Chilton's Toyota Pick-Ups/Land Cruiser/4Runner 1989-96 Repair Manual 0801986826, 9780801986826

Citation preview

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

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i!

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2

2

2

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3

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

7

7

7

7

7

8

8

8

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9

9

9

9

10 10

1

2

2

2

2

2

3

3

3

3

3

5

5

5

5

5

6

6

6

6

6

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9

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1

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4

4

4

4

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6

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e

6

7

7

7

7

8

8

8

8

8

9

2

2

2

2

3

3

3

3

3

4

4

4

4

4

5

5

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5

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6

6

6

8

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7

7

7

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8

8

8

8

8

9

9

9

9

2

2

2

3

3

3

3

3

4

4

4

4

4

5

5

5

5

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

9

9

9

9

9

9

10 10 10 10 10 11 11 11 12 12 12 13 13 13 14 14 14 15

'

1

l

i

i

2

2

2

3

3

3

4

4

4

4

4

5

5

5

5

5

6

8

8

8

a

7

7

7

7

7

8

8

8

8

8

9

'

1

1

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

8

8

9

9

9

l

’

2

2

2

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

8

8

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

8

8

8

8

8

9

9

9

9

3

3

3

4

4

4

4

5

5

5

5

5

6

6

6

6

6

7

7

7

7

7

B

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)