IN–1 INTRODUCTION – INTRODUCTION IN–2 INTRODUCTION – HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL INDEX An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the Section Title and major heading are given at the top of every page. GENERAL DESCRIPTION At the beginning of each section, a General Description is given that pertains to all repair operations contained in that section. Read these precautions before starting any repair task.
TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the cause. PREPARATION Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Special Service Materials) which should be prepared before beginning the operation and explains the purpose of each one. REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together.
Example: IN–3 INTRODUCTION – HOW TO USE THIS MANUAL The procedures are presented in a step–by–step format: Example: • The illustration shows what to do and where to do it. • The task heading tells what to do. • The detailed text tells how to perform the task and gives other information such as specifications and warnings. This format provides the experienced technician with a FAST TRACK to the information needed.
The upper case task heading can be read at a glance when necessary, and the text below it provides detailed information. Important specifications and warnings always stand out in bold type. REFERENCES References have been kept to a minimum. However, when they are required you are given the page to refer to.
SPECIFICATIONS Specifications are presented in bold type throughout the text where needed. You never have to leave the procedure to look up your specifications. They are also found at the end of each section, for quick reference. IN–4 INTRODUCTION – IDENTIFICATION INFORMATION CAUTIONS, NOTICES, HINTS: • CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people.
• NOTICES are also presented in bold type, and indicate the possibility of damage to the components being repaired. • HINTS are separated from the text but do not appear in bold. They provide additional information to help you perform the repair efficiently. SI UNIT The UNITS given in this manual are primarily expressed according to the SI UNIT(Internationai System of Unit), and alternately expressed in the metric system and in the English System.
Example: Torque: 30 N–m (310 kgf–cm, 22 ft–lbf) IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the vehicle identification number plate and certification label. Vehicle Identification Number Plate B. Certification Label ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block as shown. IN–5 INTRODUCTION – GENERAL REPAIR INSTRUCTIONS GENERAL REPAIR INSTRUCTIONS 1.
Use fender, seat and floor covers to keep the vehicle clean and prevent damage. During disassembly, keep parts in the appropriate order to facilitate reassembly. Observe the following: (a) Before performing electrical work, disconnect. the negative cable from the battery terminal.
(b) If it is necessary to disconnect the battery for inspection or repair, always disconnect the cable from the negative (–) terminal which is grounded to the vehicle body. (c) To prevent damage to the battery terminal post, loosen the terminal nut and raise the cable str– aight up without twisting or prying it. (d) Cleah the battery terminal posts and cable ter– minals with a clean shop rag. Do not scrape them with a file or other abrasive objects.
(e) Install the cable terminal to the battery post with the nut loose, and tighten the nut after installa– tion. Do not use a hammer to tap the terminal onto the post. (f) Be sure the cover for the positive (+) terminal is properly in place. Check hose and wiring connectors to make sure that they are secure and correct.
Non–reusable parts (a) Always replace cotter pins, gaskets, 0– rings and oil seals etc. with new ones. (b) Non–reusable parts are indicated in the com– ponent illustrations by the“♦” symbol. Precoated parts Precoated parts are bolts and nuts, etc.
that are coated with a seal lock adhesive at the factory. (a) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. IN–6 INTRODUCTION – GENERAL REPAIR INSTRUCTIONS (b) When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads.
(c) Precoated parts are indicated in the component illustrations by the ”*” symbol. When necessary, use a sealer on gaskets to prevent leaks. Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.
Use of special service tools (SST) and special service materials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work proce– dure. A list of SST and SSM can be found in the preparation part at the front of each section in this manual. When replacing fuses, be sure the new fuse has the correct amperage rating.
DO NOT exceed the rating or use one with a lower rating. Illustration Symbol Part Name Abbreviation FUSE FUSE MEDIUM CURRENT FUSE M–FUSE HIGH CURRENT FUSE H–FUSE FUSIBLE L!1VK CIRCUIT BREAKER IN–7 INTRODUCTION – GENERAL REPAIR INSTRUCTIONS 11. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations (See page IN–9).
(a) If the vehicle is to be jacked up only at the front or rear end, be sure to block the wheels at the opposite end in order to ensure safety. (6) After the vehicle is jacked up, be sure to support it on stands. It is extremely dangerous to do any work on a vehicle raised on a jack alone, even for a small job that can be finished quickly. Observe the following precautions to avoid damage to the parts: (a) Do not open the cover or case of the ECU, ECM, PCM or TCM unless absolutely necessary.
(If the IC terminals are touched, the IC may be destr– oyed by static electricity.) (b) To disconnect vacuum hoses, pull on the end, not the middle of the hose. (c) To pull apart electrical connectors, pull on the connector itself, not the wires. (d) Be careful not to drop electrical components, such as sensors or relays. If they are dropped on a hard floor, they should be replaced and not reused.
(e) When steam cleaning an engine, protect the distributor, air filter, and VCV from water. (f) Never use an impact wrench to remove or install temperature switches or temperature sensors. (g) When checking continuity at the wire connector, insert the tester probe carefully to prevent ter– minals from bending. (h) When using a vacuum gauge, never force the hose onto a connector that is too large.
Use a step–down adapter instead. Once the hose has been stretched, it may leak. Tag hoses before disconnecting them: (a) When disconnecting vacuum hoses, use tags to identify how they should be reconnected. (b) After completing a job, double check that the vacuum hoses are properly connected.
A label under the hood shows the proper layout. IN–8 INTRODUCTION – PRECAUTION PRECAUTION FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION: If large amounts of unburned gasoline flow into the converter, it may overheat and create a fire hazard. To prevent this, observe the following precautions and explain them to your customer. Use only unleaded gasoline.
Avoid prolonged idling. Avoid running the engine at idle speed for more than 20 minutes. Avoid spark jump test. (a) Perform spark jump test only when absolutely necessary.
Perform this test as rapidly as possible. (b) While testing, never race the engine. Avoid prolonged engine compression measurement. Engine compression tests must be done as rapidly as possible.
Do not run engine when fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter. Avoid coasting with ignition turned off and prolonged braking. Do not dispose of used catalyst along with parts contaminated with gasoline or oil.
01 IN=– FOR VEHICLES WITH AN AUDIO SYSTEM WITH BUILT–IN ANTI–THEFT SYSTEM Audio System displaying the sign ”ANTI –THEFT SYSTEM” shown on the left has a built–in anti–theft system which makes the audio system soundless if stolen. If the power source for the audio system is cut even once, the anti–theft system operates so that even if the power source is reconnected, the audio system will not produce any sound unless the ID number selected by the customer is input again. Accordingly, when performing repairs on vehicles equipped with this system, before disconnecting the battery termi– nals or removing the audio system the customer should be asked for the ID number so that the tech– nician can input the ID number afterwards, or else a request made to the customer to input the ID number. For the method to input the ID number or cancel the anti–theft system, refer to the Owner’s Manual.
IN–9 INTRODUCTION – VEHICLE LIFT AND SUPPORT LOCATIONS VEHICLE LIFT AND SUPPORT LOCATIONS IN–10 INTRODUCTION – ABBREVIATIONS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL ADD Automatic Disconnecting Differential ALR Automatic Locking Retractor A/T Automatic Transmission ATF Automatic Transmission Fluid BTDC Before Top Dead Center Calif. California Circuit Breaker C&C Cab and Chassis Dash Pot DRW Double Rear Wheel ECU Electronic Control Unit ELR Emergency Locking Retractor ESA Electronic Spark Advance Exhaust (Manifold, Valve) Ex. Vehicles Sold in USA except California FIPG Formed in Place Gasket Fusible Link Front Ignition Intake (Manifold, Valve) J/6 Junction Block Left–Hand LSPV Load Sensing Proportioning Valve LSP & BV Load Sensing Proportioning and By–Pass Valve Max. Minimum Multipurpose M/T Manual Transmission 0/D, OD Overdrive OHC Over Head Camshaft o/s Oversize PCV Positive Crankcase Ventilation PPS Progressive Power Steering Power Steering Right–Hand Rear SRW Single Rear Wheel SSM Special Service Materials SST Special Service Tools STD Standard Switch IN–11 INTRODUCTION – ABBREVIATIONS USED IN THIS MANUAL TCCS Toyota Computer Controlled System TDC Top Dead Center TEMP.
Temperature T/M Transmission U/S Undersize VCV Vacuum Control Valve VSV Vacuum Switching Valve VTV Vacuum Transmitting Valve With w/o Without 2WD Two Wheel Drive Vehicles (4 x 2) 4WD Four Wheel Drive Vehicles (4 x 4) IN–12 INTRODUCTION – GLOSSARY OF SAE AND TOYOTA TERMS GLOSSARY OF SAE AND TOYOTA TERMS M076–03 This glossary lists all SAE–J 1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their Toyota equivalents. SAE ABBRE– TOYOTA TERMS VIATIONS SAE TERMS ( )––ABBREVIATIONS A/C Air Conditioning Air Conditioner ACL Air Cleaner Air Cleaner AIR Secondary Air Injection Air Injection (AD Accelerator Pedal Battery Positive Voltage + B, Battery Voltage BARO Barometric Pressure CAC Charge Air Cooler Intercooler CARB Carburetor Carburetor Continuous Fuel Injection CKP Crankshaft Position Crank Angle Closed Loop Closed Loop CMP Camshaft Position Cam Angle CPP Clutch Pedal Position CTOX Continuous Trap Oxidizer CT P Closed Throttle Position D F!