drum has been removed. Inspect the brake
Check the
drum
for
inside diameter of the
cations chart. Replace
if
any wear or deterioration.
drum
with the Brake Specifi-
necessary.
To
8.
and
install
the drum, simply place the
tighten the retaining screw,
9.
Install
if
drum on the axle
used. Adjust the brakes.
the wheels and lower the truck.
Road
test the
vehicle checking for correct function.
INSPECTION >
See Figure 40 1.
Clean the drum.
2.
Inspect the
drum
for scoring, cracks,
roundness. Replace the drum or have
it
grooves and out-of-
“turned” at a machine
or brake specialist shop, as required. Light scoring
may be
removed by dressing the drum with fine emery cloth. 3. Measure the inside diameter of the drum. A tool 86829p23
H-gauge
caliper
your vehicle. Fig.
37 Bolts can be inserted into the holes as shown
to aid in
drum removal
86829p24
Fig.
38 Lubricate the studs to help ease the drum from
the hub
is
used.
See
called a
the Brake Specifications chart for
BRAKES Brake Shoes INSPECTION
The brake shoes can be inspected without removing brake drum
if
necessary.
the backing plate. hole.
If
they
seem
Remove
Check the shoe to
the
the inspection hole plug
in
thickness through the
lining
be less than the minimum
of 0.039
in.
(1.0mm), replace the shoes.
REMOVAL & INSTALLATION common
(••Drum brakes require the use of two tools to
make
the job easier.
A
brake
brake spring wrench and a
spring removing tool can be purchased at almost any automotive outlet for low cost. These are two of the handiest special tools you can own; they can generally be used
on
any vehicle with drum brakes.
2WD
Vehicles
LEADING-TRAILING BRAKES > See Figures 41, 42, 43, 44, 45, 46 and 47 1
.
Raise the rear of the truck and support
2.
Remove the wheels. Remove the brake drum.
3.
Using a brake
4.
Remove
it
with jack-
stands.
move 5.
tool,
remove the
return spring.
the front shoe hold-down spring and pin. Re-
the front shoe with the anchor spring.
Remove
the hold-down spring and pin and pull out the
rear shoe. 6. 7. it
Remove Remove
the parking brake cable from the lever. the E-clip and spread the C-washer to
from the parking brake
lever.
Remove
remove
the adjusting lever
spring.
Fig. 41
spring
Special tools are available to
remove the return
9-21
BRAKES
9-22 To
install:
Apply high temperature grease
8.
to the contact surface of
the brake backing plate and to the threads and end of the adjuster bolt. Pull the parking
9.
brake cable out, then attach
it
to the
lever.
is
10.
Connect the
1 1
Position the rear
.
in
strut
and
return spring to the lever.
shoe so
that the
upper end
the wheel cylinder and the lower end
plate. Install the pin
12.
stretch 13.
and hold-down
Connect the anchor spring it
in
of the
shoe
the anchor
spring.
to the rear
shoe and then
onto the front shoe.
Position the front
cylinder
is
shoe so the upper end
and the lower end
is
in
the
strut.
Install
is
in
the wheel
the pin and
hold-down spring. 14.
Install
15.
Check
the return spring. that the adjuster bolt turns while pulling
up on the
and
brake
lever. Adjust the strut to the shortest possible length
install
the brake drum. Pull the parking brake lever (inside the
truck) out until the clicks stop. 16. Remove the brake drum and check that the difference between the inner brake drum diameter and the outer brake shoe diameter is no more than 0.024 in. (0.6mm). Adjust or
replace parts as needed. 17.
the brake drum.
Install
the wheels and lower the
Install
Bleed the brakes and road
truck.
test the vehicle.
DUO-SERVO BRAKES >
See Figure 48 1
Raise the rear
.
of the truck
2.
Remove the wheels. Remove the brake drum.
3.
Using a brake
and support
with jack-
it
stands.
4.
cable, at the
tool, remove the 2 return springs. Push up on the brake adjusting lever and remove the shoe guide plate and cable guide. Disconnect the spring
brake lever and remove them both.
5.
Using needle-nose
6.
Using a brake
and
tool,
remove the 2 tension springs. remove the shoe hold-down springs
pliers,
pins.
7.
Remove
8.
Pull the parking
the shoes, the adjuster and the
strut.
brake cable out, then disconnect
it
at
the parking brake lever.
To
install:
Apply high-temperature grease
9.
to the
contact surface of
the brake backing plate.
brake cable out and attach
Pull the parking
10.
to the
it
lever. 1 1
Position the rear
.
86829g45
piston rod. Install the 12.
Install
rod. Install the
13. install
14.
15.
45 Apply high-temperature grease to the areas
indicated
its
upper end
so that the upper end
Grease the threads and end between the brake shoes.
in
is
the
pin.
is
in
the piston
pin.
of the
brake adjuster and
it
Install
the shoe guide plate
and the adjusting install
cable. In-
the rear one.
While holding the tension spring against the rear shoe,
hook the cable
into the adjusting lever
Pull the adjusting bolt
strut
hold-down spring and
the front return spring and then
stall
Fig.
that
the strut with the spring to the rear. Position the
shoe over the
front
shoe so
shoe hold-down spring and
should
turn.
and
install
cable backward and release
it;
the lever. the adjusting
BRAKES
have an assistant step on the brake pedal. Continue cess
until
the clicking noise
Remove
is
this pro-
drum and check that the difference between the inner brake drum diameter and the outer brake shoe diameter is no more than 0.024 in. (0.6mm). Adjust or 17.
the brake
replace parts as needed. 18. truck.
Install
Remove Remove
c.
Spread and remove the C-washer.
d. 7.
I
Vehicles
See Figures 1.
49, 50, 51, 52, 53, 54, 55, 56, 57, of the truck
Remove the parking brake Remove the front shoe with
lever.
the
strut.
Disconnect the
Disconnect the adjusting lever spring and remove the
8.
install:
Assemble and
9.
Raise the rear
the automatic adjusting lever.
adjuster from the front shoe.
test the vehicle.
To
4WD
the E-clip.
other parking brake cable.
the brake drum. Install the wheels and lower the
Bleed the brakes and road
b.
a.
no longer heard.
9-23
and support
Remove the wheels. Remove the brake drum. Remove the tension spring. Remove the rear shoe hold-down
it
58 and 59
install
the parking brake bellcrank as
follows: a.
Apply grease
b.
Install
with jack-
to the rotating parts of the bellcrank.
the parking brake bellcrank to the bellcrank
stands. 2. 3. 4.
then 5.
lift
bracket.
spring
and
pin
Remove
the front shoe hold-down spring and pin. Dis-
connect the parking brake cable
at the bellcrank.
and
Install
the pin with a
Install
the bellcrank boot to the parking brake bracket.
e.
Install
the parking brake bellcrank and dust cover on
and
out the rear shoe and anchor spring.
new
c.
d.
the backing plate.
C-clip
tighten
it.
9-24
BRAKES
86829p25
Fig. 49 Saturate the brake components using a commercially available brake cleaner
Fig.
50
spring
A
special tool
is
available to
remove the
return
BRAKES
86829p30
86829p27
Fig. 51
After the return spring is disengaged,
remove
it
Fig.
54 Lower the shoe, then disconnect the spring that
attaches both shoes
from the brake assembly
86829p28
Fig.
52 Push inwards then twist
9-25
.
.
.
86829p31
Fig.
55
Remove
the other side
.
.
.
BRAKES
9-26
Apply high-temperature grease
10.
plate contact surfaces 1 1
Use new
clips
and
brake backing
of the adjuster.
and the automatic ad-
Position the parking brake lever
.
juster.
12.
to the
and the threads
tighten the C-clip.
Connect the parking brake cable
to the
shoe
lever. At-
tach the other side of the cable to the bellcrank. Position the front
shoe so the upper end
hold-down spring and 13. it
is
in
the piston rod and
Connect the anchor spring
to the front shoe, then stretch
onto the rear shoe. Position the rear shoe and
hold-down spring and 14.
Install
the
install
pin.
the tension spring. Lightly pull the bellcrank
in
A until there is no slack at B. Turn the adjusting C will be 0.02-0.03 in. (0.4-0.8mm) on all models
direction
so that
excluding 1996 4Runner which
Lock the adjusting 15. install
16. travel
the
install
pin.
is
0.016-0.031
in.
bolt
(0.4-0. 8mm).
bolt with the locknut.
Connect the parking brake cable
to the bellcrank
and
the tension spring.
Check is
Fig.
that the parking brake lever (inside the truck)
correct
and
58 Bellcrank adjusting points
— except
Land
Cruiser
that the adjuster turns while pulling the
lever.
17. install
Turn the adjuster
to the shortest possible length
the brake drum. Pull the parking brake lever out
and until
the clicks stop. 18.
Remove
the brake
drum and check
that the difference
between the inner brake drum diameter and the outer brake shoe diameter 19. truck.
Install
is
no more than 0.024
in.
(0.6mm).
the brake drum. Install the wheels and lower the
Bleed the brakes and road test the vehicle.
Wheel Cylinders
REMOVAL & INSTALLATION I
See Figures 1
.
2.
Remove
60, 61
and 62
the brake
drums and shoes.
Working from behind the backing
plate,
disconnect the
hydraulic line from the wheel cylinder. Plug the line to prevent fluid loss.
86829g51
86829p33
Fig.
57 Apply high-temperature grease to the brake backing plate and the threads of the adjuster Fig.
59 Bellcrank adjustment points on the Land
Cruiser
BRAKES To
install:
Position the cylinder
3.
7
ft.
9-27
4.
and
install
the bolts; tighten
them
to
(10 Nm).
lbs.
Connect the brake
line,
tightening
it
to 11
ft.
lbs.
(15
Nm). the shoes and drums.
5.
Install
6.
Bleed the brake system.
7.
Unfasten the bolts retaining the wheel cylinder and with-
draw the
cylinder.
86829p4
Fig. 61
Remove
the bolts securing the wheel cylinder to
the backing plate
.
.
.
86829p40
Fig.
60 Using a
brake
line
wrench, loosen and disconnect the
line
REAR DISC BRAKES •'CAUTION Brake pads may contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed
dust from brake surfaces.
When
air.
2.
Raise and support the rear
3.
Remove
4.
Inspect the pad thickness through the caliper hole, then
of the vehicle.
the wheels.
replace the pads
if
not within specifications, 0.039
in.
(1
.0mm)
Remove the brake caliper as follows: a. Remove the sliding main pin and sliding sub pin. so the hoses are b. Remove the caliper and suspend not stretched. You can use a piece of wire for this. Do not 5.
Avoid inhaling any
cleaning brakes, use com-
it
mercially available brake cleaning fluids.
disconnect the hoses. 6.
Brake Pads
Remove
and wear
the brake pads, anti-squeal shim, support plate
indicators.
The support
plates can be used again
provided they have sufficient rebound, no deformation, cracks
REMOVAL & INSTALLATION
or wear. Clean
To >
See Figures
63, 64, 65
7.
and 66
them
Loosen the
lug nuts.
in.
any
rust, dirt
and foreign
particles.
Check the thickness and runout. Standard thickness in. (10.0mm) and runout maximum is 0.0059
should be 0.394 1
of
install:
(0.15mm).
9-28
BRAKES
8.
Install
the pad support plates.
9.
Install
the pad
10.
wear
indicators plate to
Place the anti-squeal shims
each
of the pads.
on the outer
into position
pad. 1 1
.
Install
the pads so that the
wear
indicator plate
is
facing
upwards. 12.
Draw
voir with
out a small
amount
of
brake
fluid
hammer
handle or a C-clamp.
13.
Press
in
14.
Install
the caliper carefully so the boot
Install
.lbs.
from the reser-
a syringe.
and
the piston with a
tighten the sliding
is
main pin and sub
not
wedged.
pin to
65
ft.
(88 Nm). the wheel.
15.
Install
16.
Check the
17.
Bleed the brake system.
18.
Lower the
19.
Before driving the vehicle press the brake pedal several
times.
fluid level,
top
off
if
necessary.
vehicle, tighten the lug nuts.
BRAKES Remove
6.
and the
the mounting bolts
9-29
caliper from the
vehicle.
To
install:
Draw
7.
out a small
amount
brake
of
fluid
from the reser-
voir with a syringe. 8.
Attach the brake hoses to the caliper.
9.
Press
in
10.
Install
the caliper carefully so the boot
Install
and
the piston with a
tighten the sliding
hammer
main
pin
handle or C-clamp. is
and sub
not
wedged.
pin to
65
ft.
(88 Nm).
lbs.
the wheel.
11.
Install
12.
Check the
13.
Bleed the brake system.
14.
Lower the
15.
Before driving the vehicle press the brake pedal several
fluid level,
top off
if
necessary.
vehicle, tighten the lug nuts.
times.
OVERHAUL 1.
Remove
2.
Using a flat-bladed
the caliper. tool,
remove the
cylinder boot from
the caliper.
Place a piece of cloth or similar
3.
the piston
and
article (lint-free)
between
caliper.
Use compressed air to remove the piston from the Keep your hands free from the piston exit area.
4.
per.
cali-
**CAUTION Brake pads may contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air. Avoid inhaling any dust from brake surfaces. When cleaning brakes, use commercially available brake cleaning fluids.
With a seal
5.
pick,
remove the
piston seal from the
cylinder.
Tap
6.
out the boot and sliding bushing.
and hammer
drift
will
do
A tapped-ended
well.
To assemble: 7.
Coat
soap based 8.
Using a thickness in.
(1
ruler, is
measure the pad
0.374
or less, or
Standard
(9.5mm) and minimum thickness
in.
.0mm). Replace the pads
minimum
lining thickness.
if
if
the thickness
is
is
0.039
not at the
the pad has severe and uneven wear.
Brake Caliper
Install
all
components
with clean brake fluid or lithium
glycol grease.
the piston seal, then the piston into the caliper
cylinder bore. Seat the piston 9.
press
Fit in
in
the bore with your fingers.
the boot into the groove
in
the cylinder bore and
the set ring.
10.
Install
the caliper and brake pads.
11.
Install
the wheels and lower the truck.
12.
Bleed the brake system.
13.
Before driving the vehicle press the brake pedal several
times.
REMOVAL
& INSTALLATION
Brake Disc 1.
Loosen the
2.
Raise and support the rear
3.
4.
Remove Remove
5.
Disconnect and plug the hoses from the caliper
assembly.
lug nuts. of the vehicle.
REMOVAL & INSTALLATION
the rear wheels. the sliding main pin and sliding sub pin. 1
.
Raise and support the vehicle.
2.
Remove
3.
Disconnect the
the rear wheels.
ABS speed
sensor.
9-30
BRAKES
4.
Remove
5.
Install
the caliper.
the hub nuts temporarily to
nout and thickness.
If
measure the
disc ru-
Place matchmarks
6.
vehicle, tighten the lugnuts.
Before driving the vehicle press the brake pedal several
on the disc and rear hub, then re-
INSPECTION
the disc.
the disc cannot be removed
>"»lf
Lower the
.
times.
replace the disc.
move
Install
1 1
12.
not within specifications of inspection,
the wheels, hand-tighten the lugnuts.
10.
easily, turn the
shoe
adjuster until the wheel turns freely.
When
deciding weather or not to replace a disc, measure
The standard thickness
To
install:
7.
Install
the disc on the hub.
and the minimum thickness
8.
Install
the caliper.
disc runout,
9.
Attach the
the thickness.
ABS speed
maximum
is
0.630
specification
is
is
in.
0.709
in.
(18.0mm)
(16.0mm). Measure the
0.0059
in.
(0.15mm).
sensor.
PARKING BRAKE Brake Lever
ADJUSTMENT Except Land Cruiser *
See Figures 1
.
67,
68 and 69
Pull the parking
brake lever
all
the
count the number of clicks to the end of
way
out (or up) and
travel.
ton vehicles should have 12-18 clicks; 1-ton,
On 2WD
2WD
V2
vehicles
and all 4WD vehicles should have 11-17 clicks. On 1989-95 4Runner check for 13-19 clicks and 1996 4Runner 7-9 clicks. If
the parking brake lever 2.
Under the truck on
bar where the 2 cables adjusting nut
Check 3.
until
not within these ranges, adjust
come
models, there
is
it.
an equalizer
together. Tighten or loosen the
the lever travel
is
within the proper range.
Fig.
that the rear brakes are not dragging.
Under the truck on
stopper screw
until
4WD
the play
zero, then loosen the 4.
is
2WD
screw
in 1
68 There are two cables which are joined by an
equalizer, the lock
and adjusting nuts are located here
models, tighten the bellcrank the rear brake links turn.
becomes
Tighten the locknut.
Tighten one of the adjusting nuts on the intermediate
lever while loosening the other
one
until
the lever travel
is
correct. Tighten the adjusting nuts.
5. is
After adjustment,
check
that the bellcrank stopper
touching the back of the brake backing plate. 6.
Recheck the parking brake
travel.
screw
BRAKES
9-31
Land Cruiser
11.
Remove
I See Figure 70
12.
Slide out the front shoe. Disconnect the parking brake
the shoe hold-down spring cups, spring
and
pin.
cable from the parking brake shoe lever. 1
.
Pull the parking
brake lever
all
the
count the number of clicks to the end of
be 7-9
clicks.
ranges, adjust 2.
If
the parking brake lever
way
out (or up) and
13.
Remove
There should
14.
If
travel. is
not within these
make
certain the rear
brakes are correctly adjusted. 3.
Remove
bellcrank assembly as follows:
it.
Before adjusting the parking brake,
a.
Using a flat-bladed
b.
Remove
remove the C-washer.
tool,
the pin, then separate the parking brake cable
from the bellcrank.
the parking brake lever cover or rear console
box.
Remove
c.
the
Next remove the pin and
clip.
then
clip,
disconnect the cable.
4.
Loosen the
lever travel
is
locknut, then turn the adjusting nut until the
correct.
Remove
d.
Tighten the locknut.
6.
Install
Remove
e.
the parking brake cover or rear console box.
Brake Shoes
Remove
Loosen the rear wheel
Raise and support the rear
3.
Remove Remove
wire. 10. 6.
move
install:
15.
Assemble and
the rear wheels.
a.
Apply grease
b.
Install
to the rotating parts of the bellcrank.
the parking brake bellcrank to the bellcrank
the pin with a
Install
the bellcrank boot to the parking brake bracket.
e.
Install
the parking brake bellcrank
Using a pair of
Remove
pliers,
remove the tension
spring.
the shoe return springs along with the shoe
strut with spring. 9.
Slide out the rear shoe, then
Apply high-temperature grease
16.
plate
and the threads
adjuster.
Remove
tighten
it.
and dust cover on
to the
Use new
clips
and
and the automatic ad-
tighten the C-clip.
Connect the parking brake cable
18.
brake backing
of the adjuster.
Position the parking brake lever
juster.
to the front
shoe
lever.
of the cable to the bellcrank. Position
the front shoe so the upper
end
is
in
the piston rod and
install
the hold-down spring and pin.
Connect the anchor spring
19.
remove the shoe and
C-clip
the backing plate.
Connect the other side 8.
and
Install
17.
cannot be removed easily, turn the shoe the wheel turns freely.
new
c.
d.
the mounting bolts, then the disc brake caliper.
7.
the parking brake bellcrank as
install
bracket.
the disc.
adjuster until
To
of the vehicle.
Suspend the disc brake caliper securely with a piece of Be sure not to stretch or damage the hose. Place matchmarks on the rotor and the rear hub. Re-
See Figure 71
Using a
ruler,
measure the thickness of the shoe lining. The is 0.157 in. (4.0mm) and the minimum
standard thickness thickness
is
0.039
(1.0mm).
in.
minimum thickness
within
If
the lining thickness
or less, or
there
if
is
is
not
an extremely
uneven wear, replace the shoes. Rotor Inside Diameter I See Figure 72
Using a H-gauge caliper, measure the inside diameter of the rotor.
Standard inside measurement
maximum measurement if
the inside diameter
9.09
is
at the
is
in.
is
9.06
in.
(230mm) and
(231mm). Replace the
maximum
rotor
value or more. Re-
place or have a machine shop grind the rotor with a lathe
has been scored or
is
if
it
worn badly.
Shoe and Lever Clearance
2.
Remove
3.
Turn the adjuster, then expand the shoes
the hole plug. until
the rotor
locks.
> See Figure 73
Using a feeler gauge, measure the clearance between the
4.
Return the adjuster 8 notches.
5.
Install
the hole plug.
parking shoe and the lever. Standard distance should be
0.0138
in.
(0.35mm).
If
the clearance
specification, replace the
The
sizes available are 0.012
and 0.035
in.
(0.9mm).
is
shim with one in.
not within the the
Bellcrank
of the correct size.
(0.3mm), 0.024
in.
necessary replace the shim, remove
If
the parking brake lever, then
parking break lever with a
install
the correct size.
1.
(0.6mm)
Install
new C-washer. Remeasure
the
the
is
2.
Screw
on the dust 3.
clearance.
Pull the bellcrank until all the play in the interior linkage
taken up. in
the bellcrank adjusting bolt to
Loosen
it
in
one
turn,
then lock
the locknut at 48 inch lbs. (5 Nm). 4.
ADJUSTMENTS Parking Brake Shoe Clearance 1.
Temporarily
Fig. 71
shoe
Using a
lining
install
ruler,
the hub nuts.
measure the thickness
of the
Install
where
it
contacts
seal.
the bellcrank spring.
it
at that position with
BRAKES
9-33
REAR WHEEL ANTI-LOCK BRAKE SYSTEM The ECU
•
General Information
electricity
rear wheel anti-lock system found
designed
on Toyota trucks
•
is
keep the rear wheels from locking under hard
to
OFF
is
If
discharge
at or
any arc welding
is
near the to
controller.
be done on the vehicle, the
ECU
should be disconnected before welding operations begin.
braking regardless of the load being carried. This function aids in
a microprocessor similar to other computer
before removing or installing controller harnesses. Avoid static
> See Figure 74
The
is
units in the vehicle. Insure that the ignition switch
keeping the vehicle from skidding sideways under hard brak-
•
the
If
the vehicle
ECU
is
be baked
to
remove
after paint repairs,
from the vehicle.
ing with loss of directional stability.
Since the anti-lock system acts only on the rear wheels,
may be
no steering response
skid;
The
INSPECTION
it
possible to lock the front wheels, causing them to possible
is
this
if
happens.
system employs one speed sensor
electro-hydraulic
in
brake
pressure within the single
line
branches
axle; the line
A that
power steering
The ABS
not the brake fluid circuit.
fluid,
as a control pressure
circuit,
and the brake
steering fluid
within the systems;
each
is
on the power steering
The power
steering fluid acts
moving pistons and valves
the actuator which control the brake
fault(s).
fluid circuit.
The dashboard warning lamp
problem
identify the
will
assign and store a
will
fault
will
code
for the
be illuminated to
inform the driver that a fault has been found.
During diagnostics, the system
transmit the stored
will
code(s) by flashing the dashboard warning lamp.
through the brake system
fluid is circulated
control solenoid acts
and the computer
running to there are
at the axle housing.
system (from 4 wheel ABS)
significant difference in this
actuator.
line
each wheel
to
a malfunction occurs, the system
If
The speed signal is sent to the Electronic Control Unit (ECU) which controls the operation of the control solenoid within the actuator. The solenoid controls the differential housing.
If
two or
more codes are stored, they will be displayed from lowest number to highest, regardless of the order of occurrence. The system does not display the diagnostic codes while the vehicle is
running.
within
The power
Visual Inspection
are kept completely separate
fluid
kept within
fluid is
its
normal system
Before diagnosing an apparent rear anti-lock problem, absolutely certain that the normal braking system and
reservoir.
Use
power steering
of the
pressurized
fluid
(from the
steering systems are fluid
in
correct working order.
allows a supply of constantly
problems (dragging parking brake, seepage,
power steeling pump) and
elimi-
nates the need for larger, bulkier actuators with electric
pumps
and accumulators.
ABS may
system.
A
visual
check
of specific
this inspection
may
Many common
etc.) will affect
the
system components
reveal problems creating an apparent
Performing
make
power
ABS
malfunction.
reveal a simple failure, thus
eliminating extended diagnostic time.
Diagnosis and Testing
Certain
components
be serviced or repaired
and
with removal •
Do
within the
system are not intended
individually.
Only those components
installation
parts included in the
Use only
•
If
DOT
3 brake
removed
or replaced,
using repair
kits,
re-
from an unopened container.
fluid
any hydraulic component is
When
kit.
(either it
power steering
cali-
holders, blockage or crimping. • Check the calipers or wheel cylinders for rust or corrosion. Check for proper sliding action applicable. • Check the caliper and wheel cylinder pistons for freedom of motion during application and release. • Inspect the speed sensor for proper mounting and correct
may be necessary
connection. or
to bleed
the entire system.
A clean repair area is essential. Always clean the reserand cap thoroughly before removing the cap. The slightest amount of dirt in the fluid may plug an orifice and impair the system function. Perform repairs after components have been •
voir
thoroughly cleaned; use only denatured alcohol to clean com-
Do
not allow
components
any substance containing mineral rags.
the reservoir.
if
all
ponents.
fluid level in
to
not use rubber hoses or other parts not specifically
•
brake)
Inspect lines, hoses, master cylinder assembly, brake
tem and components for the same conditions. • Visually check lines and hoses for excessive wear, heat damage, punctures, contact with other parts, missing clips or
procedures should be serviced.
specified for the anti-lock system.
place
Inspect the brake
•
pers and cylinders for leakage. Inspect the power steering sys-
PRECAUTIONS •
•
to
come
• Confirm the fault occurrence. Certain driver induced faults,
such as not releasing the parking brake
fully, will
code and
Excessive wheel spin
brake pedal
set a fault
may
also set fault codes
and
trigger a
riding the
warning
ples of vehicle performance outside the parameters of the con-
into contact with
used shop
light.
lamp. These induced faults are not system failures but exam-
trol
this includes
dash warning
on low-traction surfaces, high speed acceleration or
• oil;
trigger the
unit.
Many system shut-downs
are due to loss of sensor sigThe most common cause is not corroded or dirty connector. Check
nals to or from the controller.
a failed sensor but a loose,
harness and component connectors
carefully.
BRAKES
9-34
REAR ANTI-LOCK Warning Light (Combination Meter)
Fig.
74 Rear wheel anti-lock brake system component locations
— Pick-Up
shown
Reading Codes I
See Figures 1.
Turn the
75, 76,
ignition switch
approximately 12 volts 2.
Turn the
77 and 78
is
OFF. Check
battery condition;
required to operate the system.
ignition switch
ON
and check
that the
REAR
ANTI-LOCK dashboard warning lamp comes on for 2 seconds. the lamp does not come on, repair the fuse, bulb or wiring. If
3.
Use a jumper wire
to attach terminals
Data Link Connector (DLC1). This Turn the 4.
lamp
If
ignition
a
will
fault
is
of the
ON.
code has been
set, the
begin to blink 4 seconds
corresponds
Tc and El
not the service connector.
to the first digit of
a
dashboard warning
later.
2-digit
The number code; after a
of flashes 1
.5
second pause, the second digit is transmitted. If a second code is stored, will be displayed after a 2.5 second pause. it
Once
all
codes have been displayed, the
repeat after a 4 second pause. the warning lamp
no
will
If
flash continuously every
Turn the
'A?
second with
Fig. in
variation. 5.
entire series will
no codes have been stored,
ignition switch
OFF.
75 The
the dash
REAR ANTI LOCK
warning lamp
is
located
BRAKES system are
brake
correct. Also inspect the
brake pedal
any binding or
for
light
9-35
switch at the
sticking.
5. Once the codes are cleared, disconnect the jumper The dash warning lamp should go out.
wire.
Speed Sensor SYSTEM TEST i*The following procedures require driving the vehicle while it is in the diagnostic mode. The anti-lock system be disabled; only normal braking function
will
will
be
available. 1.
Fig.
76 Attach a jumper wire to the Ts and El terminals
4WD
working on a
If
2WD. Check
make
vehicle,
certain
the battery voltage with the engine
should be approximately 12
is
it
off;
only
in
voltage
volts.
ON, make certain the REAR ANTI-LOCK warning lamp comes on for about 3 seconds and
on the DLC1
With the
2.
ignition switch
then goes out. Turn the ignition switch OFF.
Using a 3-way jumper, connect terminals Tc, Ts and El
3.
Data Link Connector (DLC1).
at the
Pull the parking
4.
Trouble code (Example: code 73)
brake on securely and
start the
engine
without stepping on the brake pedal. Depressing the brake
pedal
will
cause the system
either void the test or
different diagnostic
The dashboard warning lamp should
5.
4 times per second.
instead, a
If,
code
is
flash evenly
To check
ABS
to the
blink
off.
77 Example of the code blinks on trouble code 73
no
Check
on the road. Once a speed
or repair the system as indicated by the fault
blinking occurs, the
7.
After repairs are completed, clear the
memory. troller 8.
If
the battery
memory Remove
Clearing
will
is
codes from the
disconnected during repairs, the con-
be erased
of
all
the jumper wire and reattach the service con-
.
cle to
the data
and 82
79, 80, 81
8.
3.
To
at the actuator.
the jumper wire to connect terminals
link
of
9.
connector (DLC1).
codes stored
in
the
speed range;
blink evenly
sec-
as the
failure to blink indicates
a
fault.
the warning lamp is off, do not subject the vehiany shocks or impact such as shifting, acceleration,
After the rapid pedal application, the
make
Stop the vehicle fully.
Read and
a safe location and apply the parking
in
record any stored codes which are
Turn the
ignition switch
OFF; remove the jumper wire
COMPONENT TEST
dash warning lamp
should display constant flashing, indicating a normal system. displayed,
driving the vehicle
mph (40-50 km) is come on after a one
25-31
of
ECU
seconds.
still
If
defective.
from the DLC1 connector.
clear the diagnostic trouble
codes are
is
operating correctly.
displayed.
Tc and El
by depressing the brake pedal 8 or more times within 3
4.
should begin to
deceleration or road impact.
Detach the service connector
Use
it
^While
brake 1
is
change by
the sensor signal
vehicle leaves the
system
stored codes.
Codes
See Figures
2.
is
ond pause. As before, the lamp should
nector at the actuator.
>
Check
system
achieved, the warning lamp should
code.
Once
low speed.
the warning lamp
as the vehicle leaves the speed range. This blinking
7. 6.
at
mph (4-6 km) is reached, Once the light has gone off,
normal and indicates the speed sensor Fig.
light
controller.
a speed of 2.5-37 should turn
must
the
the sensor signal level, release the parking
brake and drive the vehicle straight ahead 86829g72
If
check the parking brake switch, the DLC1
flash,
connector and the wiring 6.
about
flashed, repairs
be made and the code(s) cleared before continuing.
does not
a
to enter
mode.
certain the repairs
made
If
I
See Figures
83, 84
and 85
to the 1. is
Check
the installation of the sensor.
loose, tighten
it
to
14
ft.
lbs.
(19 Nm).
If
the mounting bolt
BRAKES
9-36
:m
1
Trouble Part
Diagnosis
Ught Pattern
Code No.
Open
circuit in solenoid relay circuit or solenoid
circuit •
Mll
12
Short circuit
in
solenoid relay circuit
Solenoid
•
Solenoid relay
•
Wire harness and connector of solenoid
and/or sole-
noid relay circuit
25
Short circuit
juuuuuui
in
solenoid circuit
•
33
41
42
JUULfUUl
Open
JUUUUl
Low
speed sensor
•
circuit
Speed sensor Wire harness and connector of
battery positive voltage (9.5
V
speed sensor
circuit
or lower)
•
Battery
•
Deceleration sensor Wire harness and connec-
Abnormally high battery positive voltage (17 V or higher)
juiaium
MOM
43
or short circuit in
Mechanical malfunction
in
deceleration sensor •
tor of deceleration
sensor
circuit
iUUOMJl
44
Always
Electrical
ON
malfunction
Malfunction
in
in
deceleration sensor circuit
ECU
•
ECU
J 86829glm
Fig.
78 Diagnostic trouble codes for the rear wheel
Fig.
79 Detach the service connector harness
actuator
ABS system
at the
Fig.
80 Use jumper wire or
the terminals
SST 09843-18020
to
connect
BRAKES 2.
Disconnect the speed sensor harness from the
9-37 ABS
harness. 3.
Measure the resistance
an ohmmeter between the
with
terminals of the sensor connector. Correct resistance
580-700 ohms.
If
the resistance
is
outside the specification, the
is
sensor must be replaced. 4.
Check and
terminal
sensor 5.
that there
is
no continuity between each sensor
the sensor body.
If
any
continuity
is
found, the
is faulty.
Reconnect the speed sensor
to the harness.
REMOVAL & INSTALLATION I See Figure 86
The speed sensor It
Depress the brake pedal 8 or more times within 3 seconds to clear the codes Fig. 81
rotational 1
.
speed
located
in
the rear differential housing.
ECU based
on the
of the differential ring gear.
Unplug the sensor cable connector from the harness.
the sensor cable
Fig.
is
transmits a small electrical signal to the
is
If
held by brackets or clamps, release them.
82 To verify that your procedure was complete, the
warning lamp should go out
Fig.
84 The ohmmeter measures the resistance between
the terminals of the sensor
86829g82
Fig. 85 Check that there is no continuity between each sensor terminal and the sensor body
BRAKES
9-38
86 Exploded view of the speed sensor mounting
Fig.
Remove
2.
the retaining bolt holding the sensor to the
Remove
3.
the sensor straight out of
its
mount. Protect the
system flashing when transmitting a code.
from impact or abrasion.
tip
To 4.
Install
not crooked
the sensor, making certain
is
firmly
seated and
6.
Reinstall
any mounting
ft.
lbs.
(19 Nm).
clips or brackets for the
cable, then attach the cable to the
Double check the cable
ABS
routing;
it
rapidly,
7.
sensor
move
harness.
8.
must be completely
any moving components.
mph
at 12.4
straight
(20 km) or greater speed. Strongly depress
the brake pedal; the warning lamp should begin flashing evenly
and
Tighten the retaining bolt to 14
clear of
it
mount.
its
in
5.
7.
Release the parking brake and drive the vehicle
6.
ahead
install:
dashboard warning lamp should once every second. This is slower than the usual
After a short delay, the
5.
flash about
differential.
about 8 times per second.
Stop the vehicle and turn the the jumper wire from the If
meet
installation of the deceleration sensor.
and securely
installed.
If
OFF. Re-
connector.
the warning lamp display does not
check the correctly
ignition switch
DLC1
installation
is
specifications,
must be OK, replace It
the sensor and retest the system.
Deceleration Sensor
REMOVAL
& INSTALLATION
SYSTEM TEST >
See Figures 1
Refer to the speed sensor system
.
87, 88
and 89
Remove
the lower center cover from the instrument
Remove
the 2 bolts holding the deceleration sensor
test.
panel. 2.
COMPONENT TESTING
bracket and 3.
With the
sensor.
The deceleration sensor cle behind the lower
ECU
located It
in
the center of the vehi-
transmits signals to the
regarding deceleration rate.
•The while will
is
dash cover.
is in
the diagnostic mode. The anti-lock system
be disabled; only normal braking function
will
be
available. 1
.
Check the
battery voltage with the engine
should be approximately 12
4.
the unit free. ignition
Remove
OFF, unplug the
wiring connector at the
the sensor and bracket assembly.
install:
Attach the wire harness connector to the sensor.
off;
voltage
lbs. (5.4
Nm).
'•The sensor must be mounted approximately level in the vehicle. The mounting bolts must be equally snug to keep the unit from rocking or being on an angle. 5.
Install
the lower center cover on the instrument panel.
volts.
2. With the ignition switch ON, make certain the REAR ANTI-LOCK warning lamp comes on for about 2 seconds and
Solenoid Relay
then goes out. Turn the ignition switch OFF.
Use DLC1
3.
the
4.
and
a jumper wire to attach terminals Tc, Ts and El at connector.
Apply the parking brake
fully,
Install
the sensor and bracket; tighten the retaining bolts to 48 inch
following procedures require driving the vehicle it
To
lift
REMOVAL & INSTALLATION
depress the brake pedal
start the engine. 1.
Disconnect the negative battery cable.
BRAKES
|N-m (kgt-cm,
ft-lbf)
:
9-39
Specified torque
|
86829g91
Fig.
87 Exploded view of the deceleration sensor mounting
— Pick-Up shown 2.
To 3.
4.
Unbolt the solenoid from the inside of the
right fender.
install:
Mount and secure the sensor. Connect the negative battery cable.
TESTING See Figure 90
>
This relay, mounted on the inside of the right fender under the hood, controls the flow of electricity to the solenoid valve of the actuator. 1.
from 2.
With the ignition switch OFF, remove the control relay bracket. The relay has 6 terminals. Use an ohmmeter to test continuity. There should be
its
continuity 3.
between terminals
1
and
6.
Place the lead of the ohmmeter on terminal
continuity at terminal 5. Place the lead Fig.
88 Remove the lower instrument panel cover
should only be found between terminals 3 and 4.
6.
Apply battery voltage
to terminal
1
for
5.
2;
Solenoid Relay
Fig.
check
4; continuity
and ground terminal
Place the lead of the ohmmeter on terminal
2:
3;
on terminal
+BS
90 The solenoid relay terminal locations
check
for
BRAKES
9-40
on terminal
continuity at terminal 5. Place the lead
should only be found between terminals 2 and All test
5.
relay
conditions must be met.
any
If
4; continuity
5.
test
is
the
failed,
must be replaced.
Electronic Control Unit (ECU)
REMOVAL & INSTALLATION The ECU system.
It
is
the electrical brain of the rear wheel anti-lock
deceleration sensor, determining occur.
speed sensor and the
interprets signals from the
The ECU output
if
wheel lock-up
is
about
to
controls the solenoid relay which ener-
gizes the actuator solenoid. Additionally, the
ECU
system readiness and
code
is
uses other input signals
integrity.
REAR
nate the
fault is
box on the upper underside 1
in
.
Remove
fault
to
determine
be found, a
fault
memory. The ECU will illumiANTI-LOCK warning lamp on the dashboard noted. The ECU is located behind the glove
assigned and stored
when a
Should a
in
of the
the 4 screws and
1
Actuator
dash. bolt holding the
glove box
place and remove the glove box assembly. 2.
Remove
the 2 screws and
place. Gently pull the 3.
ing
Make
ECU down
4.
nut holding the
for
ECU
ECU
REMOVAL & INSTALLATION
in
access.
certain the ignition switch
connector from the
To
1
OFF. Unplug the
is
and remove the
wir-
I
See Figures
^lt
install:
With the ignition OFF, attach the
ECU
95 and 96
93, 94,
unit.
to the wire
will
ABS
be necessary to bleed the system using Toyotas
actuator checker and adapter harness. Refer to the
actuator system bleeding procedure.
harness. the
unit,
tightening the nuts
5.
Install
6.
Reinstall the glove box.
and
bolts snugly.
The
hydraulic actuator contains the solenoid valve as well as
the bypass and cut valves for the brake
power steering
controls the flow of
The power
circuit.
The solenoid
fluid into control circuits.
steering fluid within these circuits act on pistons
which move the bypass and cut valves, controlling the flow brake
fluid.
The actuator
is
of
located at the lower right front of
the engine compartment. 1
Disconnect both battery cables, negative cable
.
move
the battery
and
harness
2.
Disconnect the
3.
Disconnect the two brake
the lines to prevent
electrical
fluid loss
lines
Re-
at the actuator.
from the actuator. Plug
and the entry
Turn the steering wheel clockwise
4.
first.
tray.
of
until
dirt. it
locks.
Remove
power steering pressure may be easier to work through the
the union (banjo) bolts holding the
hoses
to the actuator.
wheel house instead
It
of
from the top.
5.
Disconnect the power steering hose(s).
6.
Remove
the bolt holding the
power steering hose clamp
or retainer. 7.
body. 8.
To 9.
to 9
10.
Remove Remove Remove
vehicle
Remove
the glove box assembly form the
the actuator and bracket together. the bracket from the actuator on the workbench.
install:
Reinstall the bracket to the actuator; tighten the 3 bolts ft.
lbs.
(13 Nm).
Install
ing bolt
Fig. 91
the 3 bolts holding the actuator bracket to the
first,
the actuator to the vehicle;
Tighten each to 21 11.
Using
each
bolt to
install
the front retain-
then the middle one and then the rear most one.
new 34
ft.
lbs.
(28
Nm) when
it
is
installed.
gaskets, connect the pressure unions. Tighten
ft.
lbs.
(47 Nm).
BRAKES
9-41
Union Bolt
ABS
Fig.
93 Exploded view of the
Fig.
94 Unplug the actuator harness
actuator
components
Fig.
95 Using a
line
wrench, disconnect the brake lines
leading to the actuator
BRAKES
9-42
Whenever
power steering hoses are
the actuator or any
disconnected, the actuator should be bled using the following procedure. Normal bleeding of each system all
may
remove
not
the air from the actuator.
1 Bleed the power steering system. Refer to Section The bleeder valve is located on the steering gearbox.
8.
.
Bleed the brake system with the engine running. Bleed
2.
the brake system again with the engine
Disconnect the wiring harness
3.
off.
at the actuator
and
at the
solenoid relay.
Connect the
4.
and body
relay
ABS
checker and harness
to the actuator,
wiring harness, using the adapters as
necessary.
Connect the red cable
5.
of the
checker
and the black cable
battery terminal
to the positive
to the negative battery
terminal.
96 After the actuator be separated from it Fig.
is
removed, the bracket can
12.
Connect the power steering hose(s) and secure the hose the retaining clamp and tighten the
13.
Install
14.
Connect the 2 brake
15.
lbs.
16.
Install
17.
Fill
18.
first.
Tighten the lines
checker
to the
AIR it
it;
do
for
about 3
5 times.
this
WARNING Do not push the ON/OFF switch before the brake pedal is depressed master cylinder damage may occur. Do not release the brake pedal while the switch is engaged. Do not hold the ON/OFF switch ON more than 5-7 seconds.
—
(15 Nm).
the battery and tray; connect the cables.
the brake
ABS
depress the brake pedal and hold
Push the ON/OFF switch (on the checker)
8.
Connect the
Attach the electrical harness to the actuator.
correct
position. Strongly
at idle.
it
that position.
bolt.
lines to the actuator.
painted line to the painted actuator port ft.
Turn the selector switch on the
seconds and release
clamp(s).
to 11
Start the
7.
BLEED 9. in
engine and run
6.
fluid
and power steering reservoirs with the
fluid.
After 5 repetitions, release the switch
Bleed the brake system and power steering system.
and then release
the brake pedal.
Check the
10.
Actuator System Bleeding
level of the
their reservoirs; top off
power steering and brake
fluids in
each as necessary using the correct
fluid.
^This procedure tuator Checker
requires the use of the Toyota
ABS
Ac-
and 09990-00205) or
1 1
Disconnect and remove the
.
ABS
checker. Reconnect the
system harness.
and adapter harness (Tools 09990-00150 their equivalent.
4-WHEEL ANTI-LOCK BRAKE SYSTEM ABS
Under normal conditions, the
General Information Anti-lock
Brake Systems (ABS) are designed
to prevent
steering force
continue
in
if
The
front
wheels
of
a vehicle cannot apply
they are locked and sliding; the vehicle
the previous direction of travel.
point of locking, thereby allowing
some
will
just
below the
steering response
and
preventing the rear of the vehicle from sliding sideways. for
ABS system
which the
when the tires ride on a film paved surface. This renders
the vehicle totally uncontrollable
until
Hydroplaning
is
possible
Extreme steering maneuvers
yond the
limits of tire
independent
named
adhesion can
of vehicle braking.
road contact
is
regained.
speed or cornering be-
at high
is
For this reason, the system
is
anti-iock rather than anti-skid.
Wheel
spin during accel-
on slippery surfaces may also fool the system into detecting a system failure and entering the fail-safe mode.
The
fluid to
the wheels
when necessary.
Electronic Control Unit
(ECU)
is
the electronic brain of
speed sensors. The
unit will enter anti-lock
senses impending wheel lock
at
mode when
any wheel, and
will
it
immedi-
ately control the brake line pressures to the affected wheel(s) to the actuator
assembly.
The actuator contains solenoids which react to the signals from the ECU. Each solenoid controls brake fluid pressure to one wheel. The solenoids allow brake line pressure to build according to brake pedal pressure, hold (by isolating the sys-
tem from the pedal and maintaining current pressure) or de-
which
result in skidding
brake
by issuing output signals
provides no
of water, losing contact with the
benefit.
the
the system, receiving and interpreting signals from the wheel
The 4-wheel ABS
system used on Toyota trucks holds the wheels
There are conditions
in
hydraulic components, working together to control the flow of
locked-wheel skidding during hard braking or during braking on slippery surfaces.
system functions
same manner as a standard brake system and is transparent to the operator. The system is a combination of electrical and
crease (by isolating the pedal from the
circuit
and bleeding some
The decisions regarding these
functions are
made
very rap-
eration
idly,
as each solenoid can be cycled up
second.
fluid
line).
to
10 times per
BRAKES The operator may
feel
a pulsing
in
when
hear popping or clicking noises
Visual Inspection
the brake pedal and/or the system engages.
These sensations are due to the valves cycling and the pressures being changed rapidly within the brake system. While completely normal and not a sign of system failure, these sensations can be disconcerting to an operator unfamiliar with the system.
ABS
Although the
system prevents wheel lock-up under hard
braking, as brake pressure increases, wheel slip
increase as well. This
ABS
slip will result in
The sound should
operation.
9-43
some
steering systems are
correct working order.
in
problems (dragging parking brake, seepage,
ABS
system.
may
reveal problems creating an apparent
Performing
A
check
visual
and power
Many common
etc.) will affect the
system components
of specific
may
this inspection
allowed to
is
make
Before diagnosing an apparent rear anti-lock problem, absolutely certain that the normal braking system
ABS
malfunction.
reveal a simple failure, thus
eliminating extended diagnostic time. chirp during
tire
•
Inspect the brake
•
Inspect lines, hoses, master cylinder assembly, brake
not be interpreted as lock-up
but rather as an indication of the system holding the wheel(s)
the reservoir.
fluid level in
cali-
pers and cylinders for leakage. Inspect the power steering sys-
just outside the locking point.
tem and components
same
for the
conditions.
• Visually check lines and hoses for excessive wear, heat
Diagnosis and Testing
damage, punctures, contact
with other parts, missing clips or
holders, blockage or crimping.
• Check the calipers or wheel cylinders for rust or corrosion. Check for proper sliding action applicable. • Check the caliper and wheel cylinder pistons for freedom
PRECAUTIONS
if
• Certain
components
within the
system are not intended
motion during application and release.
of to
Inspect the speed sensor for proper mounting and correct
•
be serviced or repaired
and
with removal
installation
procedures should be serviced.
hoses or other parts not
not use rubber
specified for the anti-lock system.
place
parts included
all
Use only
• •
If
DOT
the
in
3 brake
is
removed
using repair
A
code and
Excessive wheel spin
(either it
power steering
may be necessary
or
to bleed
is
essential.
Always clean the reser-
and cap thoroughly before removing the cap. The slightest amount of dirt in the fluid may plug an orifice and impair the function. Perform repairs after
components have been
thoroughly cleaned; use only denatured alcohol to clean com-
Do
components
not allow
any substance containing mineral
to
oil;
come
into contact with
lamp.
The ECU
electricity
These induced
is
a failed sensor but a loose,
exam-
are due to loss of sensor sigThe most common cause is not corroded or dirty connector. Check
harness and component connectors
carefully.
Reading Codes
a microprocessor similar to other computer
OFF
is
1.
If
discharge at or near the controller.
any arc welding
is
to
be done on the
If
the vehicle
ECU
is
to
be baked
Turn the
ignition switch
approximately 12 volts 2.
Turn the
is
vehicle, the
ECU
ignition switch
does not come on, 3.
remove
after paint repairs,
from the vehicle.
lamp
fault(s).
will
will
assign and store a
The dashboard warning lamp
will
identify the fault
code
problem
for the
be illuminated
to
ignition
a
If
will
fault
will
transmit the stored
code(s) by flashing the dashboard warning lamp.
If
two or
more codes are stored, they will be displayed from lowest number to highest, regardless of the order of occurrence. The system does not display the diagnostic codes while the vehicle running.
code
Once
is
set,
to the first digit of
a
that the
3 seconds.
If
ABS the lamp
Tc and El
of the
not the service connector.
the dashboard warning later.
2-digit
The number code; after a
digit is transmitted.
If
of flashes 1
.5
a second
will be displayed after a 2.5 second pause. codes have been displayed, the entire series will it
repeat after a 4 second pause.
no
is
begin to blink 4 seconds
stored,
all
for
ON.
code has been
the warning lamp
inform the driver that a fault has been found.
During diagnostics, the system
and check
wire to attach terminals
second pause, the second a malfunction occurs, the system
ON
Data Link Connector (DLC1). This Turn the
battery condition;
repair the fuse, bulb or wiring.
Use a jumper
corresponds
and the computer
OFF. Check
required to operate the system.
dashboard warning lamp comes on
INSPECTION
is
failures but
nals to or from the controller.
4.
If
system
faults are not
Many system shut-downs
•
should be disconnected before welding operations begin.
the
riding the
also set fault codes and trigger a warning
unit.
trol
before removing or installing controller harnesses. Avoid static
•
may
I See Figure 97
units in the vehicle. Insure that the ignition switch
•
light.
used shop
this includes
rags.
•
dash warning
trigger the
on low-traction surfaces, high speed acceleration or
voir
ponents.
set a fault
ples of vehicle performance outside the parameters of the con-
clean repair area
system
faults,
fully, will
brake pedal
the entire system. •
occurrence. Certain driver induced
fault
such as not releasing the parking brake re-
kits,
from an unopened container.
fluid
or replaced,
When
Confirm the
specifically
kit.
any hydraulic component
brake)
connection. •
Do
•
Only those components
individually.
will
If
no codes have been stored,
flash continuously every 'k
second with
variation. 5.
Turn the
6.
Check
ignition switch
OFF.
or repair the system as indicated by the fault
code. 7.
After repairs are completed, clear the
memory. troller
If
the battery
memory
will
is
codes from the
disconnected during repairs, the con-
be erased of
all
stored codes.
BRAKES
9-44
Diagnosis
Light Pattern
Coda No.
M1MM1W1M.
off
All
Malfunctioning Part
speed sensors and sensor rotors are normal
•
Low
iiriiiarmiLTL
71
voltage of right front speed sensor signal
sensor •
•
Low
72
voltage of
left
front
speed sensor signal
•
Low
jinrmjuiri_riru^
voltage of right rear speed sensor signal
•
Low
jmiiiimrLJiRJirL
voltage of
left
Abnormal change
JUlTLJlJir^
75
rear
speed sensor signal
of right front
of
installation
Left rear
speed
speed sensor
•
Right front sensor
installation
left
front speed sensor
•
Left front
sensor
of right rear
speed sensor
•
Right rear sensor rotor
Abnormal change
of
left
speed sensor
rear
•
signal
rumrumrinrL
Sensor
Sensor
signal
jinrijinjiri
Right rear speed
rotor
Abnormal change
79
installation
•
signal
78
Sensor
rotor
Abnormal change
77
speed
Left front
sensor
signal
76
installation
sensor •
74
Sensor
sensor •
73
Right front speed
Left rear
sensor
rotor
Deceleration sensor
is
•
Deceleration sensor
•
Sensor
faulty installation
86829gll
Fig.
8.
97 Diagnostic trouble codes for 4-wheel
Remove
the jumper wire
if
ABS
one was used and reattach
Speed Sensor
the service connector at the actuator.
Clearing 1
.
2.
Codes
SYSTEM TEST
Detach the service connector
Use the jumper
at the actuator.
wire to connect terminals Tc and El of
the Data Link Connector (DLC1). Turn the ignition 3.
Clear the diagnostic trouble codes stored
in
'••The following procedures require driving the vehicle
ON. the
ECU
by
depressing the brake pedal 8 or more times within 3 seconds. 4.
After the rapid pedal application, the
dash warning lamp
should display constant flashing, indicating a normal system.
while
still
system are brake pedal 5.
Once
displayed,
make
certain the repairs
correct. Also inspect the for
any binding or
brake
light
made
If
to the
switch at the
.
working on a
4WD
the codes are cleared, disconnect the jumper wire. ing
will
be
Turn the
at the 4.
make
certain
it
is
only
make
certain the
ABS
about 3 seconds and then goes
for
ignition switch
in
OFF; voltage
volts.
With the ignition switch ON,
lamp comes on
3.
vehicle,
the battery voltage with the engine
should be approximately 12 2.
out.
If
2WD. Check
sticking.
The dash warning lamp should go
the diagnostic mode. The anti-lock system
available. 1
codes are
is in
it
be disabled; only normal braking function
will
warn-
out.
OFF.
Using a 3-way jumper, connect terminals Tc, Ts and El
Data Link Connector (DLC1). Pull the parking
brake on securely and
start the
motor
without stepping on the brake pedal. Depressing the brake
BRAKES pedal
will
cause the system
either void the test or
different diagnostic
to enter
a
mode.
2.
(FL+).
Measure the resistance between terminals The resistance should be as follows: • 4Runner 1.4-1. 8k ohms
— — 0.6-1 .8k ohms Land Cruiser — 0.97-1. 77k
The dashboard warning lamp should flash evenly about instead, a code is flashed, repairs must be made and the code(s) cleared before continuing. If the light does not flash, check the parking brake switch, the DLC1 connector and the wiring to the ABS controller. 6. To check the sensor signal level, release the parking brake and drive the vehicle straight ahead at low speed. Once a speed of 2-5 mph (3-8 km) is reached, the warning lamp should turn off. Once the light has gone off, should begin to blink as the vehicle leaves the speed range. This blinking is normal and indicates the speed sensor is operating correctly. If
and the sensor body.
no blinking occurs, the system
Replace
5.
4 times per second.
it
7.
Check the sensor
signal
on the road. Once a speed
of
is
defective.
change by
ond pause. As before, the lamp should system
speed range;
•
is
the resistance
If
4.
Check
is
that there If
is
ohms
not as specified, replace the sensor.
no continuity between each terminal
there
is
continuity, replace the sensor.
5.
Attach the speed sensor harness.
6.
Check
the installation of the sensor.
loose, tighten
Remove
it
to
69 inch
lbs. (8
the mounting bolt
the axle hub with the rotor. Inspect the sensor
rotor serrations for scratches, cracks, if
If
Nm). warping or missing teeth.
necessary.
^•To prevent from damaging the serrations, do not
blink evenly
the axle hub with the rotor. sec-
as the
failure to blink indicates
8.
Reconnect the speed sensor
to the harness.
a
fault.
(While cle to
the warning lamp is off, do not subject the vehiany shocks or impact such as shifting, acceleration,
deceleration or road impact. 8.
brake
Stop the vehicle fully.
Read and
in
a safe location and apply the parking
record any stored codes which are
displayed. 9.
Turn the
ignition switch
OFF; remove the jumper wire
from the DLC1 connector.
COMPONENT TEST Front Sensor >
See Figures 1.
98, 99, 100, 101
and 2
T100
3.
7.
(FL-)
driving the vehicle
mph (40-50 km) is come on after a one
25-31
achieved, the warning lamp should
vehicle leaves the
•
If,
1
9-45
and 102
Unplug the speed sensor connector.
100 Using an ohmmeter, check for continuity between the sensor and the terminals Fig.
strike
BRAKES
9-46
Fig. 101
The sensor
secured by a single bolt
is
Fig.
103 Unplug the harness leading to the rear sensor
Rear Sensor I
See Figures 1.
103, 104, 105
and 106
Unplug the speed sensor connector.
Measure the resistance between the terminal 1 (RL-) and 2 (RL+). The is 1 is (RR-) and 2 is (RR+) resistance should be as follows: 2.
— 0.6-2.05k ohms — 0.5-1. 6k ohms
•
T100
•
Land Cruiser
•
4Runner—
If
4.
Check
is
that there
and the sensor body.
is
ohms
1.0-1 ,4k
the resistance
3.
If
is
not as specified, replace the sensor.
no continuity between each terminal
there
is
continuity, replace the sensor.
5.
Attach the speed sensor harness.
6.
Check the
loose, tighten 7.
Remove
installation of the sensor. it
to
69 inch
lbs. (8
86829gb4
the mounting bolt
Nm).
the axle hub with the rotor. Inspect the sensor
rotor serrations for scratches, cracks,
^To
If
warping or missing teeth.
prevent from damaging the serrations, do not strike
the axle hub with the rotor.
Fig.
105 Using an ohmmeter, check for continuity on
the sensor
BRAKES
9-47
Rear Front >
I
See Figures 109 and 110
See Figures 107 and 108 1
Unplug the speed sensor harness
.
On 4WD
2.
vehicles,
to the unit.
remove the clamp
bolts
and
holding the sensor harness from the frame, upper
clips
arm and
steering knuckle.
On 2WD
Unplug the speed sensor harness
Remove
(if
Remove
4.
To
(Discard the old 3.
4.
the sensor from the knuckle.
5.
lbs. (7-8
clips.
the sensor from the axle.
Attach the sensor to the axle, tighten to 69-71 inch
lbs. (5-8
used
the
all
new
clips,
and
install
them
in
the
removed ones. 6.
Engage
the sensor harness to the
Nm).
4WD:
Fig.
lbs.
Attach the harness along the appropriate areas, then
tighten the mounting bolts to 48-71 inch lbs. (5-8 to
Nm).
Tighten the mounting bolts to 48-71 inch
Remove install:
(7-8 Nm).
Attach the harness along the upper arm and frame with
6.
new
old clips.
Attach the sensor to the steering knuckle, tighten to
69-71 inch
clips.
vehicles,
install:
5.
tank
fuel
attached).
To ^Discard the
to the unit.
the clamp bolts and nuts holding the sensor
harness from the frame, upper arm, axie housing and
remove the clamp bolts and clips holding the sensor harness to the frame and upper arm. 3.
1.
2.
107 Exploded view of the front speed sensor mounting and harness routing
— T1 00 shown
unit.
Nm). Be sure
same
angle of
BRAKES
9-48
Use a jumper
3.
wire to attach terminals Ts and El at the
Data Link Connector (DLC1). Apply the parking brake
4.
and
depress the brake pedal
dashboard warning lamp should
After a short delay, the
5.
flash
fully,
engine.
start the
about 4 times every second. Stop the vehicle on a
level
surface for about one second. Drive the vehicle straight
6.
greater speed off
when
for.
Stop the vehicle, then the
7.
of number 10. 8. The
blinks of the
light
light will
Tc and El
ABS
begin to
of the
be displayed
blink.
switch
is
Remove nals of the
OFF
the
in
Attach
light.
same
If
time, the smallest
2 or more numbered
first.
Repair any malfunctioning parts. Be sure the
9.
should be
DLC1. Read the
about 2 times ever second.
light blinks
blinks are indicated at the will
28 mph (45 kph) or
at
The warning
works normally.
it
the jumper wire to terminals
code
ahead
several seconds.
ignition
position.
the jumper wire from the Tc,
Ts and El
termi-
DLC1.
Actuator
SYSTEM TEST
REMOVAL & INSTALLATION
Refer to the speed sensor system
>
test.
COMPONENT TESTING ^The will
following procedures require driving the vehicle
1.
Disconnect and plug the brake
2.
Unplug the
3.
Remove
ABS
the bolts and nuts to release the assembly from
Unbolt the unit from the bracket.
4.
it
To
install:
5.
available.
Attach the
ABS
actuator to the bracket, tighten the
mounting nuts to 48 inch 1
.
Check the
battery voltage with the engine
should be approximately 12 2.
ing
lines.
connectors from the actuator.
the vehicle.
is in the diagnostic mode. The anti-lock system be disabled; only normal braking function will be
while
See Figures 111 and 112
volts.
With the ignition switch ON,
lamp comes on
Turn the
for
ignition switch
OFF; voltage
Install
certain the
ABS
warn-
out.
7. ft.
lbs.
lbs. (5
Nm).
the actuator with bracket to the vehicle, tighten
the mounting bolts to 14
make
about 2 seconds and then goes
OFF.
6.
ft.
lbs.
(19 Nm).
Attach the brake lines to the actuator, tighten them to (15 Nm).
1
BRAKES
9-49
9-50
BRAKES
BRAKE SPECIFICATIONS All
measurements
in inches unless noted Brake Drum Diameter
Master Cylinder
Bore
Model
Year
Lining
Maximum
Inside
Wear
Machine
Thickness
Runout
Diameter
Limit
Diameter
Thickness Thickness
0
©
©
NA
0.787
0.709
0.0035
Land Cruiser
NA
0.787
0.748
Pick-up
NA
0
©
4Runner
NA
0.787
Land Cruiser
NA
0.787
0
-
11.61
-
0.0059
11.61
©
0.709
0.748
Front
Rear
©
0.039
0.039
11.69
0.039
0.039
-
11.69
0.157
0.059
0
-
©
0.039
0.039
0.0035
11.61
-
11.69
0.039
0.039
0.0059
11.61
-
11.69
0.157
0.059
Pick-up
NA
0
©
©
0
-
4Runner
NA
0.787
0.709
0.0035
11.61
-
Land Cruiser
NA
0.984
0.906
0.0059
11.61
-
Pick-up
NA
0
©
0
T100
NA
0.984
0.906
© ©
-
11.61
-
4Runner
NA
0.984
0.906
0.0035
11.61
-
Land Cruiser
NA
0.984
0.906
0.0059
11.61
Pick-up
NA
0
©
T100
NA
0.984
0.906
© ©
4Runner
NA
0.984
0.906
Land Cruiser
NA
1.260
Pick-up
NA
0
T100
NA
4Runner
©
0.039
0.039
11.69
0.039
0.039
11.69
0.059
0.059
©
0.039
0.039
11.69
©
©
11.69
0.059
0.039
-
11.69
0.059
0.059
0
-
©
0.039
0.039
11.61
-
11.69
0
©
0.0035
11.61
-
11.69
0.059
0.039
0.0059
11.61
-
11.69
0.059
0
©
0.0035
0
-
©
0.039
0.984
0.906
©
11.61
-
11.69
0 0
NA
0.984
0.906
0.0035
11.61
-
11.69
0.059
0.039
Land Cruiser
NA
1.260 (©
1.181
0.0059
11.61
-
11.69
0.059
0
Pick-up
NA
©
©
0.0035
0
-
©
T100
NA
0.984
0.906
©
11.61
-
11.69
0 ©
0.039
4Runner
NA
0.984
0.906
0.0035
11.61
-
11.69
0.059
0.039
Land Cruiser
NA
1.260
0.0059
11.61
-
11.69
0.059
0
Tacoma
NA
0.866
0.787
0.0028
0
-
©
0.039
0.039
T100
NA
0.984
0.906
©
11.61
-
11.69
©
©
4Runner
NA
0.984
0.906
0.0035
11.61
-
11.69
0.059
0.039
Land Cruiser
NA
1.260
0.0059
11.61
-
11.69
0.059
0
Tacoma
NA
0.866
0.0028
©
-
©
0.039
0.039
1992
1993
1994
1995
1996
-
Not Available
2WD 2WD
(PD60 type
disc):
(PD66 type
disc): 1.181
2WDIFS17.
4WD 2WD 2WD 2WD 4WD
(SI
disc):
disc):
(PD66 type
disc): 1.102
(S12+12 type
2WD:
10.00,
4WD:
©
ft
1.181
ft
1.181
fa
0.787
disc):
11.61
5 2WD: 10.08; 4WD: 11.69
©
12
2WD:
0.866;
4WD: 0.787
2WD:1 Ton 0.0035
13
2WD:
0.787;
4WD: 0.709
4WD: 0.0028
14
2WD:
0.059;
4WD: 0.039
2WD:
1
Ton 0.374
4WD: 0.374
0.906
disc):
©
6 2WD:1/2 Ton 0.0028
0.787
(PD60 type
(FS17, 18 type
(S)
©
1.181
'
7 2WD: 1/2 Ton 0.433
18 type disc): 0.866
2+ 12 type
Q
0.984
8
0.787
2WD: 0.276 4WD: 0.236
0.709
3 PD60.FS17. FS18, S12+12 type 4
Minimum
4Runner
1991
2
Maximum
NA
1990
NA
Max.
Pick-up
1989
1
Original
Minimum
Original
Brake Disc
9 Rear disc:
0.0035
disc:
0.630
10 Rear disc: 0.709 11
Brake shoe Disc pad
lininq:
lining:
0.059
0.039 86829c50
EXTERIOR
ANTENNA 10-16 DOORS 10-2 FRONT OR REAR BUMPER GRILLE
HOOD
10-11
10-11
10-2
OUTSIDE MIRRORS
REAR DOOR 10-6 REMOVABLE TOP
SUNROOF TAILGATE INTERIOR
10-11
10-17
10-17 10-6
DOOR GLASS AND REGULATOR
10-51
DOOR LOCKS 10-51 DOOR PANELS 10-39 INSTRUMENT PANEL 10-23 REAR QUARTER WINDOW AND REAR WINDSHIELD 10-55 SEAT BELTS 10-66 SEATS 10-57 TAILGATE WINDOW 10-52 WINDSHIELD GLASS 10-52
AND TRIM EXTERIOR
10-2
INTERIOR 10-23
BODY AND TRIM
10-2
EXTERIOR Although the
REMOVAL & INSTALLATION
.
are using the proper size 1
Matchmark the hinge-to-body and hinge-to-door locations. on jackstands or have somebody hold
.
Either support the door it
for you.
claw and
pull
push
with a center door check,
in
on the
out the stopper pin. Alternatively, unbolt the door
it
may be necessary
Remove Remove
4.
to
5.
door
If
compensate
^Do
the lower hinge-to-door bolts. the upper hinge-to-door bolts and
lift
the hinges are being replaced,
The
fit.
striker
this
may be
adjusted
to-
thereby tightening or
can be moved up and down
door position, but
hinges
at the
Additionally,
3.
remove them from the
added
if
the door
is
correctly
should not be necessary.
some models may use one or more spacers These shims may be removed or
install:
6.
Install
7.
Adjust the door and tighten the hinge bolts to 15-22
in
combination to adjust the reach of the
After the striker bolts
4.
striker.
have been tightened, open and
close the door several times. Observe the motion of the door
and hinges
the door
with the bolts finger-tight.
as
engages the
it
ft.
and not
tion
(20-30 Nm). the door check.
striker;
deflect
Check the
5. Install
for
striker
of the car,
or shims behind the striker.
pillar.
8.
The
not attempt to correct height variations (sag) by ad-
the door
To
lbs.
bolts.
justing the striker.
the hinges.
off
mounting
loosening the door
mounted
disconnect various wires running into the door.
striker to
the released
and close the door. The striker will move into the match the door latch. Open the door and
position
to
^Depending on equipment,
in
correct location to
wards or away from the center
check from the door.
3.
necessary, hold the outer door handle
if
tighten the
On models
2.
bit.
With the bolts just loose enough to allow the
2.
move 1
it
Loosen the large cross-point screw(s) holding the striker. Know in advance that these bolts will be very tight; an impact screwdriver is a handy tool to have for this job. Make sure you 1
> See Figure
and style may vary between models method of adjusting is the same:
striker size
or from front to rear, the
linear,
it
may be necessary
its
straight-in
mo-
hits the striker.
opening and closing.
It
without any trace of grinding or
engagement and
binding during It
should continue
feel of the latch during
must be smooth and
ADJUSTMENT
it
up or down as
release.
adjustment several
to repeat the striker
times (and possibly re-adjust the hinges) before the correct
I See Figures
When
2,
door
3 and 4
checking door alignment, look carefully at each
seam
way around the door. Pay particular attention to seams at the corners farthest from the hinges; this
the area
where
even
all
is
produced.
the
door should
errors
pull
will
be most evident.
when latched to seal The contact should be even all the way
around and the stripping should be about position of the door
and
sions: fore
is
REMOVAL
& INSTALLATION
Additionally, the
against the weatherstrip
out wind and water.
The
body match
Hood
between the door and body. The gap should be constant and the door
to
up and down,
aft,
half
can be adjusted in
and
in
out.
compressed.
I
See Figures
5,
6 and 7
^You’ll need an assistant for
this job.
three dimen-
The primary
adjusting points are the hinge-to-body bolts. Apply tape to the
1.
Open
2.
Matchmark the hood-to-hinge position. Disconnect the washer hoses.
3.
Two layers of common masking tape works well. Loosen the bolts (using SST 09812-00010 necessary) just enough to allow the hinge fender and door edges to protect the paint.
Remove
4.
To
the hood.
the hood-to-hinge bolts and
lift
off
the hood.
install:
if
to
move. With the help
of
an
assistant, position the door
retighten the bolts. Inspect the door
peat the adjustment
The
until correctly
in-out adjustment
(how
seams
carefully
and
re-
door “sticks out” from the
body)
is
move
the door into place, then retighten the bolts. This dimen-
6.
Tighten the hinge bolts to the body of the vehicle.
7.
Adjust
amount
of “bite”
amount on the
of crush
is
made
ADJUSTMENT
striker.
>
at the latch plate or striker. This piece
located at the rear
bodywork; closed.
necessary.
on the weatherstrips and
See Figures
Further adjustment for closed position and smoothness of latching
if
adjusted by loosening the hinge-to-door bolts. Again,
sion affects both the
the
into position aligning the
matchmarks.
aligned.
far the
With a helper, place the hood
5.
and
it
is
edge
of the
door and
the piece the latch
is
**A
is
is
place. will
and 12
is used as the hood hinge The hood cannot be adjusted with this bolt in Remove it and substitute a bolt and washer which
tapered, self-centering bolt
set bolt.
attached to the
engages when the door
8, 9, 10, 11
allow adjustment.
BODY AND TRIM
Door Weatherstrip
10-3
Outside Rear View Mirror
Door Gtass Run
Glass Channel
Door Outside Handle
Door Lock Cylinder
Rear Lower
Frame
Armrest
Door Inside Handle Bezel (E?)
Armrest Base Armrest panel base upper
Courtesy Light 86820g76
Fig. 1
Exploded view of a typical front door
— 1995-96
Land Cruiser shown
10-4
BODY AND TRIM
86820p02
Fig. 5
Matchmark the hood hinges with
a
marker
86820p04
Fig. 6
Don’t forget to disconnect the washer hoses
86820p03
Fig. 7
the
Unbolt the hinges while an assistant supports
hood
BODY AND TRIM
1
.
Loosen the hood
fore-and-aft
10-15 2.
ft.
and
to
hinge bolts
slightly.
10-5
Adjust the hood
left-and-right directions. Tighten the bolts to
(13-20 Nm).
lbs.
Adjust the front edge of the hood by turning the two
cushions higher or lower. The hood should align with the fender edges. 3.
Except on the Land Cruiser, remove the wiper arms,
then remove the cowl cover below the windshield. Inside the
cowl plenum, adjust the hinge-to-body bolts to control the height of the rear of the hood. Reinstall the cowl panel and wipers. 4.
On
the Land Cruiser, the rear hood height
is
adjusted by
loosening the four mounting screws holding the hinge to the firewall. 5.
latch 6.
Loosen the hood by moving
it
latch retaining bolts
up-down or
and adjust the
left-right.
Close the hood and check the tension needed
the hood.
If
to release
the release requires excessive force, the latch
is
under tension and must be adjusted.
'Be
sure to tighten
all
fasteners after the adjustments are
complete.
Fig.
9 Adjust the hood
right directions
in
the fore-and-aft and left-and-
86820p01
Fig. 11 Most trucks have a ribbed, rubber cylindrical cushion seated on the front of the upper tie bar
10-6
BODY AND TRIM Rear Door
Tailgate
REMOVAL & INSTALLATION
REMOVAL & INSTALLATION I
See Figures 13 and 14 1.
Remove
2.
Disconnect the
4Runner >
the service hole cover.
See Figure 15 i
tail
gate
link
from the lock control.
If
1
needed, remove the outer gate handle.
.
Lower the door glass
into the
door
all
the way.
Remove the bolts and clamps holding the torsion bar the door. Remove the clip. 3. Remove the torsion bar and bolts from the door. Remove the torsion bar guide. 4. Remove the two bolts and the door stay. 2.
3.
Remove
4.
Unbolt the tailgate hinges.
5.
Remove
6.
Installation
the tailgate stay from the gate.
the tailgate and torsion bar. is
the reverse of removal.
5.
to
Support the door, then remove the hinge bolts and the
door. 6. ft.
|
N-m
(kgf -cm,
ft
-
Ibf )
: |
lbs.
Reinstall
in
reverse order. Tighten the hinge bolts to 22
(29 Nm).
Specified torque 86820g41
Fig.
13 Exploded view of the tailgate assembly
— Pick-Up
BODY AND TRIM
Fig.
14 Exploded view of the tailgate assembly
|N
m
(kgfcm,
ft
lbf)|
:
— T100
Specified torque
86820g45
Fig.
15 Exploded view of the rear door assembly
— 4Runner
10-7
BODY AND TRIM
10-8
Land Cruiser
UPPER DOOR I See Figures 16 and 17
*>An
assistant
is
25
Remove
the hinge bolts and
5.
Reinstall
in
the inner door panel trim. Unplug any wiring
for
harnesses running between the door and body.
Remove
the bolts holding the door supports to the door.
3.
Support the door
in
4Runner
a convenient position allowing ac>
cess
to the
4.
Remove
the hinge bolts and
remove the door. The door
when
re-
ft.
To
1.
Reinstall in reverse order, tightening the hinge bolts to lbs.
To
2.
17
2.
Fig.
the inner trim panel.
Disconnect the wiring to the license plate
adjust the door fore-and-aft, as well as left-to-right,
light
and other
— 1989-92
When
adjusted, retighten to
(23 Nm).
Adjust the door striker as follows:
a.
Loosen the
b.
Using a plastic hammer, tap the
equipment.
16 Exploded view of the rear door assembly
adjusted, retighten to
adjust the door vertically, as well as left-to-right,
lbs.
ft.
When
(33 Nm).
lbs.
ft.
3.
Remove
electrical
and 20
loosen the door side hinge bolts.
(29 Nm.).
LOWER DOOR .
18, 19
loosen the body side hinge nuts.
25
moving or carrying the door. 5.
See Figures
hinge bolts.
reasonably heavy and not balanced. Use caution
1
(34 Nm).
lbs.
ft.
remove the door.
reverse order, tightening the hinge bolts to
required for this procedure.
2.
connectors
22
Disconnect the stays.
4.
ADJUSTMENT Remove
1.
is
3.
Land Cruiser
striker
mounting screws
to adjust.
striker to adjust.
BODY AND TRIM
Fig.
17 Exploded view of the rear door assembly
— 1993-96
Land Cruiser
10-9
10-10
BODY AND TRIM Land Cruiser t See Figures 21, 22, 23 and 24 1
Adjust the upper and lower rear doors fore-and-aft and
.
left-to-right
as follows:
a.
Adjust the door by loosening the door side hinge bolts.
b.
Move
the hinge into the appropriate direction with your
hand or a plastic hammer. 2. To adjust the upper and lower doors and
vertical directions,
in
the left-to-right
loosen the body side hinge
bolts.
Adjust the door striker as follows:
3.
a.
Check
that the
door
fit
and door
lock linkage are ad-
justed correctly. b.
Adjust the striker position by slightly loosening the
striker
mounting screws, then
hitting
the striker with a plastic
headed hammer. Tighten the mounting screw when the adjustment
is
appropriate.
BODY AND TRIM Remove any
2.
trim pieces,
comer moldings,
10-11 etc.
on the
bumper.
Remove
3.
and
the nuts
bolts attaching the
bumper
to the
frame. Installation is the reverse of removal.
4.
Grille
REMOVAL & INSTALLATION
2.
Open and support the hood. Remove the turn signal and
3.
Unscrew the
4.
Reverse
1.
grille
parking lamps.
assembly.
to install.
Outside Mirrors
REMOVAL & INSTALLATION The right
removed from the door without disasother components. Both left and
mirrors can be
sembling the door
liner or
outside mirrors
(small lever
may be
on the inside
cases, electric remote.
If
either manual,
manual remote
to adjust the mirror) or, in
the mirror glass
is
some
damaged, replace-
ments may be available through your dealer or a reputable glass shop.
If
the plastic housing
entire mirror unit 1.
If
the mirror
justing handle
cracked or damaged, the
is
manual remote, check
to
see
if
the ad-
retained by a hidden screw, usually under an
is
end cap on the
is
must be replaced.
lever.
If
so,
remove the screw and remove the
adjusting knob. 2.
Using a blunt plastic or wooden
triangular cover from
Don’t use a screwdriver; the plastic 3.
tool,
remove the inner
where the mirror mounts
Depending on the model and
will
to the door.
be marred.
style of mirror, there
may
be concealment plugs or other minor parts under the cover.
Remove 4.
Front or Rear
Bumper
them.
If
electric
connectors are present, unplug them.
Support the mirror housing from the outside and remove
the three bolts or nuts holding the mirror to the door.
Remove
the mirror.
To
REMOVAL & INSTALLATION I
See Figures
25, 26, 27,
28 and 29
install:
When
installing,
fit
nuts and bolts to hold
it.
5.
attention to the
the mirror to the door, then
Connect any
wiring.
placement and alignment
of
Pay
Support the bumper.
may
result
from careless work. 6.
Install
the cover, pressing
the control lever knob
if
it
it
firmly into position. Install
was removed.
the
any gaskets or
weatherstrips around the mirror; serious wind noises 1.
install
particular
10-12
N-m
(kgf
BODY AND TRIM
cm,
ft
lbf)|
:
Specified torque 86820g62
Fig.
25 Exploded view of the front bumper components
— 4Runner
BODY AND TRIM
10-13
10-14
BODY AND TRIM
Rear Bumper Step
86820g€3
Fig.
27 Exploded view of the rear bumper components
— Land
Cruiser
BODY AND TRIM
Fig.
28 Exploded view of the front bumper components
— T1 00
10-15
10-16
BODY AND TRIM
86820g65
Fig.
29 Exploded view of the front bumper components
— Tacoma
Antenna
3.
Outside, unsnap the cap from the antenna base.
4.
Remove
cable with
To
REMOVAL & INSTALLATION
5. is
If
your antenna mast
is
the type
where you can unscrew the
mast from the fender, simply do so with a
damaged antennas similar mishap, in
pair of pliers.
are simply the result of a truck
which the mast
is
wash
Most
it,
the screw(s) and
When
reinstalling,
or
make
7.
the antenna, pulling the
Install
antenna mount area The antenna must make a
certain the
dirt.
proper ground contact through
its
base
to
work properly.
the screws and route the cable into the cab.
certain the cable
bent.
off
install:
clean and free of rust and
6.
lift
carefully.
is
retained
Connect the cable
in
Make
the clips, etc.
to the radio; reinstall the radio
if
it
was removed. Manual Antenna
Power Antenna Mast 1
.
Disconnect the antenna cable at the radio by pulling
straight out of the set.
Depending on access,
loosening the radio and pulling 2.
from
it
this
may
it
require
out of the dash.
Working under the instrument panel, disengage the cable its
retainers.
»»On some models,
it
may be necessary
instrument panel pad to get at the cable.
to
remove the
^The power
antenna system contains a relay. If the power antenna is inoperative, the relay is the first place look. The actual motor rarely fails.
to
BODY AND TRIM The power antenna mast is replaceable on the Pick-Up and 4Runners. If the mast is damaged or broken, proceed as follows: 1
Perform
.
Turn the
this repair with the battery
LOCK
ignition switch to the
2.
Remove
3.
If
cables connected.
8.
10-17
remaining bolts and tighten them to 10
Install all
(14 Nm). Install and tighten bolt B. 9. Connect the washer motor lead and hose,
install
ft.
lbs.
the
garnishes and close the tailgate. Check for proper operation of the rear window.
position.
the antenna nut.
CD
equipped with a
player, press the
AM
FM
and
buttons on the receiver and simultaneously turn the ignition switch to
ACC.
For non-CD player units, press the
4.
The antenna motor
5.
have an assistant guide the mast so
spool,
damage
the bodywork.
released.
Remove
it,
When
button and simul-
unwinding the mast from the
run,
will
AM
ACC.
taneously turn the ignition switch to
doesn’t
it
extended, the mast
fully
and leave the
ignition in the
and
fall
will
be
ACC
position.
To
install:
new
Insert the
6.
the vehicle.
cable so that the teeth face the rear of
Feed the cable
into the
reaches the bottom, about 12
Have an
7.
in.
motor
until
and prepared
assistant ready
cable. Turn the ignition switch to
the cable
(30cm). to guide the
LOCK. The motor
will
run,
winding the cable onto the spool and drawing the antenna
down
into the
8.
If
mount.
the cable does not wind, twist the cable at the top of
the housing; the part at the bottom
down the Once wound onto
being pushed 9. if
the antenna
and
is
not
retraction; the
may have
turned while
hole.
the spool,
fully retracted.
mast
will
install
the antenna nut even
Sunroof
Test the antenna elevation
eventually retract
fully.
REMOVAL & INSTALLATION Removable Top p»When removing any
interior garnish pieces,
a small supply of extra clips on hand.
REMOVAL & INSTALLATION
You
will
always have very likely
break a few upon removal. I
4Runner
See Figure 30
I See Figure 31
»»This procedure applies to the 4Runners only.
Open
window and remove the body garnishes. 2. Disconnect the electrical lead and the hose at the rear washer motor. 3. Remove mounting bolt B and then remove the other 1
.
the rear
1
.
Remove
Rear room
•
Back door
Remove
the cover and place
it
on pieces
of
wood on
the ground.
To
Rear header
•
Back and
•
Rear seat side garnish
•
Deck side
•
Front door scuff plate
•
Center
install:
^WARNING Mounting bolt B controls the cover top switch. When removed, the rear power window cannot be operated. Never install
5.
E and
it
when
the cover top
Position the cover top J. Install bolts
C and
is
removed.
Tighten
all
install bolts
bolts to 10
ft.
lbs.
(14 Nm). 6.
Loosen
7.
Install
E and
J.
bolts
and
E and
trim
pillar
lower garnish
2.
Unbolt the front seat belt shoulder anchor.
3.
Using a taped flat-bladed
tool,
remove the center
pillar
upper garnish. 4.
Remove
the following parts:
•
Front
•
Control switch
•
Inner rear view mirror
•
Front
pillar
garnish
room lamp
• Sunvisors and holders
J.
tighten bolts
trim
rear doors scuff plates
• Assist grips
on the truck body and L.
light
scuff plate
•
bolts. 4.
the following parts:
•
D and K and
then retighten bolts
5.
Remove
headliner.
the clips securing the headliner.
Lower the
BODY AND TRIM
10-18
Side Garnish
Roof Drip Channel
Sliding
Roof Glass
Side Garnish
Drive Rail
Wind Defrector Panel
7.5 (75, 65 in.-lbf)
Drive
Sunshade Trim Stopper
Gear Assembly
Sliding
|N-m (kgf-cm,
ft-
Ibf)
Roof
7.5 (75, 65 in.-lbf)
Rail
Specified torque 86820g83
Fig. 31
Exploded view of the sliding roof components
— 4Runner
BODY AND TRIM Remove
Unplug the drain hoses and connectors.
6.
10-19
the
nuts and bolts and roof housing assembly. Reinstall in reverse order. Tighten the housing
7.
65 inch
bolts to to 31
ft.
lbs. (7
Nm) and
assembly
the seat belt shoulder anchor
(42 Nm).
lbs.
Land Cruiser I
See Figures
32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43,
44 and 45
Remove
1.
the following parts:
•
Back door
•
Rear seat
scuff plate
•
Right and
•
Rear seat side garnish
quarter side trims
left
•
Rear door
scuff plate
•
Cowl side
trim
•
Front and rear door opening trims
•
Center
•
Front seat outer belt shoulder anchor
•
Center
•
Front seat outer belt shoulder anchor adjuster
pillar
pillar
32
Remove
the mounting screws for the back door
inner scuff plate
upper garnish
•
Both rear seat outer
•
Quarter
•
Rear
pillar
pillar
Fig.
lower garnish
belt
shoulder anchors
garnish
garnish
• Assist grips
garnish and sunvisors with holders
•
Front
•
Inner rear view mirror
pillar
room lamps
•
Front and rear
•
Back door opening
trim
• Sliding roof opening moulding
Remove
2.
the control switch by unscrewing the cover.
Separate the cover from the body, then unscrew the switch
Remove
body. Unplug the connector.
the body with bracket.
3.
Remove
4.
Unbolt the drive gear control relay, then unplug the
the clips retaining the headliner.
connector.
Remove
5.
the gear mounting bolts
and bracket. Separate
the drive gear from the unit then unplug the connector.
Remove
6.
the sliding roof garnishes. Pry loose the inner
Fig.
33
When
prying the quarter trim, try not to
damage
the panel
side garnish clips.
Remove
7.
Remove
the sliding roof glass.
Be sure your have all six of the shims. upwards to remove from the vehicle.
shims.
the nuts and Pull the glass
it
Remove Remove
8.
9.
the drip channel. the wind deflector.
Disconnect the drain hose, then remove the roof
10.
housing. Adjust the drive
11.
Using a flat-bladed align the
rail
2 marks shown
To
install:
12.
Adjust and
a closed and
to
tool, slide
install
in
the
link
tilted
position.
the illustration.
the the drive gear assembly as follows:
b.
Remove Remove
c.
Turn the driveshaft with a screwdriver
a.
down
forward or backward to
the screw and
cam
plate cover.
the large screw, washers and shim. to align the
housing and gear point mark.
cam
plate cover with the screw.
d.
Install
the
e.
Install
the drive gear assembly with the four mounting
bolts. f.
Plug
in
the connector.
Fig. 34 The rear seat garnish is located along the side where your knee would hit while sitting in the vehicle
10-20
Fig.
BODY AND TRIM
35 The bolt anchor
retractor
is
the top mounting bolt for the
BODY AND TRIM
Fig. 41
Unscrew the
10-21
drip channel
Fig.
44 Turn the driveshaft with a screwdriver to align
the housing and gear point mark of the drive gear
assembly 13.
Install
the drive gear control relay and bracket, then at-
tach the connector. 14.
Install
removal.
Fig.
or
43 Using a flat-bladed tool, slide the link forward
backward
to align the 2
marks as shown
in
the inset
the remaining parts
in
the reverse order of
10-22
Fig.
BODY AND TRIM
45 Exploded view of the sliding roof components
— Land
Cruiser
BODY AND TRIM
10-23
INTERIOR Remove
15.
Instrument Panel
the lower trim panel with the glove box door
The panel is held by 4 screws and 1 bolt. 16. Remove one bolt holding the lower center finish panel (around the radio and heater controls) and remove the panel.
attached.
REMOVAL & INSTALLATION
Remove
17.
1.
the heater control assembly. Don’t forget to dis-
connect each control cable
Pick-Up and 4Runner
Remove Remove
18.
MODELS
1989-95
19.
entire panel
> See Figures 46 and 47
lift
Disconnect the negative battery cable.
the radio.
the bolts holding the instrument panel and the
assembly. Because
still
bag system (SRS) must be disarmed before removdo so may cause accidental deployment, property damage or personal injury. Always store the air bag with the pad facing upward. air
Once removed from
20.
4.
Remove Remove Remove
the upper and lower steering column covers.
hood release
lever from the panel.
It’s
held
by two screws.
Remove
5.
refer to
it
7. 8.
the cowl side trim on each side.
You might
as the kick panel.
Remove Remove Remove
6.
holding the
left
the lower center instrument panel cover.
Remove
install:
21.
Assemble the instrument
it.
The
22.
Install
the radio.
23.
Install
the heater controls.
24.
Install
the lower center finish panel. Don’t forget the
the No.2 lower trim panel with the glove box door.
screw.
finish panel; this is
the panel
speaker and running under the steering the heater duct to No. 2 outlet.
heater control knobs, remove the A/C switch unit to
prying tool should have a taped or protected
meter
into
place and
27.
Bolt
down
28.
Install
and make
the
certain
all
models except Pick-Ups with 4 speed manual
31.
Attach the No.
is
duct to
air 1
air outlet
No.
2.
lower finish panel.
the ignition key cylinder cover. the lower center instrument panel cover.
34.
Attach the cowl side trim (kick panels).
For Pick-Ups with 4 speed manual transmissions, the
35.
Secure the hood release and bracket.
held only by two screws. Unplug the connectors and
36.
Install
the steering column covers.
37.
Install
the steering wheel.
38.
Connect the negative battery cable.
39.
Start the engine, allowing
remove the
trim panel.
Remove Remove it
the No.1 air outlet.
It’s
attached with 2 screws.
the four screws holding the combination meter.
out of the panel
until
access
is
gained to the
Disconnect the speedometer cable and remove the connectors.
Remove
location out of the
the meter assembly, placing
work area.
it
rear.
electrical in
a safe
each dash component including output, speaker operation
instruments.
that
correctly placed.
Install
is
screws
Check
Install
the two screws and the cup
the
finish panel. Install the
33.
surround panel outward and unplug the con-
On 4Runner, remove
holder from the panel.
Work
hood and
the vents and ductwork align.
32.
Pull the trim or
nectors.
14.
Fit
the retaining screws.
the heater control trim plate.
transmissions, remove the 3 screws holding the meter trim.
13.
place and con-
left air outlet.
each wiring connector Install
12.
install
the meter
Connect the
trim
in
nect the speedometer cable and wiring harnesses.
30.
all
pad and other
bolts. Make certain the panel is flush and The heater vent ducts must match up exactly with no leaks. Make any needed adjustments now.
29.
For
desired.
level.
the No.
edge. 11.
panel, safety
if
the panel into place, connect the wiring and
Place the combination meter loosely
equipped and gently pry up on the heater control
remove
Fit
Install
Pull off the
10. if
may be removed
To
26.
lower
due the awk-
the vehicle, the safety pad, heater
ducts and assorted brackets
25.
column. 9.
useful
is
the ignition key cylinder cover. 1
loose with
secure the retaining
the steering wheel.
the
come
will
location of the panel.
items removed.
3.
It
attached; disconnect the wiring harnesses as
soon as easily reached. An assistant
ward size and
ing the steering wheel. Failure to
2.
of the nature of the rear clips,
the panel upward at an angle.
various items
^CAUTION The
Withdraw the
at the heater box.
cables through the dash with the controller.
it
to idle.
all
Check the
function of
switches, heater and A/C
and dashboard warning lamps and
10-24
BODY AND TRIM
BODY AND TRIM 4-Speed
M/T Models
Code
Shape
Size
0=
A
Code
Shape
(0.20)
L = 14
B
(0.55)
(0.24)
Qf»
(0.20)
L = 16
Code
L = 22
C
Shape
m
Eji
(0.87)
E
(0.20) L = 16 (0.63)
(0.63)
Size
0= 5 (0.20)
L = 18 (0.71)
0=5
0= 5
0= 5
D
Size
0=6
5
10-25
F
(0.20)
(j/m>
L = 14 (0.55)
Instrument Panel
86820g07
Fig. 47 Exploded view manual transmission
of the instrument panel
and related components
— 1989-95
Pick-Ups and 4Runners with 4-speed
BODY AND TRIM
10-26
13.
MODELS
1996
I See Figures 48, 49 and 50 1.
Disconnect the negative battery cable.
2.
Remove
the steering wheel.
bag system (SRS) must be disarmed before removing the steering wheel or instrument panel. Refer to Section 6. Failure to do so may cause accidental deployment, property damage or personal injury. Always store the air bag with the pad facing upward.
Remove
and the
the cowl side trim
front
Remove
15.
Unhook
Unbolt the lower finish panel, then remove the hood and
5.
Remove
6.
Detach the No. 2 and No.
1
Disconnect the harness
and
bag harness.
Disconnect the
19.
Remove Remove Remove
To
install:
20.
Attach the instrument panel reinforcement.
21.
Install
22.
Bolt in the
23.
Plug
24.
Install
the radio and hook-up the heater register duct.
25.
Install
the glove compartment door reinforcement.
26.
Install
the glove box lamp. Attach the bolts for the panel.
27.
Install
the glove box door.
28.
Attach the A/C control cable. Plug the connectors.
8.
air
the bolts
in
the upper portion of the glove box.
the defroster nozzle. the instrument panel reinforcement. n
the defroster nozzle.
in
upper portion
of the glove box.
the air bag harness.
the center cluster finish panel.
29.
Install
30.
Attach the harness to the combination meter, then attach
for the
to the vehicle.
combination meter, then
31.
Tighten the cluster finish panel.
32.
Attach the No. 2 and No.
33.
Install
the starter switch bezel.
34.
Install
the lower finish panel, then attach the hood and
unscrew and remove. the A/C switch, heater control knob and heater
control panel.
Remove
the radio
heater-to-register duct.
cluster finish panel, then remove,
Unscrew the
8.
10.
Remove
the starter switch bezel.
7.
Remove
the glove compartment door reinforcement. the heater register duct.
17.
screws.
fuel tank release lever
9.
the bolts and the
16.
door scuff
plate. 4.
14.
1
air
3.
Remove
the glove box lamp.
side bracket.
**CAUTION The
Remove
panel.
the 2 mounting screws. Using a
flat
bladed
1
heater-to-register duct.
tool,
fuel tank release lever.
remove the panel. 1 1
.
Unplug the connectors. Separate the A/C control cable
from the 12.
35.
Install
the cowl side trim and the front door scuff plate.
36.
Install
the steering wheel.
37.
Connect the negative battery cable.
unit.
Remove
the glove compartment door.
mm Code
®
Shape
Size
1
l
Code
®
Shape
(jjxan*
Size
* = 5.22 (0.21)
t=
16 (0.63)