Haynes Toyota Tacoma, 4Runner & T100 Automotive Repair Manual 1563922991, 9781563922992

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TOYOTA TACOMA,

|W

lull

4RUNNER &T100 Tacoma

(1995 thru 1998) 4Runner (1996 thru 1998) T100 (1993 thru 1998) All

2WD

and

4WD

models

Automotive Repair Manual

Digitized by the Internet Archive in

2014

https://archive.org/details/toyotatacoma4run00madd_0

Toyota

Tacoma, 4Runner

&T100 Automotive Repair

Manual by Robert Maddox, Mike Stubblefield and John H Haynes Member

of the Guild of Motoring Writers

Models covered:

2WD

and 4WD Toyota Tacoma (1995 thru 1998), 4Runner (1996 thru 1998) and T100 (1993 thru 1998)

ABCDE FGHU

KLMNO PQRST

Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England

Haynes North America, 861 Lawrence Drive

Newbury Park 91320 USA

California

Inc

About Its

this

manual

purpose The purpose

of this

manual

is

to help

you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done, even if you choose to have it done by a dealer service department or a repair shop; it provides information and procedures for routine maintenance and servicing; and it offers diagnostic and repair procedures to follow when trouble occurs.

We

hope you use the manual to tackle the work yourself. For many simpler jobs, doing it yourself may be quicker than arranging an appointment to get the vehicle into a

shop and making the trips to leave it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop

must pass on to you to cover its labor and overhead costs. An added benefit is the sense of satisfaction and accomplishment that

you

feel after

doing the job yourself.

tion captions pinpoint the pertinent Section

means

that Section. That

paragraph) 2 within

Procedures, once described

When

is,

the illustration refers to

Chapter.

References to the vehicle

assume you

left

or right side of the

are sitting

in

Even though we have prepared this manual with extreme care, neither the publisher nor the author can accept responsibility any errors mation given.

for

in,

or omissions from, the infor-

properly complete a procedure or information which

will

provides a special procedure or special steps which must be taken while completing the is found. Not heeding a Caution can result in damage to the assembly

being worked on.

WARNING provides a special procedure or special steps which must be taken while completing the is found. Not heeding a Warning can result in personal injury.

procedure where the Warning

Acknowledgements We are grateful for the help and cooperation of the Toyota Motor Company for their assistance with technical

information

and certain illustrations. Technical consultants who contributed to this project include James Cota and John Wegman. Wiring diagrams were provided exclusively for Haynes North America, Inc. by Valley Forge Technical Communications.

©

Haynes North America,

Inc.

1998

With permission from J.H. Haynes & Co. Ltd.

A book

in

the Haynes Automotive Repair Manual Series

Printed

in

the U.S.A.

reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

All rights

ISBN

1

56392 299

Library of

1

Congress Catalog Card Number 98-85029

While every attempt is made to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

98-416

the driver's

seat, facing forward.

procedure where the Caution

A Warning

neces-

number. Cross references given without use word "Chapter" apply to Sections and/or paragraphs in the same Chapter. For example, "see Section 8" means in the same

CAUTION A Caution

the text,

it's

of the

NOTE A Note provides information necessary to make the procedure easier to understand.

in

sary to refer to another Chapter, the reference will be given as Chapter and Section

The manual is divided into Chapters. Each Chapter is divided into numbered Sections, which are headed in bold type between horizontal lines. Each Section consists of consecutively numbered paragraphs. At the beginning of each numbered Section you will be referred to any illustrations which apply to the procedures in that Section. The reference numbers used in illustra-

illustration 3.2

(or

are not normally repeated.

Using the manual

and the Step within

Section 3 and Step that Section.

1

vUl

1

1

ID

inirouuciory pages About this manual Introduction to the Toyota Tacoma, 4Runner and T100 Vehicle identification numbers

Buying parts Maintenance techniques, tools and working Jacking and towing Booster battery (jump) starting Automotive chemicals and lubricants Conversion factors Safety first! Troubleshooting

Chapter

facilities

.

0-4 0-5 0-6 0-6 0-12 0-12 0-13

U-14 0-15 0-16

1

Tune-up and routine maintenance

Chapter 2

Part

A

Four-cylinder engines

Chapter 2 V6 engines

Part

Chapter 2

Part

1-1

2A-1

B 2B-1

C

General engine overhaul procedures

2C-1

Chapter 3 Cooling, heating and

air

conditioning systems

3-1

Chapter 4 Fuel

4-1

and exhaust systems

Chapter 5 Engine

electrical

5-1

systems

Chapter 6 Emissions and engine control systems

Part A Manual transmission

6-1

Chapter 7

Chapter 7

Part

7A-1

B 7B-1

Automatic transmission

Chapter 7

Part

C 7C-1

Transfer case

Chapter 8 8-1

Clutch and driveaxles

Chapter 9 9-1

Brakes

Chapter 10 ^i icnpncion loiLM OUojJCI I

Chapter

anH QwctomQ io olCCl iy oyold \\J Qtoorinn dl

ll

1

10-1

1

11-1

Body

Chapter 12 Chassis

electrical

system

12-1

Wiring diagrams

12-23

Index

IND-1

Introduction to the Toyota T100,

Tacoma and 4Runner The T100 was manufactured beginning 1993 and is equipped with either the 2.4L or 2.7L four-cylinder engine or the 3.0L or 3.4L V6 engine. The Tacoma was manufactured beginning in 1995 and is equipped with in

either the 2.4L or 2.7L four-cylinder engine or

the 3.4L

V6 engine. The 4Runner was manuin 1996 through 1998 and

factured beginning is

equipped with

or the 3.4L All

either the 2.7L four cylinder

V6 engine.

engines are equipped with the Elec-

tronic Fuel Injection (EFI) system.

The engine drives the rear wheels through either a manual or automatic trans-

mission via a driveshaft and solid rear axle.

A

case and driveshaft are used to drive the front axle. All models are equipped with transfer

either

2WD or 4WD.

The dent:

it

front

suspension

is fully

indepen-

consists of upper and lower control

arms, and a stabilizer bar. T100 models use and shock absorbers; Tacoma 2WD models use coil springs and shock absorbers; Tacoma 4WD models and 4Runner models use an integral coil spring/shock absorber assembly. A solid axle at the rear is suspended by leaf springs and shock absorbers (T100 and Tacoma models) or coil

torsion bars

springs and shock absorbers (4Runner

mod-

4Runner models have four rear suspension arms (two upper and two lower arms) and a lateral rod. The steering box on 4WD T1 00 models is mounted to the left of the engine and is connected to the steering arms through a series of rods. The steering gear on all other models is a rack-and-pinion type and is connected to the steering knuckles by tie-rods. The front brakes are disc brakes and the rear brakes are drums, with power assist standard. Some models are equipped with els).

anti-lock brakes.

numbers

Vehicle identification and

On V6

vehicle manufactur-

on the

a continuing

are

Modifications

unpublicized process

in

Since spare parts manuals and lists are compiled on a numerical basis, the individual vehicle numbers are essential to correctly ing.

component

identify the

engines, the ID

oil filter

left

number

is

also located

side of the engine block, near the

(see illustration).

number Manufacturer Certification

The

required.

Vehicle Identification

Number

The Manufacturer affixed to the front

This very important identification number is stamped on a plate attached to the left side of the dashboard just inside the wind-

on the

driver's side of the vehicle (see

illustration).

The VIN also appears on the

shield

Vehicle Certificate of Title and Registration.

It

contains information such as where and when the vehicle was manufactured, the

model year and the body

style.

engines the

is

number on

ID

four-cylinder

located on a machined surface on

side of the block (see illustration).

left

tains the

name

Certification label

door

pillar.

The

is

plate con-

case and manual transmis-

number

is

stamped

into the

case of the component. Automatic transmission numbers are stamped onto ID plates (see illustrations).

of the manufacturer, the

month and year

of production, the

Vehicle Weight Rating

(GVWR) and the

Gross certifi-

cation statement (see illustration).

Vehicle Emissions Control Information (VECI) label and

Vacuum Schematic The emissions control information label and vacuum schematic is found under the

Engine identification number The engine

transfer

sion identification

label (VIN)

Transfer case and transmission identification

hood. This label contains information on the emissions control equipment installed on the vehicle, as well as tune-up specifications (see illustration).

The Vehicle visible

Identification

Number

(VIN) is

through the driver's side of the windshield

5VZ-FE Engine

* &

2200

D*Tt 07-97

»59

The engine

number on fourstamped on the left

identification

cylinder engines

is

side of the engine block

The engine identification number on V6 engines is also stamped onto a pad on the left side of the engine block, above the oil filter

TOYOTA FSR

BO;S !Ji

cartridge

The manufacturer's certification label is end of the driver's side door

affixed to the

1PORTANT VEHICLE INFORMATICS TOYOTA MOTOR CORPORATION

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