GIÁO ÁN BẢO DƯỠNG SỬA CHỮA TRỤC KHUỶU THANH TRUYỀN

IN–1
INTRODUCTION

–

INTRODUCTION


IN–2
INTRODUCTION

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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

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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

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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.
A. 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

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GENERAL REPAIR INSTRUCTIONS

GENERAL REPAIR INSTRUCTIONS
1. Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
2. During disassembly, keep parts in the appropriate
order to facilitate reassembly.
3. 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.
4. Check hose and wiring connectors to make sure that
they are secure and correct.
5. 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.

6. 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

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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.
7. When necessary, use a sealer on gaskets to prevent
leaks.
8. Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.
9. 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.

10. 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

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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.
12. 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.
13. 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

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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.

1. Use only unleaded gasoline.
2. Avoid prolonged idling.
Avoid running the engine at idle speed for more than 20 minutes.

3. 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.
4. Avoid prolonged engine compression measurement.
Engine compression tests must be done as rapidly as possible.
5. 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.
6. Avoid coasting with ignition turned off and prolonged braking.
7. Do not dispose of used catalyst along with parts contaminated with gasoline or oil.

01
FOR VEHICLES WITH AN AUDIO SYSTEM
WITH BUILT–IN ANTI–THEFT SYSTEM
IN=–

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

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VEHICLE LIFT AND SUPPORT LOCATIONS

VEHICLE LIFT AND SUPPORT LOCATIONS


IN–10
INTRODUCTION

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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.

Except

Fed.

Vehicles Sold in USA except California

FIPG

Formed in Place Gasket
Fusible Link
Front
Ignition
Intake (Manifold, Valve)

J/6

Junction Block

LSPV

Left–Hand
Load Sensing Proportioning Valve

LSP & BV

Load Sensing Proportioning and By–Pass Valve

Max.
Min.

Maximum
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

SRW

Rear
Single Rear Wheel

SSM

Special Service Materials

SST

Special Service Tools

STD

Standard
Switch

IN–11
INTRODUCTION

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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

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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–
VIATIONS

TOYOTA TERMS
( )––ABBREVIATIONS

SAE TERMS

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

Carburetor

Carburetor

CARB

Continuous Fuel Injection
CKP
CMP

Crankshaft Position

Crank Angle

Closed Loop

Closed Loop

Camshaft Position

Cam Angle

CPP

Clutch Pedal Position

CTOX

Continuous Trap Oxidizer

CT P

Closed Throttle Position

D F!

Direct Fuel Injection (Diesel)

Direct Injection (DI)

Distributor ignition
DLC1
DLC2

DLC3

Data Link Connector 1
Data Link Connector 2
Data Link Connector 3

1: Check Connector
2: Toyota Diagnosis Communication Link (TDCL)
3: OBDII Diagnostic Connector

DTC

Diagnostic Trouble Code

Diagnostic Code

DTM

Diagnostic Test Mode

ECL

Engine Control Level

ECM

Engine Control Module

ECT

Engine Coolant Temperature

Coolant Temperature, Water Temperature (THW)

EEPROM

Electrically Erasable Programmable Read Only
Memory

Electrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory (EPROM)

EFE

Early Fuel Evaporation

Cold Mixture Heater (CMH), Heat Control Valve (HCV)

EGR

Exhaust Gas Recirculation

Exhaust Gas Recirculation (EGR)

Electronic Ignition

Toyota Distributable Ignition (TDI)

Engine Modification

Engine Modification (EM)

EPROM

Erasable Programmable Read Only Memory

Programmable Read Only Memory (PROM)

EVAP

Evaporative Emission

Evaporative Emission Control (EVAP)

Engine ECU (Electronic Control Unit)

Fan Control
FEEPROM

Flash Electrically Erasable Programmable
Read Only Memory

FEPROM

Flash Erasable Programmable Read Only Memory
Flexible Fuel
Fuel Pump

Fuel Pump

GEN

Generator

Alternator

GND

Ground

Ground (GND)

H02S

Heated Oxygen Sensor

Heated Oxygen Sensor (H02S)


IN–13
INTRODUCTION

–

GLOSSARY OF SAE AND TOYOTA TERMS

IAC

Idle Air Control

Idle Speed Control (ISC)

I AT

Intake Air Temperature

Intake or Inlet Air Temperature

ICM

Ignition Control Module
Indirect Fuel Injection

IFS

Inertia Fuel–Shutoff

ISC

Idle Speed Control

Indirect injection

Knock Sensor

Knock Sensor

MAF

Mass Air Flow

Air Flow Meter

MAP

Manifold Absolute Pressure

Manifold Pressure
Intake Vacuum

Mixture Control
M DP

Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)

Manifold Differential Pressure

M Ft

Multiport Fuel Injection

Electronic Fuel Injection (EFI)

MIL

Malfunction Indicator Lamp

Check Engine Light

MST

Manifold Surface Temperature

MVZ

Manifold Vacuum Zone

NVRAM

Non–Volatile Random Access Memory

02S

Oxygen Sensor

Oxygen Sensor, O2 Sensor (02S)

OBD

On–Board Diagnostic

On–Board Diagnostic (OBD)

PAIR

Oxidation Catalytic Converter

Oxidation Catalyst Converter (OC), CCo

Open Loop

Open Loop

Pulsed Secondary Air Injection

Air Suction (AS)

PCM

Powertrain Control Module

PNP

Park/Neutral Position

PROM

Programmable Read Only Memory

PSP

Power Steering Pressure

PTOX

Periodic Trap Oxidizer

Diesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)

RAM

Random Access Memory

Random Access Memory (RAM)

Relay Module
ROM

Read Only Memory

Read Only Memory (ROM)

RPM

Engine Speed

Engine Speed

Supercharger

Supercharger

SCB

Supercharger Bypass

SFI

Sequential Multiport Fuel Injection

SPL

Smoke Puff Limiter

SRI

Service Reminder Indicator

S RT

Electronic Fuel Injection (EFI), Sequential Injection

System Readiness Test
Scan Tool

TBI

Throttle Body

Throttle Body

Throttle Body Fuel Injection

Single Point Injection
Central Fuel Injection (Ci)

Turbocharger

Turbocharger

TCC

Torque Converter Clutch

Torque Converter

TCM

Transmission Control Module

Transmission ECU (Electronic Control Unit)

Throttle Position

Throttle Position

Transmission Range


IN–14
INTRODUCTION

–

GLOSSARY OF SAE AND TOYOTA TERMS

TVV

Thermal Vacuum Valve

Bimetal Vacuum Switching Valve (BVSV)
Thermostatic Vacuum Switching Valve (TVSV)

twc

Three–Way Catalytic Converter

Three–Way Catalyst (TWC)
CCRO

TWC+OC

Three–Way + Oxidation Catalytic Converter

CCR + CCo

VAF

Volume Air Flow

Air Flow Meter

Voltage Regulator

Voltage Regulator

Vehicle Speed Sensor

Vehicle Speed Sensor (Read Switch Type)
Full Throttle

VSS
wot

Wide Open Throttle

WU –OC

Warm Up Oxidation Catalytic Converter

WU–TWC

Warm Up Three–Way Catalytic Converter

3GR

Third Gear

4GR

Fourth Gear

Manifold Converter


IN–15

INTRODUCTION

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STANDARD BOLT TORQUE SPECIFICATIONS

STANDARD BOLT TORQUE SPECIFICATIONS

HOW TO DETERMINE BOLT STRENGTH
Class

Mark
4–
5–
6–
8–
9–

Hexagon
head bolt

10–
11–

4T
5T
fiT
7T
8T
9T

10T
11T

Mark
Stud bolt

No mark

Hexagon
flange bolt
w/ washer
hexagon bolt

Hexagon
head bolt

Hexagon
flange bolt
w/ washer
hexagon bolt

Hexagon
head bolt

Hexagon
head bolt

No mark

Two

protruding
lines

Two
protruding
lines

Three
protruding
lines

Four
protruding
lines

Welded bolt

Class


IN–16
INTRODUCTION

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STANDARD BOLT TORQUE SPECIFICATIONS

SPECIFIED TORQUE FOR STANDARD BOLTS

Class

1 OT

11T

Diameter
mm

Pitch
mm

Specified torque


MA–6
MAINTENANCE

–

MAINTENANCE OPERATIONS

MAINTENANCE OPERATIONS
ENGINE
Cold Engine Operations
1. (3VZ–E ENGINE)
REPLACE TIMING BELT
(a) Remove the timing belt.
(See pages EG–32)
(b) Install the timing belt.
(See pages EG–41)

2. INSPECT DRIVE BELTS
(a) Visually check the belt for excessive wear, frayed
cords etc.
HINT:
Conventional type:
Check that the belt does not touch the bottom of the
pulley groove.
If necessary, replace the drive belt.
V–Ribbed type:
Cracks on the ribbed side of the belt are considered
acceptable.
If the belt has chunks missing from the ribs, it should
be replaced.

(b) Using a belt tension gauge, check the drive belt ten–
sion.
Belt tension gauge:
Nippondenso BTG – 20 (95506–00020) or
Borroughs No. BT–33–73F
Drive belt tension:
22R–E Used belt 80 ± 20 lbf
New belt 125± 25 lbf
3VZ – E
Generator Used belt 100 ± 20 lbf
New belt 160 ± 20 lbf
PS Used belt 80 ± 20 lbf
New belt 125 ± 25 lbf
A/C Used belt 80 20 lbf
New belt 125 ± 25 lbf
If necessary, adjust the drive belt tension.

MA–7
MAINTENANCE

–

MAINTENANCE OPERATIONS

HINT:
• ”New belt” refers to a belt which has been used
less than 5 minutes on a running engine.
• ”Used belt” refers to a belt which has been used
on a running engine for 5 minutes or more.
• After replacing the drive belt, check that it fits
properly in the ribbed grooves, especially in the
places difficult to see.
• After installing a new belt, run the engine for
approx. 5 minutes and then recheck the tension.
3. REPLACE SPARK PLUGS
(a) Disconnect the high–tension cords at the boot.
Do not pull on the cords.
(b) (2213 – E)
Remove the spark plugs.
(3VZ – E)
Using plug wrench (16 mm), remove the spark plugs.

(c) Check the electrode gap of new spark plugs.
Correct electrode gap:
0.8 mm (0.031 in.)

Recommended spark plugs:
22R–E ND W16EXR–U
NGK BPRSEY
3VZ–E ND K76R–U
NGK BKR5EYA

4. INSPECT AIR FILTER
(a) Visually check that the air cleaner element is not
excessively dirty, damaged or oily.
HINT: Oiliness may indicate a stuck PCV valve.
If necessary, replace the air cleaner element.
(b) Clean the element with compressed air.
First blow from back side thoroughly, then blow off
the front side of the element.
5. REPLACE AIR FILTER
Replace the used air cleaner element with a new one.
6. REPLACE ENGINE OIL AND OIL FILTER
22R – E (See page EG–236)
3VZ– E (See page EG–278)
Oil grade:
API grade SG Energy – Conserving II multigrade
and recommended viscosity oil
Engine oil capacity:
Drain and refill


MA–8
MAINTENANCE

–

MAINTENANCE OPERATIONS

22 R – E
w/o Oil filter change
3.8 liters (4.0 US qts, 3.3 Imp. qts)
w/ Oil filter change
4.3 liters (4.5 US qts, 3.8 Imp. qts)
3VZ–E
w/o Oil filter change
2WD 4.0 liters (4.2 US qts, 3.5 Imp.
4WD 4.2 liters (4.4 US qts, 3.7 Imp.
w/ Oil filter change
2WD 4.3 liters (4.5 US qts, 3.8 Imp.
4WD 4.5 liters (4.8 US qts, 4.0 Imp.

qts)
qts)
qts)
qts)

7. REPLACE ENGINE COOLANT
(a) Drain the coolant from the radiator and engine drain
cocks.
(b) Close the drain cocks.
(c) Fill system with coolant.
Coolant capacity (w/ Heater or air conditioner):
22R–E
Ex. 4WD A/T 8.4 liters (8.8 US qts, 7.4 Imp. qts)
4WD A/T 9.1 liters 0.6 US qts, 8.0 Imp. qts)

3VZ–E
2WD M/T 10.4 liters (11.O US qts, 9.2 Imp. qts)
A/T 10.2 liters (10.8 US qts, 9.5 Imp. qts)
4WD M/T 10.5 liters (11.1 US qts, 9.2 Imp. qts)
A/T 10.3 liters (10.9 US qts, 9.1 Imp. qta)
HINT:
Use a good brand of ethylene–glycol base coo–
lant, mixed according to the manufacturer’s in–
structions.
Using coolant which has more than 50% ethyl–
ene–glycol (but not more than 70%) is recom–
mended.
NOTICE:
• Do not use an alcohol type coolant.
• The coolant should be mixed with demineralized
water or distilled water.


MA–9
MAINTENANCE

–

MAINTENANCE OPERATIONS

8. INSPECT CHARCOAL CANISTER
(a) Remove charcoal canister.
HINT:Label hoses for correct installation.
(b) Visually inspect canister case.

(c) Check for clogged filter and stuck check valve.
(1) Using low compressed air (4.71 kPa (48 gf/cm2,
0.68 psi), blow into the tank pipe and check that
air flows without resistance from the other pipes.
(2) Blow air (4.71 kPa (48 gf/cm2, 0.68 psi) into the
purge pipe and check that air does not flow from
the other pipes.
If a problem is found, replace the charcoal canister.
(d) Clean filter in canister.
(1) Clean the filter by blowing 294kPa (3 kgf/cm2,43
psi) of compressed air into the tank pipe while
holding the purge pipe closed.
NOTICE:

•
Do not attempt to wash the canister.
•
No activated carbon should come out.
(e) Install charcoal canister.

9. REPLACE GASKET IN FUEL TANK CAP
(a) Remove the old gasket (0–ring) from the tank cap.
Do not damage the cap.
(b) Install a new gasket by hand.
(c) Inspect the cap for damage or cracks.
(d) Install the cap and check the torque limiter.
10. INSPECT FUEL LINES AND CONNECTIONS
Visually inspect the fuel lines for cracks, leakage loose
connections, deformation or tank band looseness.

MA–10
MAINTENANCE

–

MAINTENANCE OPERATIONS

11. INSPECT EXHAUST PIPES AND MOUNTINGS
Visually inspect the pipes, hangers and connections
for severe corrosion, leaks or damage.
12. (3VZ–E ENGINE)
ADJUST VALVE CLEARANCE
(See page EG–18)

13. (FEDERAL AND CANADA)
REPLACE OXYGEN SENSOR
(a) Disconnect the oxygen sensor wiring connector.
(b) Remove the cover (4WD), oxygen sensor and gasket
from the exhaust pipe.
(c) Install a new gasket, oxygen sensor and cover (4WD)
to the exhaust pipe.
Torque: 20 N–m (200 kgf–cm, 14 ft–lbf)

(d) Inspect oxygen sensor operation.
Inspect feedback control.
22R–E (See page EG–212)
3VZ–E (See page EG–252)

MA–11
MAINTENANCE

–

MAINTENANCE OPERATIONS

Hot Engine Operations
14. (22R–E ENGINE)
ADJUST VALVE CLEARANCE
(a) Warm up the engine to normal operating temperature.
(b) Stop the engine and remove the cylinder head cover.
(c) Set No.1 cylinder to TDC/compression.
•
Turn the crankshaft with a wrench to align the
timing marks at TDC. Set the groove on the pulley
to the ”O” position.
•
Check that the rocker arms on No.1 cylinder are
loose and rocker arms on No.4 cylinder are tight.
If not, turn the crankshaft one complete revolution
and align marks as above.

(d) Adjust the clearance of half of the valves.
•
Adjust only the valves indicated by arrows.
Valve clearance:
Intake 0.20 mm (0.008 in.)
Exhaust 0.30 mm (0.012 in.)

Use a thickness gauge to measure between the
valve stem and rocker arm. Loosen the lock nut
and turn the adjusting screw to set the proper
clearance. Hold the adjusting screw in position,
and tighten the lock nut.
Recheck the clearance. The thickness– gauge
should move with a very slight drag.

(e) Turn the crankshaft one complete revolution (360 _)
and align timing marks in the manner mentioned
above. Adjust only the valves indicated by arrows.
(f) Reinstall the cylinder head cover.
16. ADJUST IDLE SPEED
(a) Preparation
•
Install air cleaner
•
Connect all pipes and hoses of air intake system


MA–12
MAINTENANCE

–

MAINTENANCE OPERATIONS

• Connect all vacuum lines (i.e., EVAP, EGR system,
etc.)
• Make sure all MFI system wiring connectors are

fully connected
• Engine should be at normal operating tempera–
ture
• Switch off accessories
• Set transmission in neutral
(b) Connect a tachometer– to the engine
Connect the tachometer– test probe to the iG E) ter–
.rninal of the DLC1.
NOTICE:

•

NEVER allow the tachometer terminal to touch
ground as it could result in damage to the igniter
and/or ignition coil.

•

As some tachometers are not compatible with this
ignition system, we recommend that you confirm
the compatibility of your unit before use.

(c) Race the engine at 2,500 rpm for approx. 2 minutes.
(d) Set the idle speed by turning the idle speed adjusting
screws.
Idle speed:
22R–E 4WD A/T 850 rpm
Ex. 4WD A/T 750 rpm
3VZ–E 800 rpm
(e) Remove the tachometer.

BRAKES
16. INSPECT BRAKE LINE PIPES AND HOSES
HINT: Inspect in a well – lighted area. Inspect the
entire circumference and length of the brake hoses
using a mirror as required. Turn the front wheels fully
right or left before inspecting the front brake.
(a) Check all brake lines and hoses for:
•
Damage


MA–13
MAINTENANCE

–

MAINTENANCE OPERATIONS

•
•
•
•
•
•
•
(b)

Wear
Deformation

Cracks
Corrosion
Leaks
Bends
Twists
Check all clamps for tightness and connections for
leakage. .
(c) Check that the hoses and lines are clear of sharp
edges, moving parts and the exhaust system.
(d) Check that the lines installed in grommets pass thr–
ough the center of the grommets.

17. INSPECT FRONT BRAKE PADS AND DISCS
(See BR section)
(a) Check the thickness of the disc brake pad and check
for irregular wear.
Minimum lining thickness:
1.0 mm (0.039 in.)

.
HINT: If a squealing or scraping noise occurs from the
brake during driving, check the pad wear indicator.
If there are traces of the indicator contacting the disc
rotor, the disc pad should be replaced.

(b) Check the disc for wear.
Minimum disc thickness:
2WD FS17 type 21.0 mm (0.827 in.)
FS18 type 20.0 mm (0.787 in.)
PD60 type 23.0 mm (0.906 in.)

PD66 type 28.0 m m (1.102 in.)
4WD S 12 + 12 Type 18.0 mm (0.790 in.)


MA–14
MAINTENANCE

–

MAINTENANCE OPERATIONS

(c) Check the disc for runout.
Minimum disc runout:
Ex. C & C 0.09 mm (0.0035 in.)
C & C 0.12 mm (0.0047 in.)

18. INSPECT REAR BRAKE LININGS AND DRUMS
(See BR section)
(a) Check the lining – to – drum contact condition and
lining wear.
Minimum lining thickness:
1.0 mm (0.0039 in.)

(b) Check the brake drum for scoring or wear.
Maximum drum inside diameter:
2WD 256.0 mm (10.079 in.)
4WD 297.0 mm (11.693 in.)
(c) Clean the brake parts with a damp cloth.
NOTICE: Do not use compressed air to clean the brake
parts.

CHASSIS
19. INSPECT STEERING LINKAGE
(a) Check the steering wheel freeplay.
Maximum:
30 mm (1.18 in.)
With the vehicle stopped and pointed straight ahead,
rock the steering wheel gently back and forth with
light finger pressure.
If incorrect, adjust or repair.